Dubs mid engine v8 build - Cut-Weld-Drive Forums

dubber91 · November 23rd, 2013, 12:08 AM

Hi all,

Just thought I'd put a quick intro into my latest project. I'm building a mid-engine audi v8 powered beetle chassis for use under a full beetle body. Based upon rorty concepts, I've sources an audi 01e box, aqj 340hp s6 engine, fully configurable racing ECU, cortina suspension and updated brakes.

Previously the beetle ran various rotary engines, and even had a subaru in for a short while.

Chassis will eventually be going full cage but I'm working on the standard pan for now.

Hope you like!

Steve

dubber91 · November 23rd, 2013, 12:09 AM

dubber91 · November 23rd, 2013, 12:10 AM

dubber91 · November 23rd, 2013, 12:14 AM

dubber91 · February 24th, 2014, 12:59 PM

Realised I haven't updated on here.

So the chassis is coming on well: the progress;

Now I need to finish the welding and focus on strengthening all round.

I've stripped some of the engine and decided against using the laminova oil/water cooler as it is so bulky. So I've made up an Ali plate and drilled and tapped it for a remote filter and cooler;

Small amounts of progress but I'm getting there! Fun so far.....

dubber91 · May 4th, 2014, 12:44 AM

So a little update.

Started on the wishbones; I've now finished the rear uppers and am now working on the rear lowers.

I've also had to rethink my engine mounts somewhat;

Front pulley clearance:

Engine mounts

Front susp brackets

And rear- notice I've had to taper the rear upper chassis rails to clear the wheels!

dubber91 · March 19th, 2015, 02:06 AM

Very small update- although I spent a long time in the garage today

First job was easy- finish off the oil cooler adapter from the block- I drilled and tapped the Ali plate I made earlier for some jic -10 oil fittings and dowty washers- easy!

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Next came the job of moving the engine and gearbox into the shed for trial fitting and making the engine mounts. Christ! This thing is heavy, and steps between the garage a shed didn't help!

Anyway, I got it into the shed and soon found that despite the measurements I took earlier, there are just some things you can't measure with a ruler and angle gauge! The water pump outlet and oil and water fittings were set to interfere with the chassis rails I'd made and used in the designs. Essentially I needed to move the chassis tubes out of the way entirely to get them away from the various fittengs and give myself a cats chance in hell of mounting the alternator on the other side. Out with the angle grinder and out with the main chassis tubes! Bugger......

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I widened the chassis tubes and welded them in situ. Engine now sits much nicer than before and plenty of room for all the bits! A bit of a setback really.

Just enough time to re-try the engine. Hopefully this will be the view most people have when this things on the road!

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More updates soon.... Onto the suspension!

dubber91 · March 19th, 2015, 02:07 AM

A quick update-

I've mounted the front suspension, and started playing with making the rear uprights. I think the pics are self explanatory!

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dubber91 · March 19th, 2015, 02:07 AM

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dubber91 · March 19th, 2015, 02:08 AM

A little more progress. Firstly I realised I hadn't shown you pictures of the shell....here she is:

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Tonight I stripped it and dropped out the floor- it's been 40 years since the floor was removed, so I was dreading what I was to find. But in general, very happy! A couple of bits of corrosion, but nothing I can't handle, and in general, very solid!

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Meanwhile, on the chassis, I mocked up the rear uprights/wishbones

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And did the same the other side. I' going to have to have a good hard think about suspension setups, may be forced to go with pushrod due to the location of the driveshafts.

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Then I pulled the engine to get the chassis rolling and complete some welds-

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That's about it! Gotta get the chassis under the bug and have a look at fitment, then finish up the welding/bracing and prepare the chassis for powder coat.

Good progress I think!

dubber91 · March 19th, 2015, 02:09 AM

Hi chaps,

Been a while since last update so I'll try and keep it breif!

So the time came to trial fit the shell on the chassis. Lots of problems! Long story short the designs to which I was building the chassis were well off, particularly in the front bulkhead area, so that got modified and cut out....

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Eventually got it all lined up and true......

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Then I made up an Ali floor and starter on the engine.... Clearly the engine had had a bit of valve/piston interference..... So rebuild it was!

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There were issues with the tunnel as well, and fitting the seats, so I had to re snuff true it, much lower and much narrower!

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dubber91 · March 20th, 2015, 02:48 AM

So I've been working on the controls and internals for a little bit now. I Started by mounting the gear lever/handbrake mechanism...

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Then looked at the pedal box and bulkhead (the one i wasnt planning to make but had to because the rorty plans were wrong!

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The Firewall - Made from 3mm ali.....

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and it bolted together....small steps!

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