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Bay Window with 1.9 TDI engine -> READY
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Wilfred
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PostPosted: Mon Jun 11, 2018 12:03 pm    Post subject: Reply with quote

the new box really is a treat!

in 5th I am doing 110 km per hour. not sure about revs, as I have nog gauge yet, but based on engine sound its about 2500 or so.

And there is power left. when I want to overtake, which I want a lot now, I just accelarate a bit, which goes very smooth and I fly to 130 kph. The windnoise is aweful at that speed, but for a short while it's fun!

Really, these ratios work much better for me!

and no oil leak from the box, without any piece of hose or something like that
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1973 BayWindow running 1.9 110 bhp TDI with flipped gearbox.
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splitbusvanatic
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Location: Co. Mayo, Ireland

PostPosted: Mon Jun 11, 2018 10:23 pm    Post subject: Reply with quote

Brilliant stuff.
What car is the gearbox from ?
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Wilfred
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PostPosted: Tue Jun 12, 2018 6:41 am    Post subject: Reply with quote

it's from an audi A4, TDI. so basically the same donor as the old car, but there is so much variety in ratios that you really have to look for the correct code.

Basically the lower gears are comparale, but 4 and 5 are way better.
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jp
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Location: Chippenham, Wiltshire

PostPosted: Wed Jun 13, 2018 9:09 am    Post subject: Reply with quote

Brilliant stuff.. I really want to do this conversion my 2ltr box even with a taller 4th just ain't enough.
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1971 Devon Bay with 1800 Ford Turbo Diesel Engine (wip)
1983 VW Golf GTI CAMPAIGN
1979 Mini 1275 GT
2013 Scirocco TDI GT
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Wilfred
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PostPosted: Mon Aug 20, 2018 12:27 pm    Post subject: Reply with quote

I have always had a bit of trouble running the intake hoses. The passat TDI intake manifold points straight to the firewall, so there is only very little room to make it fit.

by accident, I found out that the manifold from a Caddy (and other models maybe too) points exactly the other way around.
Luckily my brother had just crashed a 2004 caddy Laugh Out Loud so I took the manifold of the leftovers of that car, and put it on my TDI. I am working on the conversion, but will make some before and after pics.
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splitbusvanatic
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PostPosted: Sat Aug 25, 2018 9:03 pm    Post subject: Reply with quote

The manifold idea sounds good.
Looking forward to the pics.
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Wilfred
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PostPosted: Mon Aug 27, 2018 12:21 pm    Post subject: Reply with quote

here is the pic of the manifolds. Top is Passat/audi a4. Bottom is Caddy.

the ports are the same, as well as the bolt patters, so it is a direct swap but it makes the tubing so mych easier.

IMG_20180822_222938 by Wilfred Roo, on Flickr
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1973 BayWindow running 1.9 110 bhp TDI with flipped gearbox.
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jp
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PostPosted: Thu Sep 06, 2018 10:25 am    Post subject: Reply with quote

Neat good find that
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1971 Devon Bay with 1800 Ford Turbo Diesel Engine (wip)
1983 VW Golf GTI CAMPAIGN
1979 Mini 1275 GT
2013 Scirocco TDI GT
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Kai
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Location: Village life.... Enter the Vale

PostPosted: Thu Sep 06, 2018 7:50 pm    Post subject: Reply with quote

Dark side tuning will sell you a DPF delete pipe for that PD Inlet manifold. The PD Inlet manifold is considered an essential performance upgrade compared to the AFN manifold. Flows air better.

I have ventured down this route myself also. Think I had a sharan Inlet which ended up pointing in the wrong direction for my application so then went onto a golf one. They cost nothing in the UK, £10. I did see a Sharan inlet sell for £70 I’m ebay as they’re the desirable ones.
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splitbusvanatic
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PostPosted: Thu Sep 06, 2018 8:35 pm    Post subject: Reply with quote

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Wilfred
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PostPosted: Mon Sep 10, 2018 9:28 am    Post subject: Reply with quote

allright, back from a 3000 km roundtrip to Italy (of which 1100 in 1 day!!!).

we had a very nice holidy, although a bit shorter than planned as our son got very sick. After keeping us awake for two nights, we went home a bit earlier than scheduled. Because our son was so sick, he was sleeping all day, allowing us to drive from south switserland to the north of holland in 1 day. Even when starting at half past 9 in the morning. that meant 1100 km in a day, including passing the alps through the gotthardtunnel. It all went brilliant.

the holiday went nearly perfect, but one campsite we choose, at a local farmer was a bridge too far for us. the road down to the farm was so steep, that all 4 wheels blocked, and we still kept going down....

of course this also meant we could not get out. the engine just doesn't have the power. I lost all water on board (60 liter). Asked the wife and kids to walk, just to loose weight, but still wouldn't do it. As I needed to keep the revs up, I played with the clutch resulting in an impressive cloud of smoke from a fastly wearing clutch. still, we had to ask somebody with a tractor to pull us out.

after that, changing gears got a bit harder. I think the clutch is just gone, but I will have to pull the transmission to make sure this is the problem.

anyway, I got my doubts about the drivetrain. The TDI is perfect. but the gearbox solution remains a problem for me. the angle of the driveshafts is bothering me. I solved this with huge tyres, but this compromises the power in low gears, and it looks crap. Especially the wife hates the wheels on the back.

I am really considering what options do I have. I do not want to lower the van, if anything, I want it higher. I am considering an original box with stronger gears. or subaru with Subarugears box. But these are expensive. Anybody got a good idea?

I really like the TDI, but the gearbox solution is bothering me too much.

Of course, also some pics:

IMG_20180904_120608 by Wilfred Roo, on Flickr

IMG_20180904_145520 by Wilfred Roo, on Flickr

DSC03749 by Wilfred Roo, on Flickr

DSC03801 by Wilfred Roo, on Flickr

DSC03803 by Wilfred Roo, on Flickr
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splitbusvanatic
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PostPosted: Wed Sep 12, 2018 11:22 pm    Post subject: Reply with quote

You’re not alone in thinking that the flipped gearbox is a huge compromise.
I too am re thinking. But the price of a rebuilt stronger box is huge.
And the cv angle is a massive negative also.
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