Custom VW Bug

I now have 4 new slide shows on the new "MR2 VW Bug pics page 7"

Tim — Fri, 18 May 2012 15:59:55 +0000

I now have 4 new slide shows on the new "MR2 VW Bug pics page 7" page. MR2 VW bug pics page 7

Flush out and mount the power steering pump #379

Tim — Thu, 17 May 2012 16:32:26 +0000

With the fuel system plumbed up, I can now focus on the power steering. The MR2 comes with an electric power steering pump. To insure that my rebuilt steering rack will not have any problems I need to clear out all debris in both the steering pump and the reservoir. I ran fluid through the pump a few times to clean it out. All I have to do now is get the feed line crimped at the hydraulic shop.

Build the fuel pump bracket #378

Tim — Fri, 11 May 2012 15:35:24 +0000

With the fuel system in place, I need to create the bracket that will hold the fuel pump firmly. I cut the top out of a piece of 3x3 14 gauge square tubing. I then bent the ends up to fit in the fuel box, marked everything and screwed it in place. The bolts holding the fuel pump to the bracket have been welded to the bracket so I don't have to try and get a wrench under the bracket.

Finish installing the stainless fuel lines #377

Tim — Thu, 03 May 2012 04:00:32 +0000

With all of the braided stainless fuel lines complete, I can now finish the mock up of the fuel system. I will be removing all the lines and devices later to complete the fuel system before starting the engine. All lines will be flushed and cleaned to insure that there is no foreign debris in the system.

Install stainless braided fuel line connectors #376

Tim — Fri, 27 Apr 2012 03:28:09 +0000

After I cut all the stainless braided fuel lines to lenght, I installed all the hose ends and can now finish plumbing up the fuel system.

Cut stainless braided fuel lines #375

Tim — Fri, 20 Apr 2012 01:53:45 +0000

I can now cut and fit the braided stainless fuel lines. I transferred the mock up tubing measurements to the fuel line and cut them to fit. I am using a tubing cutter to get a good straight line on the braided line. The tubing cutter also compresses the steel braid filaments at the point of the cut and helps keep it from fraying. The Dremel tool also gives a good fray free cut to get the hose end on correctly.

Finish mocking up the fuel system #374

Tim — Sat, 14 Apr 2012 02:52:34 +0000

I now have the fuel system completely plumbed up with the plastic mock up tubing. The stainless braided fuel line is expensive so I want to cut and fit the stuff only once. Hopefully everything fits the first time.

Continue mocking up fuel system #373

Tim — Sun, 08 Apr 2012 14:33:55 +0000

Now that I know where the fuel lines need to penetrate the rear firewall, I went ahead and drilled out the opening. With the fuel injection there is a supply line and a return line to the tank. I will plumb up the system with some cheap plastic tubing and then cut the braided stainless lines to match. This way I can do my best to not waste the expensive stainless line.

Mount fuel tank start plumbing #372

Tim — Sun, 01 Apr 2012 02:22:31 +0000

Now with the front sway bar complete, I can refocus on the fuel system. I have to locate the exact position of the fuel tank to be able to plumb everything up correctly. I created 2 brackets to hold the fuel tank solid. Now I can line everything up to get the rear firewall holes for the fuel lines.

Finish up the front sway bar #371

Tim — Sat, 24 Mar 2012 12:42:31 +0000

I now have the VW bug front sway bar finished. After welding it up I smoothed it out with a grinder and sand-paper and then panted it all up. I also finished the drop links and painted them as well. It appears to be OK now but I will have to give it a true teat when I get it driving.