Sooo jealous. Het jy my PM gekry?

Ok so the bridge plate has been made for the back of the head. Very happy with how it came out, nice round corners for allowing the water to flow easily. The plate is 25mm thick, and the cavity is 20mm deep, measuring up the inlet and outlet pipes volume wise it should allow the same of not more water to pass. Will also still flow the holes where the water is supposed to come out and go in as the edges are very sharp, not really conducive to good flow.

Marked out last night like 11:30 or so.



Milled out with a bull nose tool.





Also sunk the holes so that I could use normal capscrews, they are a but stronger and more reliable than those cheese head allen bolts.



My dad made me this here plug...



...for this here hole...



Fitted the motor today, for a moment I was panicking a bit when #4 tb was fouling on the brake booster. But quickly realised that when I let it rest on the mountings it moved away. Not enough though, so I cut another 10 or so millimeter from the zorst side mounting to lean it a bit more to that side, tb moved away some more, and now the bottom of the sump is actually level with the cross member, but you can clearly see the motor lean to the passenger side. Doesn't bother me, can only shift more weight to that side to improve the handling and balance anyway.

Intake side, looks good much more space to work on the alternator and starter than with the 16V.



Exhaust side, still lots of space left for a nice branch.



Clearance on the back of the head. Still have about 10mm left there, more than enough so it won't touch. Glad that I don;t have to panelbeat the firewall.



Clearance between the #4 tb and the booster. Going to ahve to get creative with the intake there, want to run ramtubes, but might have to angle them to make space.



Clearance to the radiator and fan, only need to trim the bottom water outlet pipe slightly so it'll fit, top one I'll need to get a slightly longer one, but everything lines up perfectly.



Bought a few things over the past week or two. New TP100 harness, new VW radiator and copper button clutch. When I bought the silvertop motor I organised with the guys to swap the flywheel with another silvertop that had a blacktop flywheel on it for some reason. Today I finally got hold of that too, and my dad sommer gave it a skim while he was at it.

New copper button and the blacktop flywheel. Lying on top of the new radiator's box.



On Saturday morning me and my brother got stuck in and stripped the boksie down. Took us about 4 hours to take everything but the dash out, that's needed to still operate the steering. I'll help Jackie take the suspension out tomorrow night, then I can sort that out while he's busy with the body. I also want to upgrade the front brakes while I'm at it.

Say goodbye to the red boksie, the colour will be a bit of a surprise... :wink:












Initially I was a bit scared to take the windscreen and back window out. well not so much the front, because that you can still buy regularly, but the last time the back window blew out, at past the maximum the clock can show :twisted:, I had to drive around without a back window for almost 4 months before I could find one again.

Underside is also very messy, that'll also be sorted out, never really was painted the last time around, they only blasted some black rubberising stuff all over. The broken gearbox seal and diff made a right mess of the underside as you can see.



6

sweet looking setup congrats!!

Ok so here's a few updates and pictures

Reference of what the engine setup looked like before this rebuild started...









As my dad would always say, "So leeg soos 'n hoer se hart","as empty as a prostitute's heart"...



Airbox removed, won't be needing that, and RWD waterpump fitted. I decided to use the 20V pump since it has on blade more than the 16V one, but you need to grind the fins down by about 1.5mm otherwise they catch on the rear housing. Not bolted down yet, still fiddling with the pre-circulation pipe.



I took of that crooked top pip, hacked of the flange, then cut of the end and another piece to make up the housing, Pitty I didn't get pictures before it was welded up. Also cut the bosses out of the rear housing to make holes for the Datsun dash guage and sender for the ECU. Just welded a piece of aluminium pipe for the pre-circulation circuit.



Inside of the housing just to give an idea, used flange and two pieces hacked to size to make the housing.



Housing being welded up...



Water outlet on the head. Must now find a curly rubber hose to connect the pre-circulation to the top of the waterpump. Still also need to make a fitting for the top of the pump.



Just another angle, nicely tucked away and looks OE from this angle. Sits in almost exactly the same spot as the 16V one did, will need a slightly longer pipe to connect to the radiator.



Rear housing removed and holes plugged up with rags. Want to flow those holes a bit to make sure the water circulates as easy as possible.



This week I'll try to get the rear cover plate made and also have the clutch modified to have the 21R center. Then the motor can go in and I can start checking for clearance and mock up the branch.

I think it's about time I give the guys on here an update.

This will be the remake thread for the Boksie*, 1.0 was still A12 , 2.0 was with the 4AGZE turbo, 2.5 was the upgraded 4AGZE turbo.

Boksie* 3.0 will thus be with the 4AGE 20V Silvertop. Motor has been acquired as everyone might have deducted already. A complete spray painting has also been booked , which will happen mid March somewhere(actually it's now end of June and the car is still over there, but I'm happy since it gives me more time to sort the other stuff out).

For a start I'll leave it NA, since this rebuild is really about getting the body as perfect as possible. I ended up on 12.3 second 1/4 mile with the 16V turbo 4AGE, but realized for some time already that I didn't originally build the car to be dragging with it. It was still very drivable on the road, but power corrupts... your right foot and if you stomp on the loud pedal to often it gets expensive to maintain all the broken parts and the rising fuel price is also a concern these days. If I get bullied to much it won;t stay NA for to long, hence the silvertop choice, since it's more suited to boost than the blacktop...

I've been busy with the rebuild for some time now, so for a start I'll simply be re-posting everything over here. It might take me some time though, since I have to log in like 10 times sometimes to make on post. Yes, I'm still having that bloody log in problem, but I can't stay away...

*Boksie is the nickname for my car, you pronounce it "boxy", and it's the Afrikaans word for "little box". My nickname on all other forums is also Boksie.