My v8 mid engine project

[Stephen Hallett]

Brief update

Now all major chassis metalwork is there or thereabouts. I still have some gusetting and cross bracing to do, but onwards I need to start thinking about suspension location and wishbones. I've found that the hubs were actually escort; so won't work. So I've sold them and am looking for some new cortina jobs.

Some pics with the rollbar installed

 

[Stephen Hallett]

I may also gave to modify the tunnel as it is a bit cumbersome- will have to try some seats and see!

 

[Doug S.]

Cool project, Stephen!

My hometown area has a lot of dry creeks, sandy bottoms. Lots of folks welded up their own frames, but always with front engines. I get that you are very savvy with tech...the sand-rail crowd seems to be doing a lot of the same...except having not looked at their stuff for many years, it suddenly dawns on me that they were mostly rear-engined at that time. One of the guys used a GM350/TH400 in a mid-engine config, but he had to give up rear suspension for that and it was WAAAAY longer than you're fabbing up. Anyway, their stuff might be helpful, have you checked out their forums, too?

I'll be lost when y'all start talking suspension....but will follow anyway :thumbsup:

Cheers!

Doug

 

[Stephen Hallett]

Thanks for your kind words Doug. It feels like I've achieved a lot, and learned a lot, already.
Suspension will be based upon ford cortina/taunus- which will be double wishbone front and rear. This means there won't be a conventional suspension strut with stub axle and hub, but a kind of floating upright and hub. Springs and dampers will be conventional eyed designs-likely avo. Most difficult bit will be arranging the rear driveshafts and rear uprights that I will have to fabricate from sheet steel.
It's been fun so far!

 

[Stephen Hallett]

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!

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......

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!

More updates soon.... Onto the suspension!

 

[Henk]

audi V engines sure are huge!
Have the v6 turbo myself, also mid engine to be.
what is the engine management you'll be using?
Look forward to seeing more on this!

 

[Hugo Zubieta]

I work in a very similar project, nice to see another one.

 

[Stephen Hallett]

Hey Hugo! Your project has been something of an inspiration to me! I'm a little way behind you now, but I'm continuing to be away at it.

I'm going to be using a pectel ECU, it's very comprehensive, more so than what I need, but nevertheless it's available.

So a little update.

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

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! Hugo I have no idea how you've got yours to fit! Haha

Hugo what have you done about the alternator- did you relocate it?

Cheers
For your interest guys

Steve

 

[chris]

Stephan in your second last photo I think I saw
a hacksaw whats that about don't you have a
grinder I have to many skinned knuckles to use
one of those enjoying your build log bloke
chris

 

[Stephen Hallett]

Haha! It's not something I use often, I gave two grinders on the go. Only issue is every now and then there's a little cut needed that you can't quite reach with a grinder.... So out comes ol' faithful!

Thanks for your kind words fella, it's good encouragement!

 

[Hugo Zubieta]

Hugo what have you done about the alternator- did you relocate it?

Cheers
For your interest guys

Steve

The alternator are in stock position, I don't have a good picture of the mounts, and right now my engine it's out of the car.
This are the only pics of two of the three mounts. (I have one on the rigth side in front, near the alternator)

Rigth side mount:



Left side mount: (the left circle in the picture is when the third support mount but in this picture it's not bolted).

 

[Hugo Zubieta]

This is how it looks now my car.

 

[Stephen Hallett]

A quick update-

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

 

[Stephen Hallett]

 

[Jim Cowden]

Nice progress Stephen.
Making chassis mods was a set back but worth it, nothing worse when you are done and you say to yourself " SELF" I should have sorted that but know its to late.

Everytime I look at your build I want to by you another shed, I get claustrophobic looking at it.
How are your neighbors handling the noise.

Well done.

Jim

 

[Stephen Hallett]

Thanks Jim! You're welcome to come build me one! I'll even supply tea and biscuits.
A little more progress. Firstly I realised I hadn't shown you pictures of the shell....here she is:

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!

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

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.

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

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!

 

[Stephen Hallett]

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....

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

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!

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!

 

[Randy V]

That is gonna be one bad-ass bug!

 

[Chris Huck]

Looks a fun project, will surprise a few people at the lights!! Is that Audi engine direct injection or port injected?

 

[Dutch]

What a great project!
Seeing what you are doing to a VW Bug make me wonder what is planned for that bicycle in the last photo.