Since I finally have made some proper progress on my swap I figured that I should probably start a build thread. The project itself is a bit over 3 years in the making. I bought a really nasty 99 mk3, yanked the engine and tossed the car asap before it could infect anyone. I didn't really do anything after that for over a year because uni kind of took over. Started back working on it last summer and made some decent progress.
The original plan called for a 2wd reg cab s10 to be the swapee but I found a really clean (rust wise, for Ontario) 4wd ext cab ranger and just couldn't pass it up.
I couldn't find any drawings for the 4.0 bell housing the ranger so I picked up an nv3500 w/ transfer case and flywheel from an S10. I figured using a good heavy sbc flywheel and clutch would net me minimal gear chatter at idle and a good strong clutch without having to resort to any upgraded after market parts. The S10 nv3500 also has the shift tower 6" farther rear than the ranger m5od so it should feel less clunky when shifting, I'm not a fan of how the rangers shift.
sbc clutch vs the stock vw clutch
Drew up the adapter from tdi-> sbc, cut it out with the torch and punched the holes on my mill. Probably out by a few thou but it'll do for now, I might remake it at some point if I'm chewing up pilot bushings in under 100k km's or so. Had the crank adapter made up because I don't trust myself to cut it out on a rotary table with zero run out. I can send any one the drawings for them if you want.
I finally sorted through 90% of the wiring today and fired it up for the first time. The bin in the back right is what I stripped out, still have some more to go. I'm using an old 1.5kW? sbc starter because I got it with the flywheel. Bit on the small side but I figure that with the added leverage from the larger radius flywheel it should work fine. I have a vid I might post if I ever get around to making a youtube account.
The current time line is to get the correct pilot bushing for the input shaft and get the engine sitting in the truck with the mounts mocked up before April. Then its accessories, rad and turbo plumbing before May. Maybe drive shaft as well. I'm giving my golf to my brother to commute to uni so I need to have it running and driving before the summer starts to have time to work out the bugs.
The original plan called for a 2wd reg cab s10 to be the swapee but I found a really clean (rust wise, for Ontario) 4wd ext cab ranger and just couldn't pass it up.
I couldn't find any drawings for the 4.0 bell housing the ranger so I picked up an nv3500 w/ transfer case and flywheel from an S10. I figured using a good heavy sbc flywheel and clutch would net me minimal gear chatter at idle and a good strong clutch without having to resort to any upgraded after market parts. The S10 nv3500 also has the shift tower 6" farther rear than the ranger m5od so it should feel less clunky when shifting, I'm not a fan of how the rangers shift.
sbc clutch vs the stock vw clutch
Drew up the adapter from tdi-> sbc, cut it out with the torch and punched the holes on my mill. Probably out by a few thou but it'll do for now, I might remake it at some point if I'm chewing up pilot bushings in under 100k km's or so. Had the crank adapter made up because I don't trust myself to cut it out on a rotary table with zero run out. I can send any one the drawings for them if you want.
I finally sorted through 90% of the wiring today and fired it up for the first time. The bin in the back right is what I stripped out, still have some more to go. I'm using an old 1.5kW? sbc starter because I got it with the flywheel. Bit on the small side but I figure that with the added leverage from the larger radius flywheel it should work fine. I have a vid I might post if I ever get around to making a youtube account.
The current time line is to get the correct pilot bushing for the input shaft and get the engine sitting in the truck with the mounts mocked up before April. Then its accessories, rad and turbo plumbing before May. Maybe drive shaft as well. I'm giving my golf to my brother to commute to uni so I need to have it running and driving before the summer starts to have time to work out the bugs.
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