Bay Window with 1.9 TDI engine -> READY

[Wilfred]

I ordered a set of porsche 944 cv joints. (second hand). these can handle a larger angle and are stronger in general. The baywindow driveshaft will fit. See this page:

http://blindchickenracing.com/How_to/CVJoints_Axles/cv_joints_101.htm

The I am gonna lower the van, to reduce drive shaft angle. Fit bigger wheels, to maintain acceptable ride hight. Another advantage of bigger wheels is less revs, which also reduces impact on the joints.

Hope this will make it last.

Bus is at the MOT station at the moment.
_________________
1973 BayWindow running 1.9 110 bhp TDI with flipped gearbox.

[Wilfred]

FRESH MOT!
_________________
1973 BayWindow running 1.9 110 bhp TDI with flipped gearbox.

[skirk]

[skirk]

[splitbusvanatic]

I too have Porsche cv joints on mine.
Something like 23 degree angle of travel as opposed to 17 degrees in standard bus cv's.
Yes the single biggest problem with this flipped box stuff is the Angle of driveshaft.

Great news you got the MOT.
Well done.

[Wilfred]

I've been making little trips like this morning I took the bus to work. When I release the throttle pedal and let the bus roll and brake on the engine, I here a rattle....

CV-Joint?

I didn't replace them yet, so I actually hope it's the CV's as I already have better replacement parts then...

No noise when just cruising... then all is chill. and powerfull!

I gotta feeling the engine keeps performing better now that I drive it more often. Replacing timing belt tomorrow! And cv's of course.
_________________
1973 BayWindow running 1.9 110 bhp TDI with flipped gearbox.

[skirk]

Hi Wilfred.

Glad you are up and running smoothly. Having a few issues with mine. Hoping its to do with air in the clutch fluid. Going to bleed again this weekend. When it's going it goes v well. Just random loss of gear selection after a run out.

[Kai]

My standard t25 cv's are fine


Best £5.5k spent on my van pay to for the engine conversion apart from buying the thing. Loving it
_________________
Think......

Don't sleep and drive!!!

[Wilfred]

5.5k????

Holy poo (pardon the language) that is more than the total sum of money that has gone into my van in the last 6 years (which is the period I owned it), including buying the thing! (and that is in EURO's)

I knew it would be expensive to have it done, but this really blows my mind.

On the other hand, you are glad you spent the money so it was totally worth it right!!! Glad you like it. I love it too! I still wanna improve stuff, but not very major jobs.

The clutch can be a pain in the ass, especially cause it's such a long way from the pedal to the box.
I had to get the right feeling for the gears. Now it works flawless.

the t25 cv's are the same right? It just depends on the angle.

My cv's were bad to start with, even with the original engine. putting a diesel into the thing did not miraculously cure this. :-)
_________________
1973 BayWindow running 1.9 110 bhp TDI with flipped gearbox.

[Kai]

It was expensive yes, but it's mostly new items and I get a 12 month warranty on everything including labour. I don't have the time to do another conversion so I had to pay the man that can. Was Tim from ultimate engineering himself that did my van. The only used items im told are the engine and gearbox. The rest was new, even the turbo. The only real world issues I've had where two oil leaks which I've fixed myself as its a 4 hour round trip. I've fixed both with new clips. I couldn't ask for more. Also I had cruise control fitted. I think it worked out I paid 1.5k in labour. The rest was new parts and the engine and gearbox.

I wouldn't have ever got it finished myself. Took me long enough to do my Subaru conversion in my notch.
_________________
Think......

Don't sleep and drive!!!

[Wilfred]

I think it is a fair price, but what matters most is you are happy with it!

I replaced the timing belt yesterday, as well as cv-joints. Now porsche style. Rattling sound is gone, which is good!

Sadly had a flat tyre yesterday. had a nail in the rubber.

Then I also made some 200 kilometers on friday/saturday. All went perfect. Still few minor issues though. (that is also the reason I wanna make miles. I wanna now the flaws before we're in Italy! :-)

-The connection of the clutch line to the master cilinder is sweaty. After two weeks, the pedal has also dropped a bit. pump it once, and it back, works fine and feels firm. Will have to think of a solution. The master cilinder is brand new...
-sometimes there is simply more power with no apparent reason. on the highway, sometimes 120 kph is half throttle pedal (most of the times), but sometimes it isn't able to keep doing 110 kph. I dont know why yet.


Also I have to remove the power steering pump still, cause the pump is just running along, consuming energy for no reason. gonna measure what belt I need for that.

all in all though, it is reliable and I feel confident to just step in and drive to southern europe. Will still be couple of weeks so lots of testing time ahead.

Some pics to make this boring story interesting.

https://lh3.googleusercontent.com/9Ft5ZbRk8no30xHgwUG_PvLkdIeE8mlaRxePoN_CbCE=w333-h187-no
https://lh3.googleusercontent.com/zGxVCY1dYgVQ8n7LAaswF2RHBozt-JKrKQY8FNrHgcs=w517-h919-no

This is at the hospital. Nothing serious, just picking up the missus after a night shift :-)
_________________
1973 BayWindow running 1.9 110 bhp TDI with flipped gearbox.

[Wilfred]

For anybody who wants to delete the powersteering pump on a passat AFN, the belt you need is 5pk1073.

:-)
_________________
1973 BayWindow running 1.9 110 bhp TDI with flipped gearbox.