Auto to Manual conversion, Porsche cv's, Linkage refurb

[multisi]

It's actually the other way around, we stopped selling the VW ones as we had a couple split, the aftermarket ones are more durable.
A plastic hinge was never a great idea really.
I've got a bag full of VW ones that I'm reluctant to even put in the clearance section.

The ones for sale on the Brickwerks shop are VW production ?  The info says the  alternative repro pedals were the weak ones. Ive never had an original vw pedal fail, always looked at every one and not seen any signs of weakness.
 

[R0B]

I must have had Friday afternoon ones

[Dueller]

I have only ever bought the bought the VW ones. And had three fail on me. Attaching a wood hinge has done the trick.

If anyone is thinking of doing this, I found shaving a bit off the ribs in order to get the hinge to sit flush with the pedal is preferable.

Great sub thread everyone

Yeah i shaved mine a bit at the back Rob to make it work better on my hinge choice, no idea what it's off but it's metal and it works, had to trim a self tapper screen with the disc cutter but otherwise an easy remedy

Drove the van and it was good

[Dueller]

Drove Valerie round the village today

Felt really good to be out and the power is solid all the way, pulled out onto the main road and gave it some as I hit second, third is long and scary, didn't get to the top of it before I ran out of road

Drives very differently from the auto, almost as if its waiting permission to go whereas the auto was all go

Shifted ok but no 5th gear so adjustment needed as grinding when it slots in so thinking middle adjustment where they join for more throw

Happy days

Also changed the starter motor as hot starting an issue now and again and if the old starter was anything like the clutch slave then its last legs time, will also add a relay for it later today as makes sense while I'm there.

Had to modify aka shrink a M10 nut down from a 15mm to a 13mm spanner as its a stud/bolt on where the D bolt used to be so a little fiddly to remove, hence the change. Wish I'd gone to m8 then could use an 11mm spanner on a beetle exhaust nut.

Lowered the box to help get more access and spanner swing , need to tidy the wiring and coolant hoses under there

[Dueller]

OMG !!

Changed the TPS as had the hesitancy problem before and it's like awesome

Pulled out onto my street and set off the neighbours car alarms, hooligan me

Then at a staggered intersection some flash Audi git tried it on, he got out first but couldn't believe how fast the van was

Same on the bypass after putting some fuel in, still nothing on the dash but the fuel gauge works!

Drove to the Doncaster Dome as had an American and Classic gathering, some really nice cars there, also my local beetle club was in attendance so nice to catch up

Freezing though compared to Barnsley

Needed a push start from there as still having starter issues, time to rethink as its just not good enough. Never had this with the autobox in all it's variations, also cornering causes slight fuel starvation so thinking need an injection tank

Believe a Golf TDI starter can be made to fit, will start another thread on it if I can't find one

Driving the van is mental, it could climb a wall it's that powerful, blast past everything pretty much

[Dueller]

Started a new thread in the Electrical forum about my starter

[R0B]

It has been moved to the modified section.

[Dueller]

It has been moved to the modified section.

Thanks Rob

[Simon Baxter]

It's actually the other way around, we stopped selling the VW ones as we had a couple split, the aftermarket ones are more durable.
A plastic hinge was never a great idea really.
I've got a bag full of VW ones that I'm reluctant to even put in the clearance section.

The ones for sale on the Brickwerks shop are VW production ?  The info says the  alternative repro pedals were the weak ones. Ive never had an original vw pedal fail, always looked at every one and not seen any signs of weakness.

Sorry, Me getting muddled.
There is old VW stock and new VW productions.
it's the New VW production that weve had bother with but JP have a lot of old stock of the old VW stock so we've buying those.
So, Aftermarket ones from JP are actually old VW stock and are robust.
VW didn't have any left, had a new tool made that's not as good as the old one and the hinges break.
That's what I should have said! 

[Dueller]

Got my exhaust sorted last week, it's now the most expensive part of the conversion

Steve at Flat4Mania did all the work with me holding bits in place once he saw the layout i wanted, sorted the linkage too after it popped out of the ball cup









Old beetle mondo compared to the new system























Proper chuffed as it sits just where I wanted it, still raspy loud at just the right note

Needs a mounting tab welding on but it's so fab to drive

On the starter motor issue I made up a more solid system with 3x 5mm plates cut and drilled to fit, bought a 76mm holesaw and it did all the centre cuts brilliantly. Had to drill the holes oversize so I could 'clock' the starter to make sure it engaged the flywheel

Bought a new battery from GSF today also as wanted a higher AMP rating for cranking the motor, so far so good

[Dueller]

That engine will shred the DW, its the early fine tooth gearbox, had one on a EJ22 in a Microbus with fat tyres and it somehow survived.
VW only put autos on their biggest engine, the 3.7 Oettinger wbx6 with 330Nm.
Good luck.

I'm very mindful of your advice here and have been babying 1st gear but 2nd and 3rd are all power, just wants to be heard!

Steve at Flat4Mania wasn't sure about my engine choice for this conversion until I took him for a drive after he sorted my exhaust, he's a believer now

Taking it one day at a time until my current electrical problem with no brake lights or rear indicators, bloody thing

[Dueller]

Biggest battery i could find that fits for cranking

[silverbullet]

Get a cover on that + terminal

And a clamp to stop it juming around

[Dueller]

There's no room bud, had to proper force it in gave it a good fitting

The lid is plastic, which is didnt know, so alls good

Cheers