Upright Bug Conversion - First Timer Questions!

[NextGen]

Prior to using the 36hp fanhousing. Mike Sharpe of Sharpbuilt showed me some of his stock fanhousings he just sliced off the sides and welded two pieces of sheet metal. I have also seen some sides with right angle bends and pop riveted..

I will try to hunt down some of the photos. BTW I had to take a hammer to the sides of my 36 hp fanhousing just to get an extra mm or 2 for carb clearance.

[topnotch]

Here we go - i managed to modify the stock fanhousing to fit and also modified the cb performance linkage so that its all straight.

Its a bit rough at the moment, but works -

[bushoarder]

I am impressed at how little you had to take out! I have a doghouse housing that I sliced quite a bit off - might try to mod another stock one like you’ve done - I don’t like my 30hp shroud much.


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[topnotch]

Thanks - it’s hard to see in those pics but I also used some 10mm spacers under the carbs which helped a little bit

[bushoarder]

I thought about making some spacers for under manifolds to head joints as this would move them up and out.


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[topnotch]

Just getting the type 1 oil cooler sorted. I've tapped and plugged the holes under the type 1 oil cooler adaptor and also drilled through and out the other side to make the holes for the feed and return

The type 1 oil cooler is nice and snug in the type 1 fan housing (as if it was made to go there lol!) - i'd like to fix it in place if possible to the fan housing, but i'm struggling to see how i can do this - or even fix it to the type 4 case somehow maybe? Any ideas!?

Cheers

[bushoarder]

This is how I did it:




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[NextGen]

Funny to read were you are at on your conversion. BTY nice work, especially the cutting and welding to get that extra space. The reason I said funny is because I have not removed my manifolds since 1990. The carbs I have to rebuild once. Well today I started to remove my carbs found some things that I did and forgot about that made it like hell to get them out.
Originally I could not fit the nuts on the manifolds because the studs were too close to the manifolds to fit the 13mm nuts. Had to use 11mm on the two outer studs.
Another was after I got the carbs on, I had a brilliant idea to stick some more rubber to act as a better cabin seal. The seal was so thick I could not move the manifold out far enough to get them off the studs... Had to cut the seals off and they just made it out.

Well think ahead -- un like me, you just moved your manifolds out 10mm on spacers. Do a test to see if once in the engine compartment if the manfolds hit the body.
Because now the intake ports are exposed, to prevent rain from getting In, i used the plastic insulator used on fuel injected T-4's, which may be the spacer you used, which may be 10mm, to seal both ports. I covered them with alum tape and temporally bolted them back on the car to prevent water from getting in.

All you are doing is fine, T-4 run real cool. PAINT THE FAN HOUSING , now the carbs are our, painting my fanhousing is my next job. The photo below is old, now is is much worse.


Below are two videos, both by the same guy, one is about the oil cooler.

https://www.youtube.com/watch?v=S3ewTqOxRZA

https://www.youtube.com/watch?v=deD2JxpUA48

[topnotch]

Thanks guys - will have a look at those videos later.

That’s a good idea about the oil cooler bracketerty - I’ll probably do something around that - painting the tinware is on the list of things to do - the most important question of course for the whole engine is which colour!?

Oh - the 10mm spacers are between the manifold and carb by the way

[topnotch]

Did some work on the engine this morning and a couple of evenings. Oil bracket is all done, tapped all the holes and adaptors neatly fitted in

Was also looking at the CSP shrouds i was using and looking into how i can make all the tin round the edge. I see no way of attaching it easily to be honest so in the end i scrapped using the CSP shrouds and went to use the Cali method of using two sets of Type 4 tin that i'd bought previously.

If i'm honest, i have no idea how CSP expect you to attach all the rest of the sealing tin around the engine. At least then, i can weld nuts onto this and they have various fittings on the edge already

So after a lot of welding and cutting this morning, i have the following - looks a bit like frankenstein with all the welding stitches! Just got a couple of bits to tidy up n this and then i 'll get the shrouds and fan housing blasted and powder coated. Also had to weld up the spark plug holes and cut knew ones (which i still ahev to tidy up) as i'm running porsche 914 heads. I'm pretty pleased with the outcome actually!

[topnotch]

So, i tidied up the tinware got it all fitting nicely and also mounted the oil cooler. I initially made a bracket similar to the one shown earlier which worked, but i was having trouble with it sitting on the engine case and not allowing the fan housing to drop into place.

So i had a good look at everything and eventually worked out that by winding the oil cooler studs out which mount the adaptor to the cooler, i couuld fix the oil cooler (and hoover tin bit) to the fan housing nicely.

I'm pretty pleased so starting to build everything else up now - rockers, carbs, heat exchangers, etc ready for a startup

[VIPERGREEN76]

Great videos on upright conversion.

https://www.youtube.com/watch?v=ohhspDJ ... vRtCyUmd1V

[bushoarder]

Wow it looks great! Need to tidy mine up and paint it. Also need to fit the thermostat parts too.

I wish i had stayed t1 cooler - going t4 took so much work to get it all to fit and I can’t get to the plug easily.


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