Author Topic: Project car T34 Karmann Ghia a.k.a Rustbucket  (Read 82607 times)

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Offline 80 Vert

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Re: Project car T34 Karmann Ghia a.k.a Rustbucket
« Reply #615 on: November 20, 2016, 05:57:32 pm »
No need for a lot of drivel this week other than IT RUNS on Bosch Motronic!!!!!  >:D

2013 Chevrolet Camaro ZL1
2010 T5 Transporter TDI
2003 Jetta Coupe soon to be R36TT
1963 Type 34 Karmann Ghia, turbo 2.0
1990 Porsche 964 Carrera 4
1980 1303 Beetle vert, in pieces

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Offline VW'n

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Re: Project car T34 Karmann Ghia a.k.a Rustbucket
« Reply #616 on: November 20, 2016, 11:10:42 pm »
Bit the drivel is the best part!.
Great that it runs that should keep the build motivated.
06 B6 Passat Wagon 2L Turbo (Family Wagon)
87 Mk2 Golf silver (the toy)
95 mk3 gti rusty ABF (Sold)
86 Mk2 Golf red (sold)
89 Mk2 Golf blue (sold)
85 Mk2 Golf GTI silver (parted)

Offline rambo_005

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Re: Project car T34 Karmann Ghia a.k.a Rustbucket
« Reply #617 on: November 20, 2016, 11:57:06 pm »
Well done John, quite an achievement!
NZ: 1988 Mk2 Golf VR6 3 door manual
UK: 2008 Mk5 Golf R32 3 door manual

Offline GLIDN

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Re: Project car T34 Karmann Ghia a.k.a Rustbucket
« Reply #618 on: November 21, 2016, 03:57:35 pm »
Storm Developments, was great to meet their head tuner while I visited them.
Can't remember ECU brand but hopefully I won't need it, really want to try and make this set up work.

He is good
Top Secret Project
MK3 GTI 16v Tornado Red - under the knife soon
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MK5 GTI DSG - Unitronic Stage 1 | Stage 1 DSG | Unitronic Intake |Tuned by HSP Tuning |
MK6 GTI DSG -  Unitronic Stage 2 | Stage 1 DSG | Unitronic Intake

Offline 80 Vert

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Re: Project car T34 Karmann Ghia a.k.a Rustbucket
« Reply #619 on: November 25, 2016, 08:03:02 pm »
Bit more done during the week, main problem was i couldn't run it for long where its parked so some aluminium home heating pipe made a great fume extractor to dump the fumes out the window.
It was quite a flaky starter at the beginning and wouldn't start at all with the cam position sensor connected so that was the first thing to try and fix. I started looking at the timing of the trigger wheel which all seemed to be in the right place and confirmed the firing order was what it should be as water and air cooled firing orders differ. The problem was the old distributor which I converted in to a cam position sensor turned out to be 180 deg out of phase.
A simple remove the drive cog and flip over fixed that and she now starts first turn of the key, even my home made tach works a charm.

Fuel trims were also not working but the donor motor all this F. I stuff came off had VVT which I have no need for, a resistor here to fool the ecu for now got the adaptations working, as we go the VVT will be coded out but for now this will do.
From cold it idles a bit higher as it should, gradualy coming down to around 800rpm as it warms up.
I'm confident enough with progress that I can carry on finishing the remaining things under the car to make it driveable.
2013 Chevrolet Camaro ZL1
2010 T5 Transporter TDI
2003 Jetta Coupe soon to be R36TT
1963 Type 34 Karmann Ghia, turbo 2.0
1990 Porsche 964 Carrera 4
1980 1303 Beetle vert, in pieces

https://www.facebook.com/pages/West-Worx/460154187360186

Offline mark2 golf

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Re: Project car T34 Karmann Ghia a.k.a Rustbucket
« Reply #620 on: November 26, 2016, 08:46:37 pm »
Very cool john.
You will have to start pulling some walls out.
Cant be far off a road test.
89 mk2 1.8t
97 mk3 gti 1.8t
97 mk3 gli
02 Allroad tdi
99 s430 merc
95 hilux surf
90 opel vectra

Online the phantom

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Re: Project car T34 Karmann Ghia a.k.a Rustbucket
« Reply #621 on: November 26, 2016, 08:58:17 pm »
you'll have to change the name of this thread John, rustbucket no more!
Land Transport New Zealand, taking the fun out of driving since August 2008

Offline 80 Vert

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Re: Project car T34 Karmann Ghia a.k.a Rustbucket
« Reply #622 on: November 27, 2016, 11:57:13 am »
Very cool john.
You will have to start pulling some walls out.
Cant be far off a road test.

Thanks Mark, yep removing a wall is only weeks away rather than months.
Still lots of small things to finish but I'll do those once on the hoist, I've probably gotten up off the floor a 1000 times but I'm really tiring of that.
Here's a picture of the fume extractor, works a charm and was invaluable for testing purposes.

A few things left to finish underneath like the charcoal canister which I decided to use running the vent line from the tank to it, these old vw's always stink of gas with the tank in front of you so hopefully this should solve that issue.
Since the original fuel line wasn't being used I've just utilised that for the vent system mounting the charcoal can at the back.
Finished the wiring for the oil cooler fan and thermo switch, there's less and less things hanging down under there so progress must be being made.
Last major thing to do is the DBW pedal and with an intercooler, oil cooler, charcoal can and air intake under there its very very tight with the only spot left on top of the gearbox.
Way too difficult to work under there so I borrowed and trans case which allows me to make the needed mountings on the bench, hopefully its all fits.
I'll use the original throttle cable cut to length to pull on the DBW pedal, made a mount with a series of holes so that it can be fine tuned for the right feel.
« Last Edit: November 27, 2016, 12:20:13 pm by 80 Vert »
2013 Chevrolet Camaro ZL1
2010 T5 Transporter TDI
2003 Jetta Coupe soon to be R36TT
1963 Type 34 Karmann Ghia, turbo 2.0
1990 Porsche 964 Carrera 4
1980 1303 Beetle vert, in pieces

https://www.facebook.com/pages/West-Worx/460154187360186

Offline RobClubley

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Re: Project car T34 Karmann Ghia a.k.a Rustbucket
« Reply #623 on: November 30, 2016, 11:47:24 am »

Offline schattenblau

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Re: Project car T34 Karmann Ghia a.k.a Rustbucket
« Reply #624 on: November 30, 2016, 12:32:05 pm »
you beat me to it rob

;D

nice video
early 911 steering wheel ?

 
« Last Edit: November 30, 2016, 12:34:38 pm by schattenblau »

Offline 80 Vert

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Re: Project car T34 Karmann Ghia a.k.a Rustbucket
« Reply #625 on: November 30, 2016, 01:28:37 pm »
Needs lowering and Porsche wheels  >:D
2013 Chevrolet Camaro ZL1
2010 T5 Transporter TDI
2003 Jetta Coupe soon to be R36TT
1963 Type 34 Karmann Ghia, turbo 2.0
1990 Porsche 964 Carrera 4
1980 1303 Beetle vert, in pieces

https://www.facebook.com/pages/West-Worx/460154187360186

Offline 80 Vert

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Re: Project car T34 Karmann Ghia a.k.a Rustbucket
« Reply #626 on: December 04, 2016, 10:53:59 am »
One of the last parts to make is a catch can for my various engine vent lines and stops the oil being routed back to the intake. One small spot in the engine bay remains which would perfectly suit a small catch tank.
I made one from cardboard first playing around with the shape so that it can be installed and removed in one piece, the place where it fits is quite an odd shape with no real straight lines so just this little tank took more than a whole day to make.
Finally had the shape which would work and clears the fan housing without needing to remove it so traced it on to Aluminium sheet, I tried to minimise the amount to pieces to weld and in the end made the whole tank from only 2 main parts which were folded in the correct shape and welded together.
A separator plate inside drilled with a bunch of holes should help to stop the oil getting as far as the filter, add a couple of hose fittings job done ready for a coat of paint.

2013 Chevrolet Camaro ZL1
2010 T5 Transporter TDI
2003 Jetta Coupe soon to be R36TT
1963 Type 34 Karmann Ghia, turbo 2.0
1990 Porsche 964 Carrera 4
1980 1303 Beetle vert, in pieces

https://www.facebook.com/pages/West-Worx/460154187360186

Online the phantom

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Re: Project car T34 Karmann Ghia a.k.a Rustbucket
« Reply #627 on: December 04, 2016, 06:06:38 pm »
it'll soon be time to get it out to enjoy the weather John, great work
Land Transport New Zealand, taking the fun out of driving since August 2008

Offline 80 Vert

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Re: Project car T34 Karmann Ghia a.k.a Rustbucket
« Reply #628 on: December 11, 2016, 10:10:54 am »
With the holidays approaching fast and a clear hoist for a few weeks the wall had to come down to get the car out of its storage area, it was well worth the effort to put it in there a couple of years ago as its been a brilliant spot to work in but its gotten to the point where I need it out of there so....
Remove the wall and drag it out, If I wasn't doing work to the building in that area in the new year I would probably put the Porsche in there to work on but that doesn't really work at this stage.
2013 Chevrolet Camaro ZL1
2010 T5 Transporter TDI
2003 Jetta Coupe soon to be R36TT
1963 Type 34 Karmann Ghia, turbo 2.0
1990 Porsche 964 Carrera 4
1980 1303 Beetle vert, in pieces

https://www.facebook.com/pages/West-Worx/460154187360186

Offline 80 Vert

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Re: Project car T34 Karmann Ghia a.k.a Rustbucket
« Reply #629 on: December 24, 2016, 06:22:03 pm »
Still more progress on the ole rustbucket, one of the last major pieces came together today namely the seats!
Been a long time coming......read a year! yes that's correct I gave the trimmer my frames exactly one year ago but then great results are worth waiting for and its not like I needed them before it was actually driveable.
The guy is great at what he does and been doing it forever so I'd rather wait and know what I'm going to get even if it takes some time.
Finished putting them together this morning cleaning up the old hardware which could be salvaged.

Passenger seat fitment was fine but the drivers side was too loose so had to remove and spread the runners a little with a block of wood and the knock o meter.
Re installed and all good, finally have something to sit on once that first test drive happens.
I have the car on the hoist now to fix a bunch of oil leaks and hopefully finish a bunch of small jobs underneath including some form of scoop to direct air to the intercooler.

2013 Chevrolet Camaro ZL1
2010 T5 Transporter TDI
2003 Jetta Coupe soon to be R36TT
1963 Type 34 Karmann Ghia, turbo 2.0
1990 Porsche 964 Carrera 4
1980 1303 Beetle vert, in pieces

https://www.facebook.com/pages/West-Worx/460154187360186