I made a gauge pod today from some 2" PVC-90 degr elbow's, cut them in half and sprayed some underbody coating on them so that they have some texture on them and painted them black with bumper paint.
Next I made an aluminum plate and cut 5 holes in it and held it against the belt sander to give it a brushed look,then glued all elbow's onto it.
Because the gauges that I used were quite deep, I made some aluminum rings that pressed into the elbow's and gave some extra dept.
It fits right over the ashtray opening.
Roof overhang
Pull it towards you to get the pin out
Pedal frame
Installed
BMW booster is on the left
Closed
New paint job
Modified synchro
Rear Bumper
Eberspacher BN2 Heater
Aux fuel transfer pump
Valves just fit in the 76 mm bore
Tool to hold piston for machining
Piston
Making Hydrogen
Shock will slide in tube
Cut the eyes off
Front shock extenders
Gauge pod
Extra retaining washer
Laser alignment tool
Intercooler
New universal joint
Part number is on box
New bushings
Undersized bushings
Drive shaft
Cleaned up surface
Drive shaft
Corrosion
Decoupler shaft and gear hub
gear hub before cutting of teeth
Coupler before torquing set screws
Machined differential housing
Locking front differential
Locking front differential
Audi A4 or Jetta VR6 rear calipers
Rear disc brakes
Audi 5000 Turbo brakes
Oil holes drilled
Pinion bearing race
How it started
Audi 2.0 TD engine
Drilling and reaming vac pump
Test fitting the engine
Prelube pump
You can see one of the two filters
Injection pump
Reaming the bushing to size
Home made 2.5" stainless muffler.
Audi logo
10 comments:
Herman, Great work!
Interesting work Herman. I have a 6 cylinder version of that engine from a Volvo. It is about 4 inches longer than the 5.
Can a Vanagon be modified to allow the extra length of the engine by moving the bumper back etc?
Will the D24 clutch fit the bellhousing if the plate and splines are right?
Your opinion ??
thanks
Thanks guys. Steve, the 5 cyl Audi engine barely fits inside the engine compartment, so in order to install a 6 cyl Volvo (Turbo I hope) you will end up with a lot of cutting.
The crank pulley, alternator and P/S pump will all stick out of the back about 3".
You would have to use a heavy duty rear bumper to act as a replacement of the chassis support beam that you will have to cut out.
The engine will bolt up to the transmission if you use a South African bellhousing, the clutch will fit in there with minor grinding on the inside of the bellhousing and you will have to use an Audi TD clutch plate, the Volvo has more splines.
Would be an interesting project for sure!
Hello Herman,
I really like your gauge pod. I am installing a three VDO gauge pod in my 1986 Westfalia. Can you tell me what connector you used for your volt gauge? I have only the starter battery in my van at the present time, but plan to install an auxillary battery at a future date. I have read the K3 terminal on the back of the fuse panel would work, but the K bank already has a plastic connector with no wire from the K3 connector. Thus I would have to figure a way to add a new wire to this VW connector. I don't have any special tools to do this. Any suggestions?
Thanks
Craig
Hi Craig, I have tapped into the wire that goes to my radio(my radio turns off when the ignition is off),you could also take the instrument cover off and tap into the wires for the rear window heating switch.
I have used the 3m connectors that you can buy in any automotive store,just put one on and with a pair of pliers push the little metal part in and close the clip.
all you need is a test light to check which wire is hot and when.
Works OK for low amperage use.
Herman, great work.
I've been working on my Syncro 16 for the last 2 years in a very similar direction to you.
I'm running a 2.5TDi AAT engine and I'm just at the point of adding an oil cooling setup to my gearbox. Spooky how minds think alike!
You can see my van here, http://brick-yard-co-uk.olympus.webwizhost.com/forum/forum_topics.asp?FID=8
You can contact me at performanceghia@hotmail.com
Keep up the good work. Wish I had your machining knowledge!
Cheers
Mike Ghia
Hey thanks Mike! Interesting project that you are doing too, sure takes a lot of time and money!
Good thing that you are doing your tranny cooling and lubrication mods, that 5 cyl 2.5 tdi has lots of torque!
Cheers Herman
cool gauge pods man! great stuff.
mugen
Hey Herman,
what do the gauges on your new pod measure?
thanks,
Lee
Hey Lee, they are 2" gauges.
Cheers Herman
Post a Comment