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build updates

build updates engine

25

Apr

ECU Programming and Running Engine

Well, we got the engine running – sort of.. We have some early problems getting it to fire at first due to the ECU not being able to recognize or deal with the stock Subaru trigger wheel (Subaru calls it a crankshaft plate – see pics below).  Kevin usually specs an aftermarket trigger wheel from Outfront Motorsports with uniform teeth.   The stock Subaru trigger wheel has a non-uniform pattern of pulse teeth and this is the essence of the problem we’re dealing with.  We needed to get the Redline ECU to understand this stock wheel.

Kevin and the gang over at Redline worked together to get support for this Subaru trigger wheel.  I found a few diagrams online showing the tooth pattern of the Subaru wheel.  I also found a pulse pattern graph and mocked up a tooth count for my own understanding.   I plan to do some software tinkering when I have the chance as the latest Redline ECU’s now have the ability to data log everything.  Data and software I get – wrenches, not so much. :)

Below are the images I found related to our situation.

ez30rcranktrigger

Stock Subaru trigger wheel (EZ30R)

subaru-trigger-wheel-clean

Subaru crankshaft diagram.

subaru-trigger-wheel-marksEZ30R-Crank2

So the car starts after prolonged cranking as the ECU struggles to get in sync.  Once synced, it runs:


Longer version:

So our next step is to get another update from Redline that should have consistent, reliable and spot syncing with this wheel.    Once done, we should be moving on to the body work phase!

build updates

14

Jan

Stance (again)..

It was only when I stepped away that I fully appreciated just how this stance is shaping up.

build updates suspension

14

Jan

A skinny “Fat Chick” gets weighed.

Got the car on the scale.  She weighed in dry at 1,895 pounds giving us a 66/33 (rear/front) weight distribution.  The weight distribution will be tuned up a bit before heading back to the east coast – would like to be at 62% rear bias.

At the moment, no complete interior, no bumpers, no fuel/coolant and no glass.

A stock Karmann Ghia is about 1,850 lbs.

Category update.

build updates performance

08

Sep

914/EZ30D video is back..

The video of the Brazilian Porsche 914 with EZ30D motor (not the EZ30R) is back online.  For some reason the guy made it private, but it’s now public again.  I know a few people wanted to know what happened to it (914/EZ30D video).

For the two guys that have sent email with questions, I’ll reply sometime this week.  I’ve been traveling quite a bit.  Thanks for the correspondence!

Oh and here’s a shout out Kyle Rice and his 1967 Karmann Ghia project!  He’s doing a Ghia with Subaru 4-cylinder and transaxle.

build updates engine performance

06

Jul

air intake work..

First round work on the air intake.. looks massive..

20130706-180243.jpg

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body build updates chassis suspension tires/wheels

03

Jul

Body to chassis work..

Just wanted to toss up some pictures of the front-end stance (top row) some folks on ShopTalkForums wanted profile shots.  These aren’t full profile but it’s all we have at the moment.

The first picture is the result of the initial body to chassis merge.  I wanted to see if we could go lower.  Kevin then tweaked the suspension to drop the front a bit more.    I keep forgetting that these are 17 inch wheels – and as pictured, no rubbing, lock to lock! Trying to find the optimal mix between aesthetics and performance.

Ghias have narrow rear wheel wells.  So on the rear we rolled the fenders a bit to comfortably fit the 205s, but now we can (and will, eventually) go to 215s with no problem.

 

build updates engine performance

02

Jul

Exhaust work

Today Kevin sent a few pics of the exhaust work.  Welding will be finished and then it’ll be sent out for Titanium-color heat coating.

Underneath the car looks great.  On top, not so much. :)

rear-left-exhaust

build updates

15

Jun

Body on new chassis..

A car is born.

A couple of photos of the body fitted to the new chassis.   17 inch wheels all around.  Front wheels don’t rub.  Stance looks very similar to the Bader Ghia.  Kevin will check to see if we can go a bit lower as we’d like to have a bit of “tuck” on both front and rear.

body build updates cooling design

06

May

Aerodynamic exploration

Tinkering with a wind tunnel simulator on the iPad.  The low light is extremely slippery in the wind.  Check out the laminar flow.

build updates

19

Mar

Chassis completed!

Sorry – I posted the Hot VW Drag Day photos before posting the completed chassis photos.

Here you go:

build updates chassis design

19

Mar

The Basilari 306R chassis featured at Hot VWs Drag Day

First public showing of the Basilari 306R (well, the chassis at least) and apparently, the chassis was a hit! Kevin said that his booth had visitors checking on the chassis all day long. Photos below!

“The Drag Day is an event held twice a year in Southern California. Since we brought this event back just over 10 years ago, it has been a tremendous success.”
-Bugin.com

build updates chassis cooling

25

Feb

Chassis assembly – coming together..

Good updates received today.  The Redline ECU was delivered.  All parts have returned from powder coating and Kevin has installed the radiator frame and coolant pipes.   The motor was re-bolted to the transaxle as well.   The car is really, really coming together although we still have a long ways to go.

Next up – kafer bars, completion of the starter system, ECU installation, fuel system and finding some cheap tires.

brakes build updates suspension

18

Feb

Back from powder coating

More suspension and brake parts have arrived back from powder coating.   I haven’t talked to Kevin for about a week – been super busy at work.  The roll cage and the kafer bars aren’t shown and I’m not sure if they are back yet.  It’s very cool seeing this car come together – back to work for me though. :)

Kevin scooped me and posted these on The Samba with this pics – enjoy..

build updates chassis

04

Feb

Silver chassis and clutch access panel.

Another quick update:

1. The chassis has returned from powder coating.  It’s two powder coat layers – one silver and the other clear.

2. The second photo shows the access panel for the hydraulic clutch system.

This chassis is going to really pop when the dark red suspension components return from powder coating.  We’ll try to hold off on updates until we get some significant progress on the chassis.

body build updates chassis

29

Jan

Powder coating preview..

pan-powder-coated

build updates

27

Jan

San Diego visit 2

Stopped by the shop in San Diego this weekend. Chassis and suspension are out for powder coating so not much to report in terms of visible progress.. Believe it or not, I hadn’t seen the motor, roll cage, wheels and radiator setup in person until this visit.  The Ford Mustang Bullit wheels are huge in person – lip to lip I think measured at 9 inches wide.  There would be no way they’d fit without the Mendeola suspension. We may still need to cut cut down the fronts.

 

build updates cooling engine

18

Jan

Cooling system, plumbing completed..

Kevin did an awesome job on the plumbing for the cooling system.  The system will be disassembled shortly for powder coating.

build updates interior

18

Jan

Steering wheel from the parts car..

The good folks over on TheSamba confirmed that this is a 1958 steering wheel.

build updates performance tires/wheels

18

Jan

Preview of the wheels..

By chance I ran across some decent wheels.  I was looking for some steel rollers to get the car moving as my first choice of wheels had a 3 month lead time for delivery.  We needed something temporary to get the fitment right.  The wheels are the “Bullit” style from a Ford Mustang (oh the blasphemy!) but they have grown on me and the offset is damn near perfect for the Mendeola suspension.   I got the complete set off eBay for 1/7th of the price of the RE30s I was looking at. Dimensions are 17×8 with an offset of around 42mm.  We’re going to roll the rear fenders a bit and maybe the front.

Here’s a mockup of the final car with the Bullit wheels.

Here is the car with wheels like set in place (not fully fitted just yet).

Ford Mustang Bullit wheels (rear) on the Bullit Ghia.

Ford Mustang Bullit wheels (rear) on the “Bullit” Ghia.

Ford Mustang Bullit wheels. 17x8s all the way around.

Ford Mustang Bullit wheels. 17x8s all the way around.

build updates chassis cooling engine transaxle

07

Jan

Body, engine and radiator fitment.

Great updates today!  Kevin did a preliminary mock fitting of the body on the chassis with the radiator and motor.  It’s starting to look like a real car.

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