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Dave99gst
PostPosted: Mon Dec 15, 2008 9:38 am  Reply with quote
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Ive always wanted to put a 4g63 into a dune buggy for the hell of it.
After the 2008 shootout i decided to go for it. My buggy is already street legal and is a berian frame with a 7piece fiberglass body. To date i have totaly stripped the frame down and repainted it. Replaced the tierods,upr/lwr ball joints,wheel bearings,shocks,brakes. I will be redoing all the brake lines and wiring. Currently this will be using a VW 3-rib swing axel trans.
Project Spreadsheet:
http://spreadsheets.google.com/pub?key=pP133HqJjEIA4inUhKou8Cg

How she looked when i got her -
Front:


rear:
I bought it with no motor to help save cost.


Frind of mine painted the frame:


Adapter Plate/flywheel:


a Friend TIG welded the motor Mounts:


Clutch:


Motor:


Last edited by Dave99gst on Mon Dec 15, 2008 11:34 am; edited 1 time in total
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89coltgt
PostPosted: Mon Dec 15, 2008 10:09 am  Reply with quote
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Joined: 11 Apr 2007
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Location: Ste Genevieve, MO

That is a sweet project. How much power/tq can the vw trans handle? That thing should be a handful even with a mild 4g63t Twisted Evil
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Dave99gst
PostPosted: Mon Dec 15, 2008 11:33 am  Reply with quote
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Shattering the trans is my only fear ( well that and not being able to keep the front tires on the ground ) There are other VW trans options i can go with if this one explodes on me.
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oldcolt75
PostPosted: Mon Dec 15, 2008 12:16 pm  Reply with quote
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Joined: 28 Feb 2008
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sweeeeeeet
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Gpz900r


Last edited by oldcolt75 on Sun Feb 27, 2011 7:49 pm; edited 1 time in total
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jeffball610
PostPosted: Mon Dec 15, 2008 6:23 pm  Reply with quote
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Info on your trans adaptor plate would be nice for others looking to run a 4G63 in a VW. I know Plebani ran a 4G63 in a Porche. I assume this is a similar swap. And there are tons of VW trans options out there. You might also want to think about some wider rear tires. The 4G63 isn't a torque monster, but you'll have lots of fun with wheel spin.

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89coltgt
PostPosted: Mon Dec 15, 2008 7:01 pm  Reply with quote
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Joined: 11 Apr 2007
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Location: Ste Genevieve, MO

Here you go:

http://www.kennedyeng.com/
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screemin eagle
PostPosted: Mon Dec 15, 2008 9:55 pm  Reply with quote
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bad ass man! i like the pocket bikes too Twisted Evil

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Dave99gst
PostPosted: Tue Dec 16, 2008 8:58 am  Reply with quote
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Yup Kennedy is exactly were you get the plate from. (also were my clutch,PP&flywheel came from)
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Dave99gst
PostPosted: Tue Dec 16, 2008 7:04 pm  Reply with quote
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More - todays pix Very Happy


Here we see the entire motor, the SS oil supply line NickNorth was kind enough to GIVE me and the SSA exhaust manifold Diviniti gave me the hook up on(both from MiDSM)
Also note: the resident garage cat is happy to be lounging on a 4G63 project again.

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Professor Quest
PostPosted: Tue Dec 16, 2008 8:38 pm  Reply with quote
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Location: High Desert, Albuquerque, NM. The NUCLEAR state!

I think you need..... Rolling Eyes MORE HARNESSES! Laughing Laughing Laughing

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89coltgt
PostPosted: Tue Dec 16, 2008 9:02 pm  Reply with quote
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Location: Ste Genevieve, MO

Looks geat! I may build one once we buy a house, I will need the extra room.
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Dave99gst
PostPosted: Tue Dec 16, 2008 9:14 pm  Reply with quote
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Professor Quest wrote:
I think you need..... Rolling Eyes MORE HARNESSES! Laughing Laughing Laughing

haha-- ya i got the entire car - from bumper to bumper
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77amc
PostPosted: Wed Dec 17, 2008 4:47 pm  Reply with quote
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Joined: 06 Jun 2007
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Location: N-W Mississippi, Under Memphis

That looks great! I had a couple 914's in the day that I wanted to do the Buick V6 or Olds 215 swap to. (still have 2-215's)
My B-inlaw has a manx buggy that i'd love to get and do what your doing.

I don't think you will have problems with the trans. With as light as it is, the tires are going to break loose before the trans goes. There are TONS of Vw shops that build them with all sorts of gear ratios to suit. OR you could always go with a 930 trans and axles..

If you want, the Ford Taurus has a electric fan that pushes up to 2000+cfms for your radiator. it would be loud though but cheap from a pull it.

Great project Exclamation Errol
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turbostellar
PostPosted: Thu Dec 18, 2008 1:01 am  Reply with quote
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looking good
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Dave99gst
PostPosted: Thu Dec 18, 2008 10:39 am  Reply with quote
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ty all -
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smog
PostPosted: Mon Dec 22, 2008 2:57 pm  Reply with quote
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damn nice project. That enigne looks beautiful in there. Keep the pics coming!

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mattmartindrift
PostPosted: Fri Dec 26, 2008 12:41 pm  Reply with quote
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that's a GIANT cat!!!!

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autox4fun
PostPosted: Tue Jan 13, 2009 1:25 pm  Reply with quote
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Awesome Build!
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turbostellar
PostPosted: Tue Jan 13, 2009 7:26 pm  Reply with quote
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anymore updates to this?
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Dave99gst
PostPosted: Sun Jan 18, 2009 9:48 am  Reply with quote
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turbostellar wrote:
anymore updates to this?

Its slow going latley, ive have sub Zero temps.
I have been playing with the dash and working on the floor.

The hole is were the boost gauge will go.

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turbostellar
PostPosted: Sun Jan 18, 2009 12:52 pm  Reply with quote
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looking good, thats going to be kick ass when its done
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Dave99gst
PostPosted: Wed Jan 28, 2009 6:19 pm  Reply with quote
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Here is the new center console - My friend Selser420 Provided the material ( 6 x 6 aluminium tube ) machined the rear and put an angle on it for me. I tossed some black paint on it and rivioted some diamond plate to it to match the dash.

Rear -you can also see my adjustable pedals


Hella Bling h2o pump pulley that was donated by Halik


ECU Box - on the side is the MPI and CEL


ECU Box with cover.


ECU Box with cover and crapload of wires (wires are stuff like gauges,blinkers,tail lights,etc )


Last edited by Dave99gst on Sat Feb 28, 2009 8:37 am; edited 1 time in total
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Dave99gst
PostPosted: Wed Jan 28, 2009 6:22 pm  Reply with quote
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Electricly speaking it should run now -
Im still missing a fuel pump/AN lines/coolant lines/exhaust/knock sensor,maft isnt hooked up yet,o2 sensor so i cant start it yet.
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77amc
PostPosted: Sun Feb 15, 2009 11:03 pm  Reply with quote
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Joined: 06 Jun 2007
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Location: N-W Mississippi, Under Memphis

Looking Great! Your flooring looks like it will be a bit slippery though..
Or are you going to use mats?

E
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Dave99gst
PostPosted: Mon Feb 16, 2009 8:46 am  Reply with quote
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na -- ill just be carefull Very Happy
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Wilbur
PostPosted: Sat Feb 21, 2009 2:20 pm  Reply with quote
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Dave99gst wrote:
Yup Kennedy is exactly were you get the plate from. (also were my clutch,PP&flywheel came from)


Are you running Stage 2 or Stage 3 on the Pressure Plate and Clutch Disc? Cable or Hydro?
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Dave99gst
PostPosted: Sat Feb 28, 2009 8:35 am  Reply with quote
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Wilbur wrote:
Dave99gst wrote:
Yup Kennedy is exactly were you get the plate from. (also were my clutch,PP&flywheel came from)


Are you running Stage 2 or Stage 3 on the Pressure Plate and Clutch Disc? Cable or Hydro?


Stage3 & Hydro.
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Dave99gst
PostPosted: Sat Feb 28, 2009 8:36 am  Reply with quote
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In this shot -- Optima in its new Mount - and you can see the ahhooogggaaa Horn in the front. ( i got it for $10 @ harbor freight )


Better shot of the Optima Mount.


Notice the hole is now FILLED ! ( boost gauge )


Fuel Cell mounted - Walbro inline, AN crap and , Filter mounted.


Piping (not bad for somone that cant weld what so ever), maft,bov,fuel rail,FPR all new.


New Air filter on the Turbo.


Shot of the Honda radiator from the bottom with the coolant lines finaly done.


Glove Box Very Happy (ammo box picked up from harys army surplus)


Glove Box in its new home.
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89coltgt
PostPosted: Sat Feb 28, 2009 12:25 pm  Reply with quote
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Location: Ste Genevieve, MO

Looking very good, I really like how the in plumbing turned out.
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screemin eagle
PostPosted: Sat Feb 28, 2009 10:56 pm  Reply with quote
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wheres the intercooler?

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Dave99gst
PostPosted: Sun Mar 01, 2009 8:52 am  Reply with quote
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screemin eagle wrote:
wheres the intercooler?

Ive got one -- ill put it on if i have a need, but for now im going to run with out one.
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Dave99gst
PostPosted: Mon Mar 02, 2009 8:10 pm  Reply with quote
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http://www.youtube.com/watch?v=fjZV7duAIec
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jezz_s13
PostPosted: Tue Mar 03, 2009 3:29 am  Reply with quote
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That's going to be insane. Cool

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Arktis
PostPosted: Tue Mar 03, 2009 3:29 pm  Reply with quote
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Dave99gst wrote:

Ok, I've got to bite.

The two handles there are bugging me. What exactly do they do?

Forgive me, I'm not used to sandrails and having 3 sticks at the right arm.
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Dave99gst
PostPosted: Tue Mar 03, 2009 5:05 pm  Reply with quote
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There Cutting brakes. ( turning brakes ) they allow you to brake 1 or the other rear wheel to aid in turning.
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Arktis
PostPosted: Sun Mar 08, 2009 2:46 am  Reply with quote
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Dave99gst wrote:
There Cutting brakes. ( turning brakes ) they allow you to brake 1 or the other rear wheel to aid in turning.

That's what I was thinking, but I wanted to be sure.

Incredible. I've seen guys in locosts do that and just run circles around themselves.
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Bill Hincher
PostPosted: Sun Mar 08, 2009 10:36 am  Reply with quote
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how did you bleed the air from the cooling system?
I have a rwd project and I been working out the details on the cooling system, and I just cant invision how the radiator would work that high up

Thanks
Bill

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77amc
PostPosted: Sun Mar 08, 2009 12:16 pm  Reply with quote
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Joined: 06 Jun 2007
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Location: N-W Mississippi, Under Memphis

Ya know, I think your project has been started and almost completed in the shortest amount of time here..

did you do anything to the head or use different cams?
Sorry if you have mentioned this earlier.

E
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Dave99gst
PostPosted: Sun Mar 08, 2009 5:36 pm  Reply with quote
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Bill : i can unbolt the radiator and move it so the filler neck is pointing up. That was the main reason i went with rubber hoses instead of hard lines to the radiator.

Addict: hehe - im laid off, so ive got alot of time on my hands Very Happy

I didnt no ANYTHING as far as upgrades to the motor. Ive got too much power going to a really small input shaft as it is. the only reason im running the maft is easyer plumbing (no bulky mass) and the exhaust manifold just looks pretty. Im even running the balance shafts :O
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Bill Hincher
PostPosted: Mon Mar 09, 2009 10:15 am  Reply with quote
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that radiator is scary dave, I dont think it will work, I cant imagine the coolant curculating up high like that, but thats just me , I can just see the driver getting scalded with hot coolant with that thing if it overheats

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Dave99gst
PostPosted: Thu Mar 19, 2009 6:41 am  Reply with quote
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i hear ya - but alot of people toss it up there on liquid cooled rails. Both of those things have entered my mind tho'
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80D50SPORT
PostPosted: Thu Oct 01, 2009 7:13 pm  Reply with quote
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I DONT KNOW IF YOU GOT IT RUNNING YET BUT FROM THE PICS I CAN TELL YOU ARE USING WHAT LOOKS LIKE FERNCO PLUMING COUPLERS FOR YOU INTERCOOLER PIPING CONNECTORS ...GET RID OF THEM ! THEY WILL BLOW UP LIKE BALLONS AND POP EVEN AT 14 PSI! BUT THEY WILL WORK IF YOU JUST WANT THE ENGINE TO RUN IN TESTING (IDLE)..ALSO IF YOU HAVE TROUBLE BLOWING CONNECTORS OFF SPRAY THE INSIDE OF THE CONNECTOR WITH AQUA NET HAIR SPRAY AND THEN SLIDE THEM ON ONCE THEY DRY YOU WITH HAVE TO PRY THEM OFF IF YOU EVER HAVE TO TAKE THE PIPE OFF AGAIN....I USED TO HAVE TROUBLE BLOWING CONNECTORS OFF ON MY ECLIPSE AND A BUDDIE THAT USE THE RACE DIRT BIKES SUGGESTED IT ..HE SAID IT WAS WHAT THEY USED TO GET NEW GRIP ON EASY AND MAKE THEM STICK IN PLACE...
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ligo1
PostPosted: Fri Oct 02, 2009 9:37 am  Reply with quote
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The couplings are fine.








Many haters,that means a job well done!
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Cheaptalon
PostPosted: Sat Oct 10, 2009 7:30 pm  Reply with quote
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Dave gave me a ride in this thing at the DSM SO. One of the coolest vehicles I have ever ridden in. It's not even the exhaust that gets ya, its the BOV right next to your ear. Haha

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Dave99gst
PostPosted: Sun Feb 06, 2011 9:57 am  Reply with quote
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@80D50SPORT - Those are no longer on there Smile

@Cheaptalon Smile

Not a ton to update - I drive the shit out of this thing in the summer.
I did fry my diff just with normal driving and upgraged the trans.

Its still not the strongest but its a bit better then it was.
I also have Rear Disk Brakes.



I got featured in mitsubishi gearbox magazine http://mitsubishi.gearboxmagazine.com/2011/01/dave-groffs-mitsu-powered-sandrail/

Notice were i referenced under "Who has helped you the most along the way" Smile

The buggy is also a Featured Ride on dsmtuners http://www.dsmtuners.com/forums/featured-member/282230-4g63-sandrail.html
both were very cool honers.
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Dave99gst
PostPosted: Sun Feb 06, 2011 10:01 am  Reply with quote
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Slightly longer vid of when it first started running. Hopfully i was get a better one this summer.
http://www.youtube.com/watch?v=eUM4G-zEGZg
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Dave99gst
PostPosted: Thu May 15, 2014 6:36 am  Reply with quote
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https://docs.google.com/spreadsheet/ccc?key=0AlXkaIt64C43cFAxMzNIcUpqRUlBNGluVWhLb3U4Q2c&usp=sharing

I realized the other project spreadsheet is VERY outdated
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