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TDI Conversions Discussions on converting non TDIs into TDIS. More general items can be answered better in other sections. This is ideal for issues that don't have an overlap and are very special to swaping engines.

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Old March 18th, 2018, 16:09   #46
J.Klassen
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Bolted to the engine.

Complete with the turbo hanging off it.
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Old March 25th, 2018, 13:33   #47
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Next I hung the engine in the bay even though it was not connected to the trans yet.

And ran into some issues. The AC pump was going to hit the front differential even though it is shorter in length compared to the vw unit. So I made some brackets.

These brackets allowed for me to swap the locations of the power steering pump and the ac.

Bracket for moving the power steering to the bottom.

A little massaging of the bottom to accept the new power steering bracket.

And mounted in place.

As you can see, a lot more room for the differential now and the belt lines up nice too!

The belt routing did not change at all, plus the pulleys for the AC and power steering are basically the exact same size. Later on I did modify the AC bracket so that the pump moved closer to the engine which gave me more clearance between the belt and the steering box that is mounted to the frame.
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Old March 30th, 2018, 10:57   #48
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Wow nice work all around. Huge undertaking to get this thing on the road. We're going to be staying in the shuswap area for a couple weeks this summer. Would love to stop by and BS for a few if you have time one day. I too have a hardbody and would be interested in seeing this up close
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Old March 30th, 2018, 15:56   #49
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Quote:
Originally Posted by CGDoig View Post
Wow nice work all around. Huge undertaking to get this thing on the road. We're going to be staying in the shuswap area for a couple weeks this summer. Would love to stop by and BS for a few if you have time one day. I too have a hardbody and would be interested in seeing this up close
I sent you a PM.

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Old April 2nd, 2018, 10:54   #50
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Ok while I had the engine hanging in the bay it became very obvious that the front of the oil pan where the oil pumps lives wanted to be in the same space as the steering link. Since moving the oil pump is not an option the steering link had to go in for some surgery.

I started by taking some measurements and then getting some pipe mocked up.



Joints to be welded were beveled and then first pass with the TIG was made without filler rod just to melt the pieces together.



After a couple more passes with filler rod we have a pretty solid piece.





Next step was to tack it to the steering link.



Then fully weld it and add some gussets from 1/4 inch plate in the corners.





And then the moment of truth. Cut the middle out and see how much the ends want to move inwards. Turns out it pulled the ends in by a total of 3/32 which is only 1.5/32 on each side. Easily corrected in the alignment.



Nice and shiny with a coat of black rust paint.



And in the truck. With the wheels straight this is as close as the link will get to the diff. When the wheel is turned in either direction the link moves towards to front of the truck and away from the oil pan.


Last edited by J.Klassen; April 13th, 2018 at 16:19. Reason: I don't why the pics didn't show up the first time but I think they work now.
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Old April 8th, 2018, 19:39   #51
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Battery time. The big battery I had in the truck was not going to work. It stuck out into the engine bay right where I wanted to put my boost pipe. And of course boost pipes are more important than batteries right haha.

Anyway the battery was 7 years old and would probably die soon anyway, so time for a upgrade and a downsizing.



A little chopping of the inner fender.



New piece cut to fit.



Hold downs and rubber mat .



Tacked in place.



Painted and battery installed.


Last edited by J.Klassen; April 13th, 2018 at 16:23.
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Old April 8th, 2018, 19:49   #52
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I had taken the mechanical fan off the gas engine and installed an electric one with those stupid clips that go through the radiator. In the process the fan shroud was also removed so it was time to make a proper one to work with the electric fan.

I started by measuring the rad and laying it out on some sheet metal.



Cut and folded. The notch in the bottom corner is for the steering box.



Lovely old rad still working great.







Painted and in the engine bay.




Last edited by J.Klassen; April 13th, 2018 at 16:26.
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Old April 9th, 2018, 05:24   #53
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A lot of your pics are not showing up for me.
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Old April 10th, 2018, 11:58   #54
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Same, apr 2nd onward.
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Old April 10th, 2018, 16:56   #55
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I don't know what's going on with the pics but I have re linked them from my google photos account and hopefully its fixed. It looks like the image addresses had changed for some reason causing the pics to not show up.

Last edited by J.Klassen; April 10th, 2018 at 17:19.
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Old April 10th, 2018, 18:03   #56
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Quote:
Originally Posted by J.Klassen View Post
I don't know what's going on with the pics but I have re linked them from my google photos account and hopefully its fixed. It looks like the image addresses had changed for some reason causing the pics to not show up.
No everything from the 2nd onward is still not showing. just shows a circle with a horizontal line for each pic.
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Old April 11th, 2018, 16:51   #57
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Ok I am looking for ideas as to whats going on with the pics. I just tried Firefox instead of Opera and the pics were not showing up. So I logged in to edit the posts and scrolled down only to find that all the pics were showing up just fine now while I'm logged in.

Any ideas?
Could somebody try multiple browsers?
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Old April 11th, 2018, 17:05   #58
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I logged out, closed firefox and then came back and the pics were not showing up. So I logged in and clicked edit and the pics were there. I canceled the edit and now I can see all the pics.

I am really confused.
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Old April 12th, 2018, 18:58   #59
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Alright I linked the pics again and they seem to be showing up for me, so let me know if they are good for you guys.
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Old April 12th, 2018, 19:55   #60
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No still not working. You can load them to the photo album on here for free and they will show up no problem. I think if your using google photo to host you can only do like 50 MB limit to 3rd party hosting then it cuts it off.
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