Author Topic: Ground up rebuild on a Aus delivered aircooled FSM Niki  (Read 21848 times)

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GTMaster

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Re: Ground up rebuild on a Aus delivered aircooled FSM Niki
« Reply #15 on: July 30, 2011, 03:54:06 PM »
You can have "I'm blue" blaring from the radio now  8)
The rocker cover gasket on the left in the picture is one i haven't seen before (maybe since it's longer at the edges it hangs out from under the cover too much and causes the oil leak? )
"One more drink, Lacikám?"

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KAL SPL

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Re: Ground up rebuild on a Aus delivered aircooled FSM Niki
« Reply #16 on: July 30, 2011, 05:34:46 PM »
Stereo is getting a major overhaul while Im doing everything else , given its my business I should be able to come up with something :P

The gasket on the right is the 1 I fitted first , I noticed it didnt sit on the head correctly on the exhaust side , I put a small ammount of gasket sealant along the head to hold the gasket central with the edge of the rocker cover and it seemed ok , the first small drive resulted in oil everywhere , I could actually see the rocker gear between the head and rocker cover when I checked it.

I had another kit there that had both gaskets in it and the 1 with the tabs is actually fatter on the exhaust side and fits 100% , no oil leaks from anywhere so far but I have only done about 15km.

Spent about 5 hours this afternoon completely rewiring the back half of the car , there is now no wires visible in the enigne bay at all.
Have also hidden away the ignition module and regulator.

Next few days driving with show any signs of issues but Im not expecting any.

Still need to rewire constant power to the relay for the ignition module and somehow move the coil pack.
The fuel filter will also be moved top under the car next to the tank.

Dont think theres much else I can do now except repaint and smooth the bay out a little.
Aus's cleanest Niki !

skelz

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Re: Ground up rebuild on a Aus delivered aircooled FSM Niki
« Reply #17 on: July 31, 2011, 06:14:38 AM »
i am super impressed!!

KAL SPL

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Re: Ground up rebuild on a Aus delivered aircooled FSM Niki
« Reply #18 on: July 31, 2011, 10:35:32 AM »
Now has 48sqft of Dynamat spread from 1 end to the other , new carpet is also in place.

Moved the fuel filter and re ran the consant power for the ign module relay to the front of the car , just need to get myself another coil pack and move that up a bit higher out of the way and shorter leads.

Excuse the blemishes in the paint it now needs redoing but it is 6 years old so fairing pretty well.

The engine now has its own single harness with 6 pin deutsch plug , as you can see by the pics theres a second grommet which feds the wires into the rear quarters after crossing over inside the air intake.
The ignition module and relay are mounted in behind the drivers tail light and regulator is behind passenger tail light.

Have also run the reverse/number plate light out directly into the bumper.







Aus's cleanest Niki !

KAL SPL

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Re: Ground up rebuild on a Aus delivered aircooled FSM Niki
« Reply #19 on: July 31, 2011, 10:37:38 AM »








Aus's cleanest Niki !

KAL SPL

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Re: Ground up rebuild on a Aus delivered aircooled FSM Niki
« Reply #20 on: August 01, 2011, 02:59:16 AM »
[youtube]jwoz1NhiTAE[/youtube]
« Last Edit: August 01, 2011, 03:01:11 AM by KAL SPL »
Aus's cleanest Niki !

Aaron

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Re: Ground up rebuild on a Aus delivered aircooled FSM Niki
« Reply #21 on: August 01, 2011, 05:27:37 AM »
Love the the look of the modified engine bay ;).  I bet that's what the designers originally had in mind.

KAL SPL

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Re: Ground up rebuild on a Aus delivered aircooled FSM Niki
« Reply #22 on: August 02, 2011, 04:59:26 PM »
Its clean but I reckon I can go further , electric fuel pump and a small pod filter plus catch can ?
Maybe the motor I just pulled out I might play around with , anyone got a suggestion for electric fuel pump ?
Aus's cleanest Niki !

KAL SPL

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Re: Ground up rebuild on a Aus delivered aircooled FSM Niki
« Reply #23 on: October 08, 2011, 04:23:03 AM »
So gearbox/diff is now all back together.
6 brand new bearings , new gaskets/boots and reverse signal.
The main front bearing that was shagged was causing it to jump out of 3rd but everything else looks good.
I got the casing sand blasted and it currently sits in black etch primer until I can get time to paint it in 2 pac silver to match the engine then will swap it over into the car.









Aus's cleanest Niki !

bis13

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Re: Ground up rebuild on a Aus delivered aircooled FSM Niki
« Reply #24 on: October 08, 2011, 09:29:46 AM »
great work!

lupo

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Re: Ground up rebuild on a Aus delivered aircooled FSM Niki
« Reply #25 on: October 08, 2011, 02:48:01 PM »
Wow, that DOES look good; I'm jealous!  Continue the great job! :)

KAL SPL

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Re: Ground up rebuild on a Aus delivered aircooled FSM Niki
« Reply #26 on: October 09, 2011, 09:45:56 AM »
Box is painted , just need to fit the new boots to the axles/diff and then swap it over.







Hopefully all my gaskets are good , dont really want to pull it apart again !
Aus's cleanest Niki !

KAL SPL

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Re: Ground up rebuild on a Aus delivered aircooled FSM Niki
« Reply #27 on: October 10, 2011, 01:06:55 PM »






All swapped over , just needs oil then hope for the best !

For those playing at home , took me 2 hours to drop motor/box , swap clutch and box then lift all back in by myself :) with the aid of a hoist obviously ...
Aus's cleanest Niki !

nrg19uk

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Re: Ground up rebuild on a Aus delivered aircooled FSM Niki
« Reply #28 on: October 10, 2011, 02:17:41 PM »
wow looks great you got me worried for a second when i see you had painted the rubbers  :P

a little tip i got from the vw aircooled forum was to set the idle to 600-800 rpm to prevent over heating whilst stationary.

higher revs at tick over keeps oil circulation and better cooling from the fan  ;D stopped the oil light coming on whilst stuck in traffic for me.
Neil gargaro

KAL SPL

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Re: Ground up rebuild on a Aus delivered aircooled FSM Niki
« Reply #29 on: October 11, 2011, 01:41:46 AM »
I havnt pulled that engine down yet but suspect the oil pressure drop was pretty serious as the light stayed on under any rev load.
1 day I will find time to strip it and rebuild that as a spare.
Having a complete spare box and engine is quite useful with these cars ....

The rubbers were old but still ok but figured instead of masking I would just leave them there and swap with new once it was dry.
Aus's cleanest Niki !