4G63T Sandrail

Dave99gst · Post by **Dave99gst** » Mon Dec 15, 2008 9:38 am

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= ... inUhKou8Cg

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:

89coltgt · Post by **89coltgt** » Mon Dec 15, 2008 10:09 am

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

Dave99gst · Post by **Dave99gst** » Mon Dec 15, 2008 11:33 am

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.

jeffball610 · Post by **jeffball610** » Mon Dec 15, 2008 6:23 pm

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.

89coltgt · Post by **89coltgt** » Mon Dec 15, 2008 7:01 pm

Here you go:

http://www.kennedyeng.com/

screemin eagle · Post by **screemin eagle** » Mon Dec 15, 2008 9:55 pm

bad ass man! i like the pocket bikes too

Dave99gst · Post by **Dave99gst** » Tue Dec 16, 2008 8:58 am

Yup Kennedy is exactly were you get the plate from. (also were my clutch,PP&flywheel came from)

Dave99gst · Post by **Dave99gst** » Tue Dec 16, 2008 7:04 pm

More - todays pix

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.

Professor Quest · Post by **Professor Quest** » Tue Dec 16, 2008 8:38 pm

I think you need.....

MORE HARNESSES!

89coltgt · Post by **89coltgt** » Tue Dec 16, 2008 9:02 pm

Looks geat! I may build one once we buy a house, I will need the extra room.

Dave99gst · Post by **Dave99gst** » Tue Dec 16, 2008 9:14 pm

Professor Quest wrote:I think you need..... MORE HARNESSES!

haha-- ya i got the entire car - from bumper to bumper

77amc · Post by **77amc** » Wed Dec 17, 2008 4:47 pm

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

Errol

turbostellar · Post by **turbostellar** » Thu Dec 18, 2008 1:01 am

looking good

Dave99gst · Post by **Dave99gst** » Thu Dec 18, 2008 10:39 am

ty all -

autox4fun · Post by **autox4fun** » Tue Jan 13, 2009 1:25 pm

Awesome Build!

turbostellar · Post by **turbostellar** » Tue Jan 13, 2009 7:26 pm

anymore updates to this?

Dave99gst · Post by **Dave99gst** » Sun Jan 18, 2009 9:48 am

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.

turbostellar · Post by **turbostellar** » Sun Jan 18, 2009 12:52 pm

looking good, thats going to be kick ass when its done

Dave99gst · Post by **Dave99gst** » Wed Jan 28, 2009 6:19 pm

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 )

Dave99gst · Post by **Dave99gst** » Wed Jan 28, 2009 6:22 pm

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.

77amc · Post by **77amc** » Sun Feb 15, 2009 11:03 pm

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

E

Dave99gst · Post by **Dave99gst** » Mon Feb 16, 2009 8:46 am

na -- ill just be carefull

Wilbur · Post by **Wilbur** » Sat Feb 21, 2009 2:20 pm

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?

Dave99gst · Post by **Dave99gst** » Sat Feb 28, 2009 8:35 am

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.

Dave99gst · Post by **Dave99gst** » Sat Feb 28, 2009 8:36 am

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

(ammo box picked up from harys army surplus)

Glove Box in its new home.

89coltgt · Post by **89coltgt** » Sat Feb 28, 2009 12:25 pm

Looking very good, I really like how the in plumbing turned out.

screemin eagle · Post by **screemin eagle** » Sat Feb 28, 2009 10:56 pm

wheres the intercooler?

Dave99gst · Post by **Dave99gst** » Sun Mar 01, 2009 8:52 am

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.

Dave99gst · Post by **Dave99gst** » Mon Mar 02, 2009 8:10 pm

http://www.youtube.com/watch?v=fjZV7duAIec

jezz_s13 · Post by **jezz_s13** » Tue Mar 03, 2009 3:29 am

That's going to be insane.

Arktis · Post by **Arktis** » Tue Mar 03, 2009 3:29 pm

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.

Dave99gst · Post by **Dave99gst** » Tue Mar 03, 2009 5:05 pm

There Cutting brakes. ( turning brakes ) they allow you to brake 1 or the other rear wheel to aid in turning.

Arktis · Post by **Arktis** » Sun Mar 08, 2009 3:46 am

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.

Bill Hincher · Post by **Bill Hincher** » Sun Mar 08, 2009 11:36 am

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

77amc · Post by **77amc** » Sun Mar 08, 2009 1:16 pm

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

Dave99gst · Post by **Dave99gst** » Sun Mar 08, 2009 6:36 pm

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

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

Bill Hincher · Post by **Bill Hincher** » Mon Mar 09, 2009 11:15 am

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

Dave99gst · Post by **Dave99gst** » Thu Mar 19, 2009 7:41 am

i hear ya - but alot of people toss it up there on liquid cooled rails. Both of those things have entered my mind tho'

80D50SPORT · Post by **80D50SPORT** » Thu Oct 01, 2009 8:13 pm

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...

ligo1 · Post by **ligo1** » Fri Oct 02, 2009 10:37 am

The couplings are fine.

Many haters,that means a job well done!

Cheaptalon · Post by **Cheaptalon** » Sat Oct 10, 2009 8:30 pm

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

Dave99gst · Post by **Dave99gst** » Sun Feb 06, 2011 9:57 am

@80D50SPORT - Those are no longer on there

@Cheaptalon

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/2 ... -sandrail/

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

The buggy is also a Featured Ride on dsmtuners http://www.dsmtuners.com/forums/feature ... drail.html
both were very cool honers.

Dave99gst · Post by **Dave99gst** » Sun Feb 06, 2011 10:01 am

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

Dave99gst · Post by **Dave99gst** » Thu May 15, 2014 7:36 am

https://docs.google.com/spreadsheet/ccc ... sp=sharing

I realized the other project spreadsheet is VERY outdated