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  #21 (permalink)  
Old 09-22-2014, 06:22 AM
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Default Cha2ga's Fusca Tdi

The USP Motorsports/Spulen silicone boost hose; looks like a nice piece.... I doubt they would ever make one for the New Beetle but it looks like you could make the TSI version work, with some cutting or modifications., at that point...... Does it beg the question: should you just make your own out of silicone hose to begin with?

http://www.uspmotorsports.com/SPULEN...ter-Hose-.html


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  #22 (permalink)  
Old 09-22-2014, 01:14 PM
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I used silicon tubing from McMaster Carr for replacing all the 3mm and 5 mm lines. The brake booster will collapse the sidewalls which is why that is a hard pipe.
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Old 09-22-2014, 05:53 PM
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Well, the kit they sell! was specifically designed for the brake booster; I would assume it would be reinforced and stiff enough to handle thee vacuum? Spulen Engineering still hasn't responded to my inquiries on Facebook; I wonder who these guys are or if they are just a house. brand for USP Motorsports?


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  #24 (permalink)  
Old 09-28-2014, 09:23 PM
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My large cooling fan was not working at all. This fan should come on anytime the AC is on. After researching this problem over at tdiclub, I found out this is a very common occurrence and that usually that fan is not burned out. There are four brushes on the commutator of the motor. Apparently these stick and do not allow for proper operation. Over on tdiclub mechanics are reporting 90 percent success rates on multiple fans.
I took mine out in about 20 minutes. Took another hour to take it apart, clean, lube, reassemble it. A couple hours for the quick JB Weld to cure. It is now working flawlessly.

Here is the thread with embedded pdf instructions that I followed.

HAPPY MOTORING!

http://forums.tdiclub.com/showthread.php?t=286603
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  #25 (permalink)  
Old 10-04-2014, 11:20 PM
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Oil change day. Gonna try Mobil 1 0W-40 since winter is coming. Maybe it will have easier starts. A Mann oil filter and a tire rotation along with a under carriage and suspension inspection. Checked air pressure, including the spare. Should be ready for my road trip next weekend to The University of Chicago.
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  #26 (permalink)  
Old 10-18-2014, 08:53 PM
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The road trip went well. One tank each way from Liberty SC to Chicago. 724 miles each way! 49 mpg up there and 51 on the way back!
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  #27 (permalink)  
Old 10-18-2014, 09:13 PM
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Default Cha2ga's Fusca Tdi

I repaired my blend doors today. Credit for the technique goes to bgrave1 (Bob G.).

Removed the center dash, stereo, lower control panel.Name:  ImageUploadedByAutoGuide1413662555.543483.jpg
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Cut a hole using dremel tool and side cutter bit.Name:  ImageUploadedByAutoGuide1413662628.797259.jpg
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You can see missing foam on both doors.Name:  ImageUploadedByAutoGuide1413662722.560776.jpg
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My daughter has small arms and wrists. She installed two layers of the hvac aluminum tape on each door for me.Name:  ImageUploadedByAutoGuide1413662829.931659.jpg
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Then layed tape from the inside covering the opening that was cut she was able to reach into the vent holes to do this.Name:  ImageUploadedByAutoGuide1413662990.520568.jpg
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Placed the cutout plastic onto the tape.Name:  ImageUploadedByAutoGuide1413663035.786247.jpg
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Installed two layers of tape over the plastic.Name:  ImageUploadedByAutoGuide1413663076.320548.jpg
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Reinstalled the dash and stereo. Checked functionality and all is working. More airflow out of the correct ducts than ever!

Last edited by cha2ga; 10-19-2014 at 02:35 AM..
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  #28 (permalink)  
Old 11-24-2014, 01:49 AM
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update:
The blend door mod is a 100% success! Wow! In typical tdi fashion, it takes a little longer to be hot, but once it reaches temp it gets hot in the cabin now that outside air isn't leaking into the cab!
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  #29 (permalink)  
Old 11-28-2014, 08:06 PM
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Default Cha2ga's Fusca Tdi

Got a catectomy and mufflerectomy done today! Love the sound. Not any louder but deeper tone. Can hear the turbine whine!
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Last edited by cha2ga; 11-29-2014 at 01:05 AM..
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  #30 (permalink)  
Old 12-03-2014, 11:16 PM
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Installed a new VR6/G60 clutch kit with 22# flywheel today. Work was done by DJ's VW in Easley. Next on the list will be egr cooler delete and egr delete.
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  #31 (permalink)  
Old 12-04-2014, 12:53 PM
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While the clutch was out the rear main deal was found to be weeping. Replaced it at the same time.
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  #32 (permalink)  
Old 12-04-2014, 12:57 PM
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$339 clutch kit + $75 main seal + $500 labor = $914
Current mileage = 173,224
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  #33 (permalink)  
Old 12-20-2014, 10:58 PM
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Last tank 48mpg. Drove it pretty hard. Mostly city. Looks like straight exhaust may have a positive impact. Will continue to monitor. Fuel prices continue to drop. Picture of pump in Easley SC, earlier today.Name:  ImageUploadedByAutoGuide1419116308.310390.jpg
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  #34 (permalink)  
Old 12-21-2014, 10:44 PM
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Repaired my fuel cap tether strap. First I covered the fuel tank inlet. Then I cut both edges so they were not angled. Inserted a 2 inch length of 0.250 inch diameter heat shrink over one end of the tether. Used SuperGlue to the secure the ends together. Slid the heat shrink over the repair and heated it! Works great.
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Old 12-25-2014, 04:34 PM
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My daughter painted the VW logo by hand and then tie dyed a shirt for my Christmas! Also got a RossTech VCDS! Name:  ImageUploadedByAutoGuide1419525229.853510.jpg
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Old 12-26-2014, 08:36 PM
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Had a MIL for BRAKE and ABS. Used new VCDS to clear after replacing blown fuse #12 (Battery Positive Voltage for data link connector). The ABS fuse (# 9) and all fuses on battery cover were good. The light originally came on doing the cluster output test in VCDS. There was no real problem. The fuse blew and that wouldn't allow VCDS to clear the codes because of no communication to the data port. New fuse and problem fixed.
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Old 12-26-2014, 08:47 PM
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Santa brought me a brand new old stock Thule 752 rack!Name:  ImageUploadedByAutoGuide1419626272.748749.jpg
Views: 249
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Installed the leading edge of the front base pads exactly 7.5 inches back from the leading edge of where the roof meets the windshield (measured from the yellow paint, not the windshield). The leading edge of the rear pads are 27.5 inches back from the mark of the front bar (35 inches from the leading edge of where roof meets windshield). Locks are installed.
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Last edited by cha2ga; 12-26-2014 at 08:58 PM..
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Old 01-16-2015, 08:15 PM
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  #39 (permalink)  
Old 01-20-2015, 01:35 AM
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My ABS and BRAKE lightS came on after I disconnecting and reconnecting my battery a couple of weeks ago. I did find that fuse #9 inside the car was blown. I replaced that fuse and reset codes with VCDS. BRAKE light extinguished but the ABS remained lit. Tried resetting codes multiple times with no success. Opened the hood and removed all three fuses on the battery fuse box. None of them were blown. Reinserted fuses in the same slots they came out of however I inserted them 180 degrees from how I took them out. I Pushed on the fuses laterally to ensure good contact in the fuse block. Reset code. ABS light extinguished and has not come back on. ABS is working.
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Old 01-27-2015, 01:22 AM
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Here is an old picture of me with my Beetle. I had just got home from basic training at Marine Corps Recruit Depot Parris Island. This was 1998. I had installed a one pice tilt fiberglass front end (everything from the windshield forward). One piece side glass. Lowered running 135's front and 185's rear. 1776cc with dual Webber's. External oil cooler. 041 heads. Lift the front tires off the ground. 86 Mustang killer (1/8 mile).Name:  ImageUploadedByAutoGuide1422321762.927690.jpg
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