ansonivan Posted February 3, 2010 Report Share Posted February 3, 2010 (edited) I put this car together during the winter of 2005 with the intention of entering the GRM $2005 challenge. Somewhere along the line I became sidetracked by strong drink/dirty girls and the Challenge dream went raisin. After almost 5 years of collecting rust/dust the car is finally going to attend the $2010 challenge. At this point I'm focusing on making the car reliable and safe, over the course of this summer I hope to cut the weight to 2600lbs and increase the collective horsepower to around 300. http://grassrootsmotorsports.com/events/2010-challenge/ http://durocco.com/ Original specs: - 1.8 16v engine front - stock - 123hp - 2.0 16v engine rear - stock - 134hp - 2x agb 020 linkage shift 5 speed transmissions - 2700lbs - actual weight - 50/50 front/rear distribution Current specs: 2x 2.0 16v engines - flipped exhaust cam mod - roughly 145hp each 2x 02A cable shift 5 speed transmissions - 2800lbs - estimated weight after transmission upgrades and firewall installation http://farm2.static.flickr.com/1424/3266577265_77fe35ab64_o.jpg http://farm4.static.flickr.com/3031/3022969349_83d914e905.jpg 4-11-09 Firewall After a fruitless search for cheap honeycomb sandwich aluminum I went with .040 sheeting. I bought the material fromResearch Alloys, $20 got me what I needed and they sheared it to rough sizes so that I could haul it home in my e30. After shaping the three sections using cardboard templates I took the sheets to a friend's aviation shop and had a go with his bead roller. The machine was pretty basic and operated with a hand crank... some of my beads ended up a little wiggly. Mid 90's automatic bmw's with the GM transmission use 6mm bolts to fasten the transmission pans, trans filters for these cars come with new bolts. I saved a bucket full of the used bolts with the intention of using them for something nifty... firewalls are nifty. By careful use of the WAG method I determined that the firewall sheeting needed a bolt every 4 inches, this meant I needed to drill and tap about 120 holes. I welded a 1/4" drive socket to a cheap tap handle, tapping was still a pain. I still need to seal the edges of the sheet, I may paint them and add some sound deadening material as well since the panels are quite boomy despite the beads. Rough sheared sheets http://farm4.static.flickr.com/3610/3433418714_29a2fdec2b.jpg?v=0 Cardboard template http://farm4.static.flickr.com/3566/3433418176_9f6a500529.jpg?v=0 Shears be good http://farm4.static.flickr.com/3629/3432609441_3f1d0c938a.jpg?v=0 Marked and ready for bead rolling http://farm4.static.flickr.com/3582/3433420822_70f077e5dd.jpg?v=0 The roller http://farm4.static.flickr.com/3334/3433421274_8174cc2617.jpg?v=0 http://farm4.static.flickr.com/3338/3432611223_3fe49af845.jpg?v=0 http://farm4.static.flickr.com/3593/3433425616_f62a3ed1bc.jpg?v=0 Mighty Mound of free 6mm bolts http://farm4.static.flickr.com/3301/3433419890_9b01b6c87a.jpg?v=0 The barrier is! http://farm4.static.flickr.com/3643/3433427850_3f06c02b43.jpg?v=0 2-10-2010 - early shifter design/development VW Motorsport built cable shifter for their race teams in the early 1990's, the same design is now available from several aftermarket companies for around $450 at the cheapest. The OG and subsequent reproduction parts are all built from aluminum using three tools I don't have; a milling machine punch press with dies and tig welder. My shifter is all steel, it's heavy, ugly and cheap but with enough tinkering it should work well. My shifter contains the following: - pair of bmw automatic brake pedal pivots to form the two axis of movement - these are throw away parts from 5 speed conversions and therefore come in at scrap prices - bmw m30 rocker shaft as the shift lever - pulled from cracked head - scrap steel prices - 1" square tubing cut in half and drilled in a vain attempt to reduce weight - research alloys - scrap price - 1/8" plate - research alloys - scrap price - stock scirocco shifter base plate forms the base for the new shifter Original http://i74.photobucket.com/albums/i273/Chris_Eyre/VW%20Motorsport/Mk1/VKM/Transmission/VWMshifterincar.jpg My chunky reproduction http://farm3.static.flickr.com/2773/4346099012_a706aba057_b.jpg Edited February 10, 2010 by ansonivan Quote Link to comment Share on other sites More sharing options...
spankis Posted February 3, 2010 Report Share Posted February 3, 2010 Very cool sir, and lots of work I'm sure. Quote Link to comment Share on other sites More sharing options...
zeitgeist57 Posted February 3, 2010 Report Share Posted February 3, 2010 Cool indeed. Is there a lot of labor involved with trying to "sync" the power output of both engines, or is it more or less just a T-fitting on the throttle cables and keep the differentials open to prevent the torque of one engine from popping the other? Quote Link to comment Share on other sites More sharing options...
ansonivan Posted February 3, 2010 Author Report Share Posted February 3, 2010 Since the engines are completely independent of each other running through their own transmissions no syncing is required. Even with the significantly different power output of the 1.8/2.0 setup I had no issues. Quote Link to comment Share on other sites More sharing options...
flyinbrian Posted February 3, 2010 Report Share Posted February 3, 2010 I love this project. Subscribed to thread. durocco.com is in my favs folder now. Quote Link to comment Share on other sites More sharing options...
Aaron Posted February 3, 2010 Report Share Posted February 3, 2010 very cool Quote Link to comment Share on other sites More sharing options...
CRed05 Posted February 3, 2010 Report Share Posted February 3, 2010 Cool! Quote Link to comment Share on other sites More sharing options...
ICEMAN1647545504 Posted February 3, 2010 Report Share Posted February 3, 2010 Interesting... Quote Link to comment Share on other sites More sharing options...
Jeff1647545535 Posted February 3, 2010 Report Share Posted February 3, 2010 cool Quote Link to comment Share on other sites More sharing options...
Trouble Maker Posted February 3, 2010 Report Share Posted February 3, 2010 Holly shit... I remember you posting about this back when you were originally doing it. Cool to see it finally come together. GL at the GRM $2010 Challenge! Quote Link to comment Share on other sites More sharing options...
Dave1647545494 Posted February 4, 2010 Report Share Posted February 4, 2010 awesome Quote Link to comment Share on other sites More sharing options...
Rally Pat Posted February 5, 2010 Report Share Posted February 5, 2010 Fucking tits. Quote Link to comment Share on other sites More sharing options...
Crossle Posted February 5, 2010 Report Share Posted February 5, 2010 I NEEEEEEED to meet you! And drive your car! Quote Link to comment Share on other sites More sharing options...
Erica Posted February 5, 2010 Report Share Posted February 5, 2010 oops, Sean keeps leaving his profile up on my computer so I repeat, I NEED to meet you! And drive your car! Quote Link to comment Share on other sites More sharing options...
ansonivan Posted February 5, 2010 Author Report Share Posted February 5, 2010 My current shifting arrangement requires two hands, a little luck and a lot of patience. I should have the car driving again in the next month, I plan on doing a few autocross(s?) this summer to iron out the suspension. I've always allowed anyone drive the car who was sober enough to climb in without assistance. shifter cable joy. http://farm5.static.flickr.com/4036/4332692819_b456d80d6d.jpg Quote Link to comment Share on other sites More sharing options...
Rally Pat Posted February 5, 2010 Report Share Posted February 5, 2010 If you are going to autocross this year, I would love a chance to drive it. Quote Link to comment Share on other sites More sharing options...
Nicksredline Posted February 6, 2010 Report Share Posted February 6, 2010 sweet setup and looks like a very clean car Quote Link to comment Share on other sites More sharing options...
Zipline Posted February 9, 2010 Report Share Posted February 9, 2010 Wow. So each engine drives the wheels it's over? Is there any way you could link the transmissions to one common shifter so the car is easier to drive, or are they already linked? I couldn't tell. Quote Link to comment Share on other sites More sharing options...
Ramsey Posted February 9, 2010 Report Share Posted February 9, 2010 is it crazy awesome or awesome crazy. either awesome build. Quote Link to comment Share on other sites More sharing options...
ansonivan Posted July 7, 2010 Author Report Share Posted July 7, 2010 I now have a working shifter, it's ugly and heavy but functional. I still need to fab a reverse lockout release lever. Thinking of heat bluing the steel and giving it a coat of gun oil to keep the rust off. I don't like paint or painting. Parts list: 3x bmw automatic brake pedal pivot tube/bushings/spacer - used as the main x and y axis shifter pivots and the rear shift tower bell crank pivot 1x bmw v8 drive belt tensioner swivel - used for the select motion bell crank swivel 2x Mitsubishi Galant shift cable spherical joints - select motion linkage 4x stock VW 02A shift cables 1x bmw M30 rocker shaft - used for the gear lever 1 zillionx washers - shift knob 1 bmw m30 head bolt - shift knob center shaft bunch of scrap steel was used for the shift tower. Other hardware - scrounged from my parts Passats. Image hotlinked from Tim's pictures of C&C - let me know if this is not ok Tim. http://www.pbase.com/timothylauro/image/125980646/original.jpg Quote Link to comment Share on other sites More sharing options...
Rally Pat Posted July 7, 2010 Report Share Posted July 7, 2010 Holy fabrication, Batman. Looks like an old style Sequential shifter from an old rally car. Quote Link to comment Share on other sites More sharing options...
ansonivan Posted July 7, 2010 Author Report Share Posted July 7, 2010 Holy cheapass fabrication, Bateman. Looks like an old grain silo had sex with an erector set. Fixxored Thanks man, I had a ton of fun making it. Quote Link to comment Share on other sites More sharing options...
iwashmycar Posted July 7, 2010 Report Share Posted July 7, 2010 niice. subscribing for more Quote Link to comment Share on other sites More sharing options...
Rally Pat Posted July 7, 2010 Report Share Posted July 7, 2010 Fixxored Thanks man, I had a ton of fun making it. Quote Link to comment Share on other sites More sharing options...
Das Borgen Posted July 7, 2010 Report Share Posted July 7, 2010 http://i135.photobucket.com/albums/q158/heathmun/mother-of-god.jpg Quote Link to comment Share on other sites More sharing options...
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