throttle valve reverser dimensions for EJ2x engines

[Prtexx]

mwebber,
The part you are refering to is a 3/8 tube to allow the air pressure to equalize between the manifold and the TB for the IAC. It was made for an 2001 2.5 SOHC I installed in a 79 Westy next time I will just do a nipple and use a hose to connect it. On the 64 bus because of the lower deck the curveture was the same but I did cut 1.5 out of the center since I couldn't get a tighter radius. That puts the TB just above the coil and everything clears.

As for reversing the intake I looked at that and opted against it since I find it better to leave it stock I did shortened where the hose mounts to avoid hitting the deck lid. I mount my filler neck there and have no issues filling the system. It's pretty tight by the starter why make it more difficult to work to work on the car.

Just FYI on the last 2 projects I started using the 03 Jetta TDI 9 tooth starter and it works great. It does take some grinding to make it work. It no longer sounds like I have a dead battery when the car is warm.

[Buggin_74]

I wasn't trying to poopoo anyones ideas, I think its great what Marshall is doing and I'm happy to help out with what any info I can.
The reason I did my conversion thread was back when I fitted my subi I couldnt find any good threads that covered all aspects of an N/A phase 1 engine into a bug.

It was just hard to put even a rough $$ figure on it as I worked at my own pace and probbaly took a bit longer than a better equipped shop.

The only solid number I can give is I paid $44au for the 180 degree 2.5" mandrel bend.
I cut the flanges out of scrap metal I had which was a slow process.

Once I got it all together and installed I had to mod it anyway as it sat to high for the Beetle decklid spring.



I modified the linkage so it uses a stock beetle throttle cable.

[mwebber]

Just FYI on the last 2 projects I started using the 03 Jetta TDI 9 tooth starter and it works great. It does take some grinding to make it work. It no longer sounds like I have a dead battery when the car is warm.

I had heard that the TDI starters could be made to work more reliably than the IMI units. How much grinding? 30 minutes? Or just, 'grind until it fits'? I really do prefer to use the OEM parts when possible.

By the way, on any body trimming you've done, I presume you've used a plasma cutter rather than just an air powered cut off wheel. True?

M

[mwebber]

I don't think he is trying to convince you to make them Buggin_74. He only wants an opinion on what one might expect to pay someone else to make said item. What he's trying to do is make a sticky for a guy that shows up here and wants to convert his bus. Said threads goal is to give an explanation of every step. So I guess maybe if you don't have a guess on price then a general description that someone could walk into say a muffler shop with and say make me one of these please. I got the impression he's done a conversion or two already but wants to think tank different steps to see if we can't refine and simplify them as a group. Or I could be totally missing the point /shrug

No, you nailed the point right between the eyes:

I'm very flattered that you think I sound knowledgeable enough to have done several conversions. This will be my first but I've researched it heavily for about 3 years, and I always got the impression that many more people would jump into conversion fun if they didn't feel like they had to engineer the whole solution themselves. In other words, make the conversion more of a bolt together affair (modular WALL-E style) rather than 'a bit o this and a bit o that' Frankenstein job.

When you do adaptation, fabrication always comes with it. But if you do enough of them, standardization comes with it too.

M

[Prtexx]

I had heard that the TDI starters could be made to work more reliably than the IMI units. How much grinding? 30 minutes? Or just, 'grind until it fits'? I really do prefer to use the OEM parts when possible.

By the way, on any body trimming you've done, I presume you've used a plasma cutter rather than just an air powered cut off wheel. True?[/quote]

The grinding is on the Jetta starter longating the holes to match the bell housing. After that it fits perfect. I havent had to do much trimming on the beetle I removed a couple of gussets by the apron to clear the cam gears and on the bus I trimmed the sides back 2" for a little room to work in case the valve covers have to be removed. No other body modifications were made to the bus. BTW I don't have a plasma cutter.

[Steve Arndt]

search vanagon TDI starter (it will be on samba)

[mwebber]

Thanks Steve. Anything we can do to drive down the cost and UP the reliability.

Prtexx, What did you use to make your cuts? Air powered cut-off wheel? Nibbler? Tin-snips and a strong grip?

I have a cut off wheel, but such a one-lung compressor, I run down the capacity before I've cut more than a few millimeters working at that thickness. Takes FOREVER.

M

[Prtexx]

I paid $122 for the Jetta starter at Autozone including the core charge (limited lifetime warranty) not much to making it work just longate the holes.

I use a cut off wheel and or tin snips and I also have an electric hand held shear for full sheet.

[mwebber]

I paid $122 for the Jetta starter at Autozone including the core charge (limited lifetime warranty) not much to making it work just longate the holes.

I use a cut off wheel and or tin snips and I also have an electric hand held shear for full sheet.

I have the opportunity to put a loaner plasma cutter to work if I can get power to it. I'm not going to use it on the Bus for any trims....yet. (I'm still naively optimistic that I can get a pair of radiators into that space without having to carve on the body.)

I have an air driven high speed metal saw (10,000spm) that is a hell of a lot cheaper than the sixty feet of 10AWG / 4 conductor cable that I would need to run to get the right juice out into the garage to drive either a plasma cutter or Flux Core welder.

Can you imagine asking your in-laws to contribute to buying you electrical cable for Christmas? No wonder they think I'm nuts.

M

[fezzic181]

I don't think he is trying to convince you to make them Buggin_74. He only wants an opinion on what one might expect to pay someone else to make said item. What he's trying to do is make a sticky for a guy that shows up here and wants to convert his bus. Said threads goal is to give an explanation of every step. So I guess maybe if you don't have a guess on price then a general description that someone could walk into say a muffler shop with and say make me one of these please. I got the impression he's done a conversion or two already but wants to think tank different steps to see if we can't refine and simplify them as a group. Or I could be totally missing the point /shrug

No, you nailed the point right between the eyes:

I'm very flattered that you think I sound knowledgeable enough to have done several conversions. This will be my first but I've researched it heavily for about 3 years, and I always got the impression that many more people would jump into conversion fun if they didn't feel like they had to engineer the whole solution themselves. In other words, make the conversion more of a bolt together affair (modular WALL-E style) rather than 'a bit o this and a bit o that' Frankenstein job.

When you do adaptation, fabrication always comes with it. But if you do enough of them, standardization comes with it too.

M

Ah ok. Haven't started my conversion either. Still doing body work here. So can't provide any insight of intake mods. Mines a
Thing so space requirements will be decidedly different then the busses anyway.

[mwebber]

Well, I got C-Notes in my pocket and a 97 Impreza on my mind. We'll see if she comes home with me. Then this will get a sharp kick in the tail away from theory and right into practice.

M

[Prtexx]

Good luck hope you get it.

[mwebber]

Looks like the Impreza will be mine. Still have to move it to my house, and unfortunately I'm out of town this weekend and all next week.

The only down side is that this engine will have the single port exhaust, which makes it a lot harder to find headers.

[Prtexx]

If your not going with a turbo make your own using the stock parts. That's what I installed on the 64 bus.

[Buggin_74]

Headers for Subarus aren't much good in a VW conversion anyway as they hang down too low unless ground clearance isnt an issue.

I just cut down an EJ20 header for mine, tucks up nice and tight and sounds awesome.