Author Topic: Project car T34 Karmann Ghia a.k.a Rustbucket  (Read 82647 times)

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Offline 80 Vert

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Re: Project car T34 Karmann Ghia a.k.a Rustbucket
« Reply #630 on: January 07, 2017, 09:04:45 pm »
I had these big plans to do all this work on this thing over the holidays but none of it has really come to much, one thing though is that having it on the hoist has made life a 1000x easier.
Anyway a few bits and pieces here and there gets me a little further ahead at least, started on a scoop of some sort today to direct some air in to the intercooler under the car. Making the pieces from cardboard which I'll then trace on to aluminium.

Also couldn't resist taking the front end apart again to re index the torsion bars for another 20mm drop but unfortunately that meant the front was sitting on the bump stops so I took them off and cut them down giving me some travel back.
Annoyingly the fuel gauge didn't work so that wasted another 1/2 day, found the sender to be faulty....
the great thing about this old junk is that you can actually take stuff apart and repair it, as was the case with the sender.
Corrosion between the housing and copper element stopped it working however upon testing it the gauge would either read nothing or completely full.
Bit more fault finding done a bad ground on the back of the gauge was problem 2, now have the 6V gauge working on 12V lets see how long that lasts.
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 80 Vert

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Re: Project car T34 Karmann Ghia a.k.a Rustbucket
« Reply #631 on: February 12, 2017, 12:21:49 pm »
Been a while since the last update and have had my fair share of issues to deal with, once all of the items I wanted to do over the holidays were completed the time came to actually drive it and considering its running a stock standard 1.8T ecu it actually runs and drives really well.
I was really surprised how well it drives and feels, not a lot of noise and seems pretty effortless. I don't think I'm making any boost for some reason but that's not a bad thing while the engine is bedding in.
A couple of trips down a very quiet road near work all seemed fine..................until the 3 mile mark..............a huge cloud of smoke coming back to work.
Cut a long story short it blew a hose clean off the oil cooler loosing around 5L of oil in an instant, oil over absolutely everything underneath. I've never had such an epic mess to clean up.
5 hours on the hoist degreasing and washing everything down, amazing where oil goes when sprayed under pressure!!
But why?
Fundamental mistake on my part, running an external filter and oil cooler both of these see unregulated oil pressure direct from the pump meaning it could be as high as 300psi pressure maybe more.
Normally you fit a pump cover with a relief valve but being a type 3 engine I don't have room, after looking at other options I settled on a Jaycee oil filter mount with a bypass valve built in which has a hose back to the sump.
Above 80psi it will send oil back to the sump doing the same job as the pump cover.
Very lucky that I'm running a deep sump as otherwise I think the engine would have been toast, with this deep sump I'm running more than double the original oil capacity.

Few weeks of waiting for parts to arrive yesterday I pulled the sump to drill and tap for the return line, changed the rubber hoses to the cooler for ss braided ones (probably not necessary but I'm not taking any more chances)
Ran the new hoses and buttoned everything up, primed oil pressure and all seems fine so far.
Hopefully this is it for a while and can now just concentrate on tuning the thing, this has by far been the most stubborn car ever as it seems it just doesn't want to be finished.
« Last Edit: February 12, 2017, 12:23:49 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 badhabit

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Re: Project car T34 Karmann Ghia a.k.a Rustbucket
« Reply #632 on: February 14, 2017, 10:17:34 am »
"I was really surprised how well it drives and feels, not a lot of noise and seems pretty effortless."

that's just how a type 3 drives john! I've been telling people for years! ;D :o  :P
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1991 Porsche 911/964
1960 VW karmann ghia

Offline the phantom

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Re: Project car T34 Karmann Ghia a.k.a Rustbucket
« Reply #633 on: March 31, 2017, 02:07:45 pm »
Land Transport New Zealand, taking the fun out of driving since August 2008

Offline wilco

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Re: Project car T34 Karmann Ghia a.k.a Rustbucket
« Reply #634 on: April 01, 2017, 11:32:26 am »
Looks like it's stuck...

Offline gti vr6

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Re: Project car T34 Karmann Ghia a.k.a Rustbucket
« Reply #635 on: April 02, 2017, 01:10:09 am »
Looks like it's stuck...

air cooled v-dubs don't get stuck that easily.
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Offline 80 Vert

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Re: Project car T34 Karmann Ghia a.k.a Rustbucket
« Reply #636 on: April 09, 2017, 09:24:09 pm »
Realised I never updated the oil pressure situation, after ordering a new filter mount with a built in pressure relief valve which has a line plumbed back to the sump seems to have worked wonders for the old girl.
Also had new braided oil lines made to the oil cooler so those should be trouble free as well from now on, started out driving very short distances around work gradually venturing a bit further, I have a whopping 52km on it now still on the stock 1.8T map which runs good enough.
I have reached a decision on tuning though which is going to be Eurodyne and that will happen over the next few months.
There's no major panic as it starts and runs good enough to break the motor in, seems to make some boost and gets along pretty well.
Fan on the oil cooler used to come on pretty quick but even that seems to have sorted itself out and by all accounts the motor temps seem fine as such but the proof will be longer trips I guess.
Only a few months to tune before winter at which time I'll pull all the glass and start putting right some of the stuff annoying me.
« Last Edit: April 09, 2017, 09:49:31 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 the phantom

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Re: Project car T34 Karmann Ghia a.k.a Rustbucket
« Reply #637 on: April 10, 2017, 12:29:33 pm »
looking sweet
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Offline Fizz

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Re: Project car T34 Karmann Ghia a.k.a Rustbucket
« Reply #638 on: April 10, 2017, 01:00:03 pm »
mmm... so nice  :)
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Offline virus-zn

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Re: Project car T34 Karmann Ghia a.k.a Rustbucket
« Reply #639 on: April 10, 2017, 05:10:19 pm »
That pic does not do this car justice... the attention to detail and craftsmanship, especially in the engine bay is phenomenal...
 

Offline badhabit

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Re: Project car T34 Karmann Ghia a.k.a Rustbucket
« Reply #640 on: April 12, 2017, 10:34:31 am »
i think you need to borrow my 1200 beetle "race car" HA! and i think you'd go WOW my ghia is quick!?!
you've been driving to many modern cars!  ;D ;D
2007 Honda Euro
1973 Datsun 240Z - RB25det build
1991 Porsche 911/964
1960 VW karmann ghia

Offline coons

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Re: Project car T34 Karmann Ghia a.k.a Rustbucket
« Reply #641 on: September 24, 2017, 05:24:59 pm »
First time on here in a while. Car looks epic John - nice one  8)
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