RetroVans's "Fugly Braziliamba" Project

[hitlers revenge]

Squire, what wiring diagram did you use on the bus???

[retrovan]

Squire, what wiring diagram did you use on the bus???

Hi Dave, To be honest, I did not use any Wiring diagram.

What I did was See where the wire came from, Looked at the colour of the wire, and tested it along the way to where it should go.

If I wound it there, I connected it to where it must go, I it had a break before it got there, I fixed it, then I connected it.

Had a lot of loose wires under the dash, and a lot of dirty connections along the way, but no train smash.

I do believe it is a wiring harness of the early Bay, but not sure.

Herman

[Johan Eagle]

You taking the Golden Fugly to George?

So I must spark to get the yellow one going and join you!!
Greetings

[retrovan]

Hi Johan,

That will be great if you go along to George,

Two Brazilia's in convoy.

How is you bus going........??????

Herman

[hitlers revenge]

Maybe bring mine, then it will be 3.

But, the question is, will it be mobile. There are secret plans in the pipe line. I do believe a rather large christmas box is on its way.

More, closer to the date.

[retrovan]

Yes bring it, Please, and now you got me excited, for you, Love these Boxes from "OverSeas" ..........

Herman

[retrovan]

So not much done this weekend, but with the ageing process, and the rain weather, we got some thing done.

Got the new type 4 ready for fitment into the bus.

And NO, its not getting a Upright fan, its going in as is.

Had me a few test fits, had to modify a bit all over, had to grind the bell housing to clear the 228 Flywheel,
Have decided to keep it 228 mm as I have big wheels on the back, and this could lead to clutch burn out on a smaller clutch plate, with the load on pull away.

Will be keeping the body work as near as original in the bus, so that the old motor can go back without much effort.
But then again, the motor will stay as close to original as possible as well, in case I want to fit it to the Fastback.

So we will have to make one-off made tins to fill the gaps, but not to look like a crushed tin accident at the scrap yard.

Well here is the engine on one of these test fitments.... Not bad single handed, for an old toppie......





And no Sean, the wood blocks are not stands, but safety stop blocks, should the engine have other ideas......

Till its fully in ...



Herman

[Tony Z]

Nice work old toppie.

Isnt the engine too long to fit without going upright?

[retrovan]

Nice work old toppie.

Isnt the engine too long to fit without going upright?

Noting this Toppie can not do with a Angle Grinder...............

No, all jokes aside, as I want the motors to stay as STD. as possible, so that they are interchangeable, we will "Make a Plan"

As you can see I kind of like the Type 4 engine, and all my AC have one, even thinking of fitting one into the Audi A4...

This challenge is there to be overcome,

I Hope..

Herman

[retrovan]

So this weekend has been an exhausting one, or should I say an In-Out kind of weekend.

Trial fitted the motor a few times, no I lie, I had the dam thing in and out 6 times......

Always not wanting to take off the bell housing too much, I was grinding, fitting, removing, grinding, fitting, removing, grind........

Here is proof....









So I ground the out of it ...



And fitter my new filter, Fuel Pump, and shut-off valve, as well as clean tank filter, and new fuel lines...



OK, so then I painted the bell housing black inside so I can see where she still scrapes.......



And would you know, it went in perfect, and turned freely... ..... finally..

So I fitted new tins, and modified a few, made sure there ids no place for the hot exhaust air to get in, and then fitted the engine se-round seal.





So now the engine se-round rubber will seal on the engine hatch when closed, making sure we do not re-breath the hot air.

Now for the bumper mounts, and then the tow hitch..............

Till then

Herman

[hitlers revenge]

Now for the bumper mounts, and then the tow hitch

I did mine today, unfortunately it was only on my wife's Opil.

[retrovan]

So I got a few things done this week end,

The engine was not happy, as it still touched on one spot, so out it came again, Boy am I glade I sprayed it black in side the bell housing. spotted it strait away where it was touching, would not have picked this spot to have been a problem.

Made the 10 mm spacer for the starter.

Made the stiffer bumper mounts, and built up a tow hitch with solid 10 mm clamping bars, on to the body.

Got the tow hitch on as well as the bumper.

completed the fuel lines, now just the vacuum pipe to the brake booster.

Must set up the clutch.

Also want to fit a heat plate between the bumper and the exhaust, think it will look good, and stop heat coming up behind the bus.

Temporary fitter some Plastic wing mirrors that came with the Fastback, must try get some elephant ears from some where for this bus.

Well hoping to start the 2Lt type 4 tomorrow, see if all else runs.

Till then

Herman

[retrovan]

So finally have the Flat Type 4 Motor into the Fugly,
Paid a lot of School Fees, to make this happen, and as I was told by a few of the Forum experts, " go for the Up-right conversion, its the only way to go." I have my reasons for staying flat.

Never one to miss a challenge, and also I want all my Type 4 motors to be near standard, as then I can swap them out between the cars, BUT I also do not want to HACK the cars, where I can not go back to the original engine.

So the brief on the project was simple, ... ..Leave all the 1600 motor engine rubbers intact in the engine bay, BUT fit the Type 4 2Lt motor with its own tins and seals into the engine bay with out cutting any of the bus, or engine parts. ..

That means that the engine will protrude by approx. 50 mm out the back hatch. So now I had to make new tins on the motor to form a sealing line into the flat part of the engine hatch. Also I had to make sure the hatch seals on the sides when closed, so as not to suck air into the engine bay from the exhaust. Made wedge tins to seal these sides as well.



So here is a photo of the back with engine in ;-



Here the sides sealed to keep hatch sealed ;-





Also fitted a heat guard over the exhaust to keep the hot air from coming up the back of the bus .

Now here is the "Fugly" on its Dr Watson wheels, with the Flat Type 4 2Lt motor in and sealed, with back bumper and tow
hitch.





The carbs are not right, these must be set, or maybe Santa will bring me another set of 34 Weber's...

Have started the Fugly, and drove here in the yard,but still needs more work on the steering, as its too tight.

Till the road test ....

Herman

[hitlers revenge]

Looking good, but those 15's

[Warwick-Lowlight]

Hr up nice and early - where the pics of your fugly

Really looking good there Uncle Retro