1963 Baja project - 2.5 V6 mTDI mid-engine (Netherlands)

Update from my side:

I've been busy with designing the pump support for the Bosch VE pump. Normally the 2.5 V6 TDI is only delivered with a Bosch VP44 pump. So I'm creating a new adapter.

I directly created a Bosch VE pump in 3D.

Forgive me for the crappy pictures of the screen, I will take decent screengrabs and replace these.




The pump I used for the dimension.

The reverse engineering of the gearbox is making progress too. I think I will need another 100 hours to get it finialized in CAD.


At this moment I'm getting the bolt pattern exactly and also the drive axle flanges in the right position.

Below the first version of the bolt pattern, after this I made changes to CAD and lastercut the second set.



In the second version only minor changes are left. Too bad that there are only CAD drawings available for the marine TDI 4 cylinder and nothing for the V6 TDI.


Also I have been placing off-road tires on original 15" beetle rims. For our homologation we only may differ max 2% on the original track width... So
the original rims with 10mm spacers are possible and this is going to work perfectly. After homologation change to Porsche 968 rear suspension...

Made some progress on the bodylift set. I checked if the dimensions I got from internet were correct... NOT

So I measured the differences and now I have to modify the CAD model again and check if its good.




Hope to give a bigger update soon again!

Yep.. liking it!!

Finally an update. Not that I haven't been doing anything, but it has been so terrible busy at work (Aerospace) and at home building fuelpumps. So where I am at this moment.

The first version of the fuelpump support has been designed, lasercut and welded. The testfitting of a VE37 pump went good. The only thing is that the timing belt pulley was a couple of mm's wrong in offset. I corrected this error in the second pulley and this is now also lasercut and needs welding.








And the second version:



Also I found a fresh Fuelpump from an army truck with Cummins 6BT engine on it. This is going to be the base of the final fuelpump.






the modified timing belt pulley and adapter

The body of the Beetle is going to one of the most experienced classic VW welding specialist (Ronald Veldhuis - Apeldoorn NL) He is going to make the body ready for vehicle inspection ( RDW it is called in the Netherlands )

Also I found out after a long discussion with the same organization that I need to bring the beetle in original condition to them when I want to have the licence re-activated (has not been driving since 1975) This was at the beginning sad news, because I had no reasons to make the original 1200 engine or gearbox ready... So last week I bought a 1200 engine in Belgium that is going to be used for spare parts for my own engine.

I had a second session of 3D scanning at my former employer:







10mm Cummins 6BT fuelpump

With this as temporary mock-up. Now I need to reverse engineer the scan data to usable 3D data in Catia







And a quick mockup to a beetle gearbox, because it might be needed to get the V6 engine on licence to have it mounted in the original position first before converting it to mid-engine



Including engine adapter


It almost fits...


Last update from my side is that I found an additional chassis (from 1958) with all documents and registrations. I might build this one up to to have one of the frames used for testing and experimenting.

Sweet Jesus man, you have a lot of time on your hands. Major props on the CAD designs.

I've got a 68 beetle (my first car) and a tdi jetta sitting in my shop. I have fantasized about mating the two. I seriously dig this build.

This Saturday the body went to the most known Dutch Beetle and T1 / T2 welder (Ronald Veldhuis)

He is going to make the body ready for painting. The heating channels are going to be replaced by KlassicFab versions and some other welding needs to be done


I droped the body back on the chassis for transportation





Ready for the trip to Apeldoorn

I expect to get the body back in something like 6 till 8 weeks and in the meantime I want to have the engine rebuilt.

I have to admit I am jealous of your 3d scanner access! lol

great design process and results! like your thread very much. The V6 in that thing is going to be very cool..all that torque!

Thanks for your reply TDIsyncro!

Update:

The body welding is finished. I brought it to Ronald Veldhuis, because he seems to be one of the best Aircooled welders in the Netherlands. I must say I'm very satisfied about the result!

I also got tips how to restore the paint, so the patine look will remain.










KlassicFab heater channels

Back home in the rain.











Now I'm going to finalize the car for road approval. (hasn't been on the road since 1975)

Hi. I want to join to your project. I am working with SolidWorks and 3DS MAX. I have VW passat with 2.5 TDI V6 engine and I wants to do transfere it into computer using reverse engineering technology. I am looking for more people who wants to join in a team to make similar projects like these. If we create whole international team which doing same things like we do reverse engineering process could be much more faster then working alone...

More about my project:
https://photos.google.com/share/AF1QipMdpYRQ2B5eqFniJlfKBIcnaF0oX8k3WEmuDxAfLPb3z4tpBMf35dlT4btM5tso8Q?key=eFYzRFA1Mm5Ud1JBLWpnNHpUdXZrX3VnXzVxakZR

I'm still progressing on my build, the only obstacle is that we moved to the United Arabic Emirates some months ago and this country is very limited on diesel engines.

Big benefit that we are living in the middle of the desert!!! (Al Ain)

@GiMax: My compliments on your skill! Sorry, I'm not interested in working together, I have my own speed and way of doing.
I don't want to create an optical design, I need to design and calculate the car to be able to build and drive it. I already have what I needed reverse engineered and currently working on shifting mechanism and gearbox supports.