The Cal-look Lounge

OK, as I'm fairly new here not many of you know my car. I've owned her 4 1/2 years and hardly a week goes by without some tinkering, fettling or repair.

Four weeks ago she suffered some major vandalism AND a 360 flat spin on the motorway resulting in this;
(http://i60.photobucket.com/albums/h40/russlolly/DSC00374.jpg)

and this,

(http://i60.photobucket.com/albums/h40/russlolly/DSC00377.jpg)

What you can't see is the damage to the back. As I swung round the rear hit the barrier too. The long and short of it is that she's been written off. But... I bought her back off the insurance company and she will live again.

After some VZi searching I found a complete front end. What's more, it came complete with a pair of rear wings.

(http://i60.photobucket.com/albums/h40/russlolly/Fibre3.jpg)

(http://i60.photobucket.com/albums/h40/russlolly/Fibre4.jpg)

(http://i60.photobucket.com/albums/h40/russlolly/Fibre1.jpg)

(http://i60.photobucket.com/albums/h40/russlolly/Fibre1.jpg)

(http://i60.photobucket.com/albums/h40/russlolly/Fibre5.jpg)

(http://i60.photobucket.com/albums/h40/russlolly/Fibre6.jpg)

I went all the way to North Wales to collect them, and I've been given a tail light.

I need to source some Mini style kit-car lights, indicators and fuel filler as this will need to be relocated

She was collected today by Phil Woodward (HRC Body & Paint) For those of you who haven't heard of him, he's over near Paddock Wood and races a mental flip-fronted, Mopar V8 split screen camper. Look him up if you need anything from stone chips, restoration to custom work.

The plan is to fit the fibreglass flip-front end, and use the rear wings and decklid to cast a removable one piece rear end. While she's there Phil's going to construct and fit an MSA spec cage.
Another good bit is she'll also be treated to a well deserved paint job.

I've scratched my head a bit, and looked at loads of stock, custom & downright mad paintjobs and decided on a bone stock Pacific Blue base & clear, if you've got Summer 2003 Volksworld to hand (as you do) there's a feature car in the same colour.

Phil's gonna keep me updated with pics, so I'll add them to this thread

Meanwhile, I'm just waiting for the last engine parts to arrive so my friend Darren and I can get the 1914cc motor rebuilt. This let go earlier in the year due to a faulty distributor and some poorly chosen components (NEVER use ali valve spring retainers) The spec will be as before except for a 125 cam and twin 40's.

And we're off, first work-in-progress pics have arrived.

Here's the damaged rear - sporting  a replacemend decklid as the original was dented in the grille area by the yobs.

(http://i60.photobucket.com/albums/h40/russlolly/HRC5.jpg)

Here we see all the dead metal, which Phil assures me weighs a fair bit

(http://i60.photobucket.com/albums/h40/russlolly/HRC2.jpg)

(http://i60.photobucket.com/albums/h40/russlolly/HRC4.jpg)

And here she is in all her glory, still a fair amount of metal to get rid of, but I think you get the idea.

(http://i60.photobucket.com/albums/h40/russlolly/HRC3.jpg)

I'll add more as and when they get taken. I'll be over there for a few days next week, so expect a load more.

Well, Phil's been a busy bee

Here's the front end all cut away. Inner wings trimmed, edged and seam-welded over some 13mm tube.

(http://i60.photobucket.com/albums/h40/russlolly/DSC00760.jpg)

Some horrors were uncovered and taken care of

(http://i60.photobucket.com/albums/h40/russlolly/russghia029.jpg)

Now here's the REALLY clever bit. Phil has fabricated a hinging AND cantilever closing system incorporating BMW bonnet anti-rise guides and Honda Civic gas struts

(http://i60.photobucket.com/albums/h40/russlolly/russghia003.jpg)

The wood is only in there for mock-up purposes, it'll be replaced with mild steel tube

(http://i60.photobucket.com/albums/h40/russlolly/russghia007.jpg)

(http://i60.photobucket.com/albums/h40/russlolly/russghia035.jpg)

You can see the anti-rise brackets just in front of the scuttle panel

(http://i60.photobucket.com/albums/h40/russlolly/russghia038.jpg)

And here she is in all her glory

(http://i60.photobucket.com/albums/h40/russlolly/russghia041.jpg)

(http://i60.photobucket.com/albums/h40/russlolly/russghia045.jpg)

(http://i60.photobucket.com/albums/h40/russlolly/russghia046.jpg)

To say I'm happy with the result is a massive understatement. Phil's skill and ingenuety knows no end.

I removed the support for the front seatbelt mounts, incorporating the rear seat support as this will foul where the cage needs to be.

I'm popping back over today. I'll be cutting the nose for the trademark Ghia nostrils to be refitted, same for the headlamps and indicators.

Righto, here's the photos from yesterday;

o/s inner wing stripped

(http://i60.photobucket.com/albums/h40/russlolly/DSC00407.jpg)

Got some of the n/s too

(http://i60.photobucket.com/albums/h40/russlolly/DSC00408.jpg)

Repairs to the n/s wing/sill
(http://i60.photobucket.com/albums/h40/russlolly/DSC00409.jpg)

(http://i60.photobucket.com/albums/h40/russlolly/DSC00410.jpg)

Today's instalment coming up

Phil had other customer's cars in today, so I was left to my own devices.

I was let loose with the air-saw, and set about fitting the lamps and grilles.

Nice and narrowed beam sir? You can see the bracing for the flip-front, and also the locating pin for the A-post

(http://i60.photobucket.com/albums/h40/russlolly/DSC00414.jpg)

And she got her face back!

(http://i60.photobucket.com/albums/h40/russlolly/DSC00411.jpg)

(http://i60.photobucket.com/albums/h40/russlolly/DSC00412.jpg)

(http://i60.photobucket.com/albums/h40/russlolly/DSC00413.jpg)

(http://i60.photobucket.com/albums/h40/russlolly/DSC00415.jpg)

(http://i60.photobucket.com/albums/h40/russlolly/DSC00416.jpg)

Phil used his magic Rivnut gun to make the captive nuts for the headlamp bowls. I want one:)

I also got rid of some more tar-board from the driver's floor, and removed the driver's seat as it'll soon be time to mock up the cage with the new seat in.

Looking good Russ, good to see you're looking at dropping some weight out of it ;D

There's a lot of weight in a late Ghia! Should see your time's tumble dude  ;D

VERY cleaver on you brackets and gas shock

Thats great work Russ....

I can't see the pictures (school firewall blocks them!) but it sounds impressive! Just thinking though - a one piece rear end could be something of an arse to use! I'd certainly look into removeable rear wings, but I think I'd keep the decklid seperate! On my KG I cut out the rear valance and had it held in with Dzus fasteners, made it much easier to get the engine out!
Something I've just thought of for the front too - how about some inner wings in aluminium, it'll give you some semblance of weather protection for the under bonnet area. Something similar to the Lee Leighton oval. For the fuel filler problem, just run an early Beetle tank - Ghia and Bug are the same!

Awesome work so far!! Going to enjoy watching this develop  ;)

J

Good stuff Russ, keep the pics coming.

Thanks for the encouragement folks, I'll let Phil know.

A few pics from today.

Phil has replaced that piece of timber with some tube. This will all be bonded into place and reinforced with glassfibre matting, as will all of the fittings inside the front end - so no fixings will be visible from outside the car.

(http://i60.photobucket.com/albums/h40/russlolly/russghia1311091.jpg)

(http://i60.photobucket.com/albums/h40/russlolly/russghia1311092.jpg)

(http://i60.photobucket.com/albums/h40/russlolly/russghia1311093.jpg)

(http://i60.photobucket.com/albums/h40/russlolly/russghia1311094.jpg)

I picked up my new seats today. The old ones were 14Kg each, the new ones are just 6Kg each :)

I suppose I'll need to add a harness and a window net onto my Xmas list

Its looking good Russ, you can't beat a mean looking ghia. :)

Very clever front end design 8)

Is it going back onto the street or race only when done?
Cheers,
Kev

 :o

Funny you should drop by. I was chatting to John the other day, the chap that now owns your old car - he's got my old rear seats in it now

Kev

She'll be Taxed & MOT'd. She'll blend in nicely with all the black Cayennes on he school run :)

Thats a bloody clever canterlever set up  8)

now that's proper quality work, I love that setup. too cool  ;D

A quick update.

I popped over to Phil's 'shop today to deliver the new seat. We fitted this as we'll shortly be drawing up the cage. Was a fairly straightforward job, we used the existing side runners to fix to.

(http://i60.photobucket.com/albums/h40/russlolly/DSC00422.jpg)

(http://i60.photobucket.com/albums/h40/russlolly/211120096.jpg)

(http://i60.photobucket.com/albums/h40/russlolly/211120097.jpg)

Phil's better half is a whizz with fibreglass and resin and bonded-in the front inside fittings.

(http://i60.photobucket.com/albums/h40/russlolly/DSC00420.jpg)

And a sneeky peek at the new paint.  :) The inner wings have been shutzed and the whole under-bonnet area painted.

(http://i60.photobucket.com/albums/h40/russlolly/DSC00423.jpg)

(http://i60.photobucket.com/albums/h40/russlolly/211120091.jpg)

(http://i60.photobucket.com/albums/h40/russlolly/211120092.jpg)

(http://i60.photobucket.com/albums/h40/russlolly/211120093.jpg)

(http://i60.photobucket.com/albums/h40/russlolly/211120095.jpg)

Nice work overthere.And I love the fact,that you are re-using the nosegrills.(for me,it's a must have on a ghia)
 ;)

Thanks. I know some fill them in, but I've never been a fan of that. To me they're one of the cues that makes a Ghia a Ghia

Damn Phil works fast  ;D

Loioking great there Russ....

I'm very lucky to be surrounded by some skilled friends.

My  mate Ade popped round tonight with something he'd knocked up in his spare time (as you do when you have a TIG welder knocking around).
Last season I was using a standard Bugpack type oil breather box, which had shown some signs of seepage, which is expected when you're pushing up to 6500rpm.
So there was only one thing for it, a 1ltr tank/can. This has 4x13mm unions on it; 2 for the rockers, 1 for the filler breather and 1 for the fuel-pump block-off, and also 2x18mm unions for the breather filters (which I picked up for a couple of quid from ebay). He's added a couple of brackets for fitting to the firewall begind the fan housing.

Something else to put a smile on my face

(http://i60.photobucket.com/albums/h40/russlolly/DSC00424.jpg)

I also picked up a new steering box this weekend as the old one required constant adjustment, and the last parts for the engine rebuild - it's all coming together:)

Good work ! ;)

Not Red then bother in law. :D ;D

If that's not a typo, that's possibly the funniest thing I've seen you write. ;D

No for the first time in my life i meant it like that.

I knew you would find it funny. ;D

That's a first , you never mean to DO anything  ;), first it was the S button playing up on your keyboard , now your having trouble with your R's .
Who do you think you are Jonathan Wross  ;D

Hi 'bother', yes im here!!
anyway its looking good bro, and i do like the colour even if it isn't red, but i like all the same, love the seats too
I just need to get my ass in gear get rid of the 3 cars sittin at home ::) and get myself a race car for easter!!!!  ;D

Good old ebay.

For next year I needed to sort out an FIA spec harness. Basic 3 point harnesses start at around £110

I've just secured this new SCHROTH Profi II-6 which retails at £185, for just £56

(http://i60.photobucket.com/albums/h40/russlolly/SCHROTHProfiII-6.jpg)

:)

Tinware has been stripped and repainted as well, with some help from my little lady

Can't wait to see it Russ
(do you think you'll let me take her down the strip again with all her newness?!) ;D
When you next going to Phil's to get some updated pics to show us all? 
Luv ya, Loulou xx

Of course you can Lou, I guess Big Bang will be the first meet where there'll be any RWYB. And remember Lou, she'll be a little quicker - gotta make sure you locate all required gears this time

I popped in at Phils 'shop again today.

He's had other customers' cars in this week, so just a wee bit of progress.
He's been concentrating on gapping/blending the shut line for the front end.

(http://i60.photobucket.com/albums/h40/russlolly/DSC00425.jpg)

(http://i60.photobucket.com/albums/h40/russlolly/DSC00426.jpg)

[/quote]
Of course you can Lou, I guess Big Bang will be the first meet where there'll be any RWYB. And remember Lou, she'll be a little quicker - gotta make sure you locate all required gears this time

I popped in at Phils 'shop again today.

He's had other customers' cars in this week, so just a wee bit of progress.
He's been concentrating on gapping/blending the shut line for the front end.




[/quote]  LOL :D

That would be soooo good seen as i dont think im gonna have a race car by then?? xxx

Thanks again for al the encouragement.

I've recently broken my laptop and can't get on Photobucket on my works PC so the updates have been a little thin on the ground - I am about to make amends:)

I could never get the driver's door to hang/shut properly after doing the n's heater channel a few of years ago.
(http://i60.photobucket.com/albums/h40/russlolly/DSC010401.jpg)

 I'd allowed the B-pillar to move, so Phil has painstakingly put this right
(http://i60.photobucket.com/albums/h40/russlolly/DSC010421.jpg)

(http://i60.photobucket.com/albums/h40/russlolly/DSC010461.jpg)

Also welded up the trim holes on te door
(http://i60.photobucket.com/albums/h40/russlolly/DSC010541.jpg)

And here's what she looked like about 10 days ago
(http://i60.photobucket.com/albums/h40/russlolly/DSC011441.jpg)

Here's what we started with on the offside rear
(http://i60.photobucket.com/albums/h40/russlolly/DSC011411.jpg)

Most of the manky mangled wing/rotten arch removed
(http://i60.photobucket.com/albums/h40/russlolly/DSC011481.jpg)

All the inner arch rot repaired
(http://i60.photobucket.com/albums/h40/russlolly/DSC011541.jpg)

Here's the finished arch
(http://i60.photobucket.com/albums/h40/russlolly/DSC011581.jpg)

A couple more of the front
(http://i60.photobucket.com/albums/h40/russlolly/DSC00432.jpg)

(http://i60.photobucket.com/albums/h40/russlolly/DSC00433.jpg)


And some side shots, you can see where the offside has been repaired and primed
(http://i60.photobucket.com/albums/h40/russlolly/DSC00434.jpg)

(http://i60.photobucket.com/albums/h40/russlolly/DSC00435.jpg)

Now here's where it starts to get funky:D

The kit-car wings have been bonded to a decklid to create a buck for the new one-piece fibreglass rear end
(http://i60.photobucket.com/albums/h40/russlolly/DSC00439.jpg)

(http://i60.photobucket.com/albums/h40/russlolly/DSC00438.jpg)

All looking good so far

And here's the best bit yet. I'm a little hesitant to show these as they'll really give the gane away, but I thought Phil's work deserves to be shown.

Here's the rear end prepared to take the one piece rear end.
(http://i60.photobucket.com/albums/h40/russlolly/DSC00437.jpg)

(http://i60.photobucket.com/albums/h40/russlolly/DSC00436.jpg)

(http://i60.photobucket.com/albums/h40/russlolly/DSC00440.jpg)

The spot-welds have been drilled out and in their place some captive nuts installed to make the rear tray removable. This has also been strengthened with some tube.
I'll probably relocate the battery to the boot floor to keep this area tidy. There'll also be some side tins made to stop the ingress off road dirt, rubber off the tyres;) and heat from the exhaust.

I've also been given a window net by fellow VWDRC racer Laurie Craig. Thanks mate

Also tracked down a replacement IRS box as the current one whines a fair amount, when it turned up I checked the code and it's a late 1303s/Karmann Cab one which means it's got the shorter 3.875 final drive, I'm currently running the standard Ghia/Type3 4.125. Happy Days:) Thanks Harv

On the engine front - I've sourced a new early style fan-housing and double valve springs from Airspeed UK, thanks Rich & Martin

Longer term I plan to build a full-on 2442 stroker motor, I've already sourced a T04 turbo and Holley 4Barrel for that, although I'm giving myself well over 2 years to build the beast.

What you said,a BEAST.This is gonna be a hell of a ride.
Good work and let the pics come.  ;)

Now thats cool, a one piece rear end, cool car also.
Keep pictures coming, nice to follow.

I've sorted out a couple of slightly earlier rear lights as the fibreglass wings I've got are 69-71 and won't take my standard late Ghia lights.
The Holley turned up and everything appears to move as it should. It's a 750 Vac Sec, so should suit a turbo set up nicely, ie it should behave itself through all throttle conditions.

ahahah like chevy in "two lane blacktop"  ;D[attachment=1]

Yep, separated at birth ;)

 ;D

You are doing an excellent job on the one piece parts but...........I think unless you paint the car black, the amount of vertical seams are going to distract from all your hard work. two extra vertical lines  added to a car that was somewhat seamless. Just an opinion and I do like the work and concept!

Well here's the moment I've been waiting for, the rear end is fresh out of the mould, no trimming, no cleaning-up.

(http://i60.photobucket.com/albums/h40/russlolly/07012010.jpg)

(http://i60.photobucket.com/albums/h40/russlolly/07012010_001_.jpg)

Starting to look like a complete car again

Looking good fella, liking Phil's work!

Thanks.

Actually it's Lorraine his missus that does the GRP/Resin work, Phil prefers steel :)

They make a good team ;)

Reminds me of this one off Cobra, nicknamed "Flip Top"

(http://www.ultimatecarpage.com/images/large/4338/AC-Shelby-Cobra-427--Flip-Top-_4.jpg)

Almost identical  ;)

The rear piece will be forward hinging/removable though because of the engine access required. As with the front, the aim is for no visible fixings, as nice as dzus fasteners are.

I was reassembling the engine today and it soon became apparent that the case is shot. The rear beariing has a standard thrust and wouldn't drop into place on the dizzy side of the case as it was too narrow. When I tried it on the right side of the case it wasn't even round! So it hought maybe a line-bore might save it, but as I bolted the two halves together without the crank there was a huge gap betweenthe case halves - it had obviously got too hot.

So I've no idea what I'm going to race in April, I can't afford a new case, and even sourcing a used case & getting it cut for my 94mm B&Ps (if indeed I want to do that) is going to cost another couple of hundred quid on top of what I've already poured into the car over the last few months.

Bugger.

Russel, with all this money/work invested...I would take another year for the build. Time flies when your having fun !

Well, I'm keen to get the car finished for the Volksworld show in March and out on the strip the following weekend at Easter Thunderball. So I'm picking up a case from the machine shop on Saturday

Back on track!

Good luck!

Allready looking verry nice!

gr
Wout

Well I've got the case. It's been freshly tapped for full flow, cut for my B&Ps and shuffle pinned. Whilst I was there I dropped my heads off as these are to be cut for double valve springs. So I should have the short block assembled this week, ready to build the heads up next weekend.
All the tinware has been refurbed so it should look pretty tidy when it's all assembled.

Some nice work & fresh ideas in there Russ 8)
Decided on the colour yet?
Cheers,
Kev

The colour was always going to be Pacific Blue, even before all this rebuild malarky it was how I wanted it

lookin good russ will drop that dizzy over to sis this week  ;)

nice man

I am, nice of you to mention it :)

Glenn, thanks mate

We're really getting somewhere now.

All the parts for the motor are here, so that can all go back together.

And Phil's just sent me some progress shots from the workshop.

(http://i60.photobucket.com/albums/h40/russlolly/Jan102.jpg)

Looks like another Beemer has donated its bonnet sliders

(http://i60.photobucket.com/albums/h40/russlolly/Jan10.jpg)

(http://i60.photobucket.com/albums/h40/russlolly/Jan103.jpg)

The grille section from my spare decklid has been grafted into the removable section

(http://i60.photobucket.com/albums/h40/russlolly/Jan104.jpg)

Some funky sprung hand access panels have been cut for one-man removal.

(http://i60.photobucket.com/albums/h40/russlolly/Jan105.jpg)

She'll be ready for paint in just over 3 weeks time, and then the motor can just be slipped into place. Simple.

Splash-pans added & engine bay painted. This is really gathering pace now :)

(http://i60.photobucket.com/albums/h40/russlolly/29012010_004_.jpg)

(http://i60.photobucket.com/albums/h40/russlolly/29012010.jpg)

VERY nice Russ!

showing us all the way Russ, nice one.

Thanks Greame. Welcome to the lounge

Dropped dizzy off today fella , no bod about , left it a plant pot  ;)

Cheers, it has been found.

Spoke to Steve Large today who's buliding my cage, just the door bars and harness rail to finish off, hopefully some pics on Monday.

Cage all done now - thanks to Steve Large.


(http://i60.photobucket.com/albums/h40/russlolly/Cage1.jpg)

(http://i60.photobucket.com/albums/h40/russlolly/Cage2.jpg)

(http://i60.photobucket.com/albums/h40/russlolly/Cage4.jpg)

(http://i60.photobucket.com/albums/h40/russlolly/cage3.jpg)

I've yet to get in it, we'll soon see how nimble I can be.

Glenn, collected the dizzy at the weekend, many thanks. Did the car it came off have a harsh tag up the rear?

Russ,  now thats a race car.

Do you think the lounge is a place I could post the rebuild of my car with its Scooby motor, or would i get abused. :P

Well there's a hefty thread on here showing the bulid up of another flat-four'd water-pumper. Hell, why not, I'm sure you'll love the abuse.

Had a little surprise today.

Went to fit a new steering-box and front tyres - only to find Phil's only gone and painted her!

(http://i60.photobucket.com/albums/h40/russlolly/DSC00497.jpg)

(http://i60.photobucket.com/albums/h40/russlolly/DSC00498.jpg)

(http://i60.photobucket.com/albums/h40/russlolly/DSC00499-1.jpg)

(http://i60.photobucket.com/albums/h40/russlolly/DSC00500-1.jpg)

I think she looks great. I'm still smiling ;D

Looking good Rus

You going to be putting sticker all over that nice new paint work. :D

Actually, I started a sticker amnesty today. Essential ones - race numbers and sponsors only.

Awesome! What a different! And yeah remove the stickers  8)

gr
Wout

Just in the windows too! ;) The lines of the Ghia body are far too smooth to ruin with stickers. I can't see the pics at work, but I can't remember if the roof is now blue too. If it isn't, how about painting it black? That would look really good with the blue lower half. :)

Race numbers only now.

Neil, I've never been a fan of 2-tone Ghia's TBH, this is Pacific Blue all over.

Some better quality pics (and less stickers)

(http://i60.photobucket.com/albums/h40/russlolly/Paint3.jpg)

(http://i60.photobucket.com/albums/h40/russlolly/Paint4-1.jpg)

(http://i60.photobucket.com/albums/h40/russlolly/Paint5.jpg)

(http://i60.photobucket.com/albums/h40/russlolly/Paint6.jpg)

Good man. Two tone only works on certain colours, and I had it in my head that you'd got a white roof?! I'm looking forward to seeing the pictures when I get home! :)

A little bit of coverage;

http://www.eurodragster.com/news/news.asp?Story=february25#february25

Every little helps.

Almost there.

She's all painted! Kirkey race seat & Schroth harness fitted. N/S/F hub and track-rod end have been swapped out, so both sides have the track-rods turned now.
Engine-wise, the bottom end has been built, just need to tweek the endfloat a teeny bit. This should be finished over the next week.

(http://i60.photobucket.com/albums/h40/russlolly/DSC01581.jpg)

(http://i60.photobucket.com/albums/h40/russlolly/DSC01595.jpg)

(http://i60.photobucket.com/albums/h40/russlolly/DSC01593.jpg)

Good gob!

Is looking sweet! 

What a different in such a short term!

gr
Wout

Looking good Russ 8)
Need a money shot pic though - side on with both ends flipped open ;D
Cheers,
Kev

I second that!  ;D

J

Maybe this weekend. The motor should be in which will pull the back down. Wheels have had some attention, so she'll be looking much better.

Well the body's finished and being delivered tomorrow, so more pics to follow this weekend.

Will this do you?

(http://i60.photobucket.com/albums/h40/russlolly/DSC00560.jpg)

(http://i60.photobucket.com/albums/h40/russlolly/DSC00555.jpg)

More to follow

Nice shot Russ , car looks kinda cool - front and rear end

(http://i60.photobucket.com/albums/h40/russlolly/DSC00550.jpg)

(http://i60.photobucket.com/albums/h40/russlolly/DSC00551.jpg)

(http://i60.photobucket.com/albums/h40/russlolly/DSC00553.jpg)

And, remember this?

(http://i60.photobucket.com/albums/h40/russlolly/DSC00379.jpg)(http://i60.photobucket.com/albums/h40/russlolly/DSC00562.jpg)

Awesome!!! The 'aged' pictures looks verry 70ties  :o

Just don't like the blinkers  :-\, maybe original <70 ones look way better?

gr
Wout

Thanks. The pictures are really simple, just switch your camera onto night mode, and if it has a setting for non-natural light switch that on as well, it enhances the blues over the reds and yellows


I agree, however this was simply an economic decision as they were less than £10 new and origianal ones aren't exactly cheap. A friend of mine is making some stainless bases. I'll trim them so the indicators point forwards. Anyway, anything is an improvement on the '71> inducators

I understand the blinker economic thing  ;), I have an early 69 with lots of bodywork to do and I was blown away of the prices for parts   :-\. In the states there much cheaper, but it cost a lot to get it here  ::).

Good luck!

gr
Wout

Brief update.

Barrels are STILL at the machine shop, so that's held up the engine build as I daren't get my heads cut until I've got the barrels back on and rechecked the deck.

Picked up an AM box yesterday This is a late 1300 IRS box and as such has the 4.375 final drive. Should be a 20 minute job to change seeing as the engine's already out and I have the luxury of a removable rear valence.

I've also just landed a full N2O kit. After I've shaken the car down a few times I'll add that in the mix. Most probably at the end of the season when there's more time for tinkering, but you never know....

And it's in!

(http://i60.photobucket.com/albums/h40/russlolly/DSC00641.jpg)

All electrics relocated to luggage area to keep the engine bay clear. Just need a little bit of fettling as she's not really in tune, and then out for Open Sport Nationals.

After that, I'll be playing with the blue bottle, some solenoids & foggers ;D

Ace Russ, looks great!

Looking good russ 8)

Can see a trend for removable rear bodywork begining... ;)

Nice !

looking good ;)

Cheers.

HRC Body & Paintshop has the mould for the rear end, so if anyone needs one, Phil can lay one up. The access to the engine in a Ghia to begin with is much better than a bug, and with the rear end coming away - look at the room around the carbs. No contorting your arm to access the mixture/air screws from the engine bay, or no need to remove a rear wheel and poke around inside the arch.

With good rear clips becoming harder to get hold of, especially in the UK, I'm sure we'll start to see more & more.

Great news today.

I collected the Ghia from Day's Autoservices (07730 586133) who has fixed her non-running issue. This was traced to a faulty distributer (counterweight baseplate had become separated from lower shaft). Replacement installed, all AOK.
Drove her to the local VOSA centre where she passed her Vehicle Identity Check - so she's now all street legal.

A massive turning point as she's now back at home where I can do all the last little fiddly bits.

Good news Russ, will you be racing the Ghia at shakey?

Probably not Ben. She could do with going to a rolling road, and I've probably not got time to get that organised, as I'm away next week. Unless by some miracle they've got room this Friday or Saturday. Still got s few weeny bits to do as well (window net, line-lock, bellhousing strap) So it'll be VW Action for some testing and out for National Finals end of September.
So I'll be borrowing back the #cough# GTi #cough# from my sis at Shakey.
See you there.

So, she finally made it out this season. Only 3 runs, but I got to use her in anger  :)
I already knew from the rolling road last month that I had an issue with fuel pressure at high RPM and I hadn't got round to changing the pump over. On the first run I got to about the 1/8 before she went flat, so I was off the gas, and rolled over the stripe at almost 21 seconds. What was apparent though was that she was much more powerful as I could feel her snaking through 100ft
I then changed the fuel pump to a silver top and put the regulator back in, set to 3.5. A quick spin-up through the water and a decent launch. Again, a little bit squirrely through 1st & 2nd, but at about 800ft she went flat again and I was off the gas, but I managed 16.36 - not bad considering my previous PB was 16.16. First time I'd ever managed the 1/8 under 10 seconds, and just off my best 60ft but with heaps of wheelspin. I ran the tyres slightly higher as a bit of security.
3rd run I wound the reg up to 4.5 and decided not to burnout or stage at launch RPM in an attemp to keep the floats full. Strong through 1st & 2nd, might have left her in 2nd a little too long, but made it to about 1000ft before she went flat again. The good news though is that she ran a new PB of 16.01, and that's lifting-off the last 320ft
After chatting to a few people I'm pretty sure that the 1/4" pipe through the tunnel is causing a restriction, so changing up to 8mm should resolve that. Once sorted I reckon that 130BHP is achievable, so a '14' might be within my grasp.
I had Mark Norton check the cage over and he was happy to furnish me with a 10.00 second sticker.
Now, at Finals last year I had her weighed - bumpers on, seats in - full street weight and she was 917kg. This year she was 804! I was quite surprised considering there's an 8pt cage in there.
All in all a very productive weekend. Thanks to everyone in the VWDRC for the RNJ Car of the Meeting trophy, it appears most of you appreciate the hard work it's taken to get her out there this year.

And here's the proof she made it to the Pod

(http://i60.photobucket.com/albums/h40/russlolly/GhiaFinals.jpg)

 ;D

Little update:
11lb bottle installed in the now redundant passenger area )
Nitrous + fuel solenoids mounted-up in the engine bay.
Holley regulators for carbs & nitrous fuel installed.

I've collected a new flywheel oil-seal, shims & dowels, so I'll pull the motor again (it was bolted back in just to move it) after my new stainless exhaust has been trial fitted, then it should be all systems go. Main job now is still to run the 8mm fuel lines

Had the tank out today to upgrade the connector to 8mm. Remounted the fuel pumps, so I've got the comp one (carbs) mounted correctly upright on the bulkhead under the tank, and the smaller one (nitrous) mounted on the framehead apron.
All the pipes are now routed so they won't foul the long steering arm. Just need to run the larger pipe through the car and sort out some unions for my Holley regulator.

Jeez,
This thread has been starved of updates.

In a nutshell; trashed the crank/fly at Bug Jam 2013, rebuilt to 2109cc reusing everything except a new Forged CB 76mm crank and lightened flywheel. Upped the CR a little.

Got her out at Bug Jam 2014 where I ran 14.77 @ 88.2 mph on 7" slicks.

Trashed the diff in the AM gearbox attemping a big RPM launch in a bid to get into the 13's for the night racing at VW Action 2014.

Now under construction; CE type2 trans, Porsche 944 Turbo stubs, CVs & shafts. Rear mount kit from Cogbox. Everything came up pretty cheap. In fact, after selling my old shafts, CVs, broken box & spare box the only real outlay was the mount.

I started to collect parts for a motor upgrade too, bearing in mind my mild heads and carbs, this was the first pace to look. As luck would have it some 44x37.5 Street Eliminators and a set of 44s came up pretty much straight away. Almost immediately following that, Kuhltec rods, FK89, Engle lifters, straight-cuts, 1.4 rockers, Jaycee tubes etc all came up at the right price. So the motor came apart pretty much straight away. Then I met a girl and I've hardly touched any of the car/engine in the last year! Anyway, with the next season looming it's time to get the build underway, heads have been recut to give 11.3:CR, so I'm hoping to be into the 13s at some point in 2016. Manifolds have been tapped for foggers, so once I've got to grips with the new motor/trans combo it'll be time to add some gas and hopefully chase a 12 before the year is out.

Other jobs; swapping out the stock tank for a 2-gallon cell, lexan and getting around to finally fitting the line-lock

We got the bottom-end built up, and assembled the heads using the pushrod springs.

The CB 1.4 rockers measured-up to 1.45:1, so I have .603 lift.

We swapped out my old Scat springs as they've been used for a couple of seasons, and checked the new springs for bind & retainer clearance. All measured-up well.

Got a fair amount of match-porting to be done as the inlets on my S/E heads aren't round like my manifolds.

Also sourcing an 1 3/4 header.

Russ what springs you using now? just an advisory incase, the scat duals wont work at that lift

cheers Richie

Russ what springs you using now? just an advisory incase, the scat duals wont work at that lift

cheers Richie
[/quote]

Cheers Richie.

The new Scat Duals measured-up identical my used ones. The Empi ones were huge, but came with ali retainers which are now in the bin, (been there). I don't have the figures with me, but the there was surprisingly ample tollerance when we checked for bind and guide-retainer clearance

 :-X

Oops, forgot to update.

Lots of changes - Box conversion complete, so CE code Type2 box with 944Turbo CVs, driveshafts & stub-axles.

Motor has been finished, cam burn completed. Dyno'd at 160bhp@fly, beyond that there was points bounce. So now running pertronix.

Got her out at Big Bang, where she ran down to 14.1 @ 96.6, but with huge wheel hop. Trashed the box and an outer CV because of it.

Next meeting, Springspeed at Shakey replaced the box, added a trapeze bar, hop was better, but still noticeable. Another 14.1

Summer Nationals - fitted the slicks , this cured the wheel hop 100%. (ill still add further frame-horn support, change to Delrin grommets though). 13.81@96.3. Picked the front wheels up too.

1.95 to 60, 8.784@79.93 to the 1/8th.  Could have had a few more revs at the hit, and the in car footage shows I was ignoring the tacho, resulting in short shifting (my ears had got used to changing at 5800 I think), so maybe there's a mid 13@100mph in there

Of course, I'd love to be in our Pro Class, so if 13.5 is all she's got with this motor, then the easiest option to get into the 12s would be a bit of gas.. I'm not really prepared to put any more than 40 in though, so if she's a 13.8 car then so be it.

Bug Jam - looks like previous judder had caused the flywheel to crack between the dowels, causing axial play. Not the end of the world as the crank has zero signs of damage. I still managed the quarter final in my daily, but it's not the same.

She should be all fixed for National Finals at Santa Pod in September, with a new set of KYB GR11 adjust-a-rides. We'll see what we can do, and then plan some work for the winter.

Ok, well....
I got her all fixed for National Finals last September, got some air under the front tyres on all 3 runs and a new PB of 13.66 @ 93mph.
Unfortunately on the 3rd run I missed 3rd, over-revved, threw a rod, broke 2 pistons, lifters, cam.... you know the story. Nothing salvageable from the bottom-end.
Looking at a repair bill in the region of £3K, and realising that any gain in power would cost even more, I've had to call it a day for air-cooled motors for now.
I'm converting to an APX 20V Turbo motor from an Audi TT Quattro. This will hopefully bring me the power upgrade I'm looking for without costing the earth.
I know it's no longer fitting with the Cal-Look spirit, but it suits my purpose & budget better.