Burnt Pig - 356 Pre a Build Thread

[Robneal]

Just a few little Updates from me:

Have now swapped the Rear backplates over on the trailing arms and these are now ready to go off to RED9 at the beginning of next month..

Have now got a copy of the MAP from the Emerald ECU from the Orange 356 Coupe Martin and Walker build from VZi that has a similar engine to mine so should be OK to get it started with in front of a full rolling road tune when I get to that stage. I downloaded the software from Emerald and struggled to get my computer to talk to the ECU. I only had a USB port on my computer so had to use a USB to serial cable. Eventually I tried plugging the USB to serial into the Emerald Serial cable and that worked so I was able to upload the MAP and this is now loaded and ready to go.

Next job is to build the engine bay wiring loom for the ECU; I have drawn it out in 2 ways , one as a logical diagram then when I get to measure an engine bay up to work out how long each cable run needs to be then a wire by wire diagram to show how the loom should be built. I have attached the diagrams of the sensors I am using so any comments you have on what works for a fuel injected Air-cooled then please chip in.





Lastly I was debating the air filters to use with the Jenvey throttle bodies and I really love the look of the Vintage Speed 356 pseudo replica ones that fit IDF carbs, but I read on Simon Hambly's Outlaw Speedster website that they did not fit. On investigation there are 3 problems:



1. Fuel rails on the Jenvey's with Std. injectors go above the top of the throttle bodies so do not allow the filters to fit flat.
2. The holes to attach the filters to the Throttle Bodies are half a hole offset to the standard IDF pattern.
3. There is a hole in the base plate of the filter that allows for the adjustment of the jets on IDF carbs but on the throttle bodies this would be open.
So to solve these problems and get the air filters I want I am doing the following:
1. Fitting Pico Injectors to replace the standard ones that brings the fuel rail down under the level of the top of the throttle body.
2. Elongating the holes so that the filters can be bolted up with some washers to cover the resultantoval holes
3. I Have asked Dan at Vintage Speed UK very nicely if he can persuade the manufactures to make me some base plates without the middle hole - failing that I will just make a plate to fill the hole as it will not be able to be seen when all bolted up.

Latest on Engine is that the Align bore can't be done till April at the earliest.

[Richardab1967]

Rob, i saw your posting on the 356 replica facebook page. Seems there are quite a few coupe builds starting.

Great to here about your plans, sounds like you are well under way with parts and engine and ideas.

I have the first Pre-A Gary built. Only got the body at Christmas although i had finished my chassis (standard bolt on style) a while back whilst waiting for the body to be made.

Interested in reading that you planned to go IVA route, lots of people seem fairly coy about this (so i assume they aren't doing it!). I am planning on doing the IVA, quite daunting...have you read the manual.

Look forward to seeing your car develop and hopefully bounce around some problem solving. It would be great if all the current coupe builds were on here, i think there are quite a few out there. I will endeavour to start a build thread myself!

Cheers
Richard

[Robneal]

Rob, i saw your posting on the 356 replica facebook page. Seems there are quite a few coupe builds starting.

Great to here about your plans, sounds like you are well under way with parts and engine and ideas.

I have the first Pre-A Gary built. Only got the body at Christmas although i had finished my chassis (standard bolt on style) a while back whilst waiting for the body to be made.

Interested in reading that you planned to go IVA route, lots of people seem fairly coy about this (so i assume they aren't doing it!). I am planning on doing the IVA, quite daunting...have you read the manual.

Look forward to seeing your car develop and hopefully bounce around some problem solving. It would be great if all the current coupe builds were on here, i think there are quite a few out there. I will endeavour to start one myself!

Cheers
Richard

Hi Richard,
Good to hear from another builder....and only too happy to share my trials and tribulations with my build. I am already in contact with another coupe builder but he has his own website to document his build. If you do a search for Spartan porsche 356 you will find it.
Where are you based as it would be good to meet up and talk through your plans as although my chassis and mechanical plans are pretty much sorted, I have still got a lot of plans to make for the body and interior.
I am based in Chelmsford Essex, but travel around a fair amount for work so let me know where you are and perhaps we can meet up.
Cheers
Rob


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[Richardab1967]

I'm south coast near Portsmouth.

I don't really have alot worked out, i seem to be flitting between jobs, so my bench is a complete state of unfinished bits for the car. I am finding it daunting starting an area without all the components that are required, ie the door needs, the frames in, handle, lock, window regulator, door opener all to hand to see how they fit and inter-relate before drilling holes, couple that with complying with IVA, sometimes it seems i am trying to build two cars simultaneously, one to pass the test and the one i will drive after.

I have concluded that my build will be very much in two stages, first, no frills, no paint, no trim, ugly modern plastic fittings etc to pass IVA, i see this at least a year away, assuming I pass, i can see another year to get it looking how i want.

If you are serious about IVA its really worth downloading the manual, the interior fittings section is fairly prescriptive.

Have you given any thought to registration, are you expecting a Q plate or are you shooting for an age related plate? This area seems a bit blurry to me, but i did read something about needing 2 major components from a donor to get age related plate. Normally probably not that difficult, but looking at your build list you have lost engine, suspension, axles (i think), steering, and only have gearbox left. In truth i am not sure what constitutes 'steering' or 'axles' or 'suspension' on a vw.

[Robneal]

OK I get close to Portsmouth sometimes for work so when I am next that way I will drop you a PM and hopefully I can come and see your progress and we can discuss our projects in depth.

I have taken a pretty structured approach to my build. As I make decisions about how I want to do things then I add all of the parts I need to my shopping list which is a massive excel spreadsheet and then I set-up searches on EBAY and check the various forums for the parts and as they turn up then I buy them when I can get them at a good price. Some items are still elusive like original door frames and rear quarter windows, but only last week I finally found a 3.44 ring and pinion for the gearbox in Canada that was new and a third of the price of one from Weddle which seems to be the only place you can get them new from now.

I have the same plan as you, build it first to go through the IVA and then sort the bodywork and interior trim afterwards. But I will sympathetically change things like rear fog lights, reversing lights afterwards . I have a copy of the IVA manual printed and I have read it all once, but I will continue to refer to it as the build progresses. The IVA Thread on here is also very helpful as to what is practical and acceptable. etc.

Registration wise I hope to get a period plate, but I need some advice on how to do this, and have not really looked in to this yet so any help anyone can offer on how best to do this then please chip in.

[Robneal]

Small update - Dropped off my rear suspension, front hubs, wheels and CoolRydes 6 point brace at Red 9 yesterday ready for them to modify the front frame of the Speedster Clinic chassis to allow the double wishbone front suspension to be bolted up. Their work schedule means its going to be the end of the month now before it is all done and dusted, so waiting for some photos to start to come through from them when they get started on the work.

[Richardab1967]

That is some serious underpinnings you have there!!

Will be awesome, looking forward to the pics.

With regards registration, this is the document i read.
https://www.gov.uk/vehicle-registration ... d-vehicles
Clearly we are not in the 'keep vehicles original reg' section.
I was hoping to get an age related number. The wording in this section baffles me and I have asked before if anyone understands it as it says you need 2 major components (thats what jumped out to me with your build as so much is modified!) and either a new chassis from a specialist kit manufacturer or an altered chassis from the original vehicle.

I would like to think whether a diy shortened or a speedsterclinic chassis would comply, although its a mystery to me how in the 'radically altered' classification an altered chassis gets you a Q plate on its own. Regarding the 'major components, these are classified as:
1. Suspension (front and back)
2. Axles (both)
3. Transmission
4. Steering assembly
5. Engine

Quite where the line is drawn between suspension, axles, steering on a VW I am not sure. Also I believe you need both front and rear original suspension to count for 'suspension' and both front and rear axles to count for 'axles'.

Even with my tame build I was worried I was pushing up against the 2 major components, so I had been wondering if you had found a loophole.

[AccidentalGenius]

Hi, i am new here and this is my first post but i too am building a Speedster Clinic Pre-a Coupe (Gary is literally putting the body on as we speak, the latest images on his FB page are of my car). I always knew i would have to deal with the IVA 'thing' but i have been ignoring it really... then i read this thread last night and thought... right, i need to understand this and start planning it.

When i first spoke to Gary about my options one of my key concerns was keeping my original number plate and he suggest i would be able to do that... following a quick read i am not sure how?! I think i will ask him about it in the next few days when my car is complete (or at least body on).

Its such a shame that would should be a massively exciting time has this constant nag of IVA in the background... Life should be more straightforward than this!

[Bootsy]

Hi, i am new here and this is my first post but i too am building a Speedster Clinic Pre-a Coupe (Gary is literally putting the body on as we speak, the latest images on his FB page are of my car). I always knew i would have to deal with the IVA 'thing' but i have been ignoring it really... then i read this thread last night and thought... right, i need to understand this and start planning it.

When i first spoke to Gary about my options one of my key concerns was keeping my original number plate and he suggest i would be able to do that... following a quick read i am not sure how?! I think i will ask him about it in the next few days when my car is complete (or at least body on).

Its such a shame that would should be a massively exciting time has this constant nag of IVA in the background... Life should be more straightforward than this!

Welcome - worth reading this one too viewtopic.php?f=15&t=44851

[AccidentalGenius]

Thank you, I'll give it a read now

[Robneal]

Just a quick update, no new work going on at the moment as still waiting for chassis work and engine build, but I have managed to find some of the rare parts that I have been looking for from the outset of the project. I am now the proud owner of 2 x original Door Frames (found them via Facebook in Sweden) and 2 x original Pop out rear quarter windows (Found on EBAY USA) with all of the mounting hardware and seals. Both were sensibly priced and not in the range of parts that you normally see on the forums / EBAY...

I have waited 2 years for these bits to turn up and was thinking I was going to have to either go repro or make my own, so now very happy with my new bits. Moral of the story is when you are looking for these rare parts then you have to be patient and set-up the searches to notify you as the rear quarter windows were on a 3 day listing and I was one of only 2 bidders so easily missed.

[davidoft]

Small Update on the engine - Whilst Paul is waiting for the cases to be align bored he has drilled and tapped the head for the Type 4 Fuel injection Cylinder Head Temperature Sensor that will provide a vital feed to the Emerald ECU. According to Emerald this is the best way to get their ECU working on an air cooled engine.

First picture of the Tapped Hole


With Cylinder Head Temperature Sensor installed

How come you chose not to use the factory hole for the temp sensor just to the right of the inlet stud hole pictured?

[Spyder-finder]

I have seen both positions used and thought the one nearer the spark plug better as its nearer the heat source.

[sladey]

Happy days - nice one

[Robneal]

Small Update on the engine - Whilst Paul is waiting for the cases to be align bored he has drilled and tapped the head for the Type 4 Fuel injection Cylinder Head Temperature Sensor that will provide a vital feed to the Emerald ECU. According to Emerald this is the best way to get their ECU working on an air cooled engine.

First picture of the Tapped Hole


With Cylinder Head Temperature Sensor installed

How come you chose not to use the factory hole for the temp sensor just to the right of the inlet stud hole pictured?

It Was Paul Foreman's recommendation to tap the head there and on the basis he knows much more about Type 4 Engines than me then I went with his recommendation. I am probably going to run with a Cylinder head temperature Gauge anyway so will use the original hole for this.