CJ3A Volkswagon TDI

What engine are you swap are you doing BrownCoat? Do you have a build on here?

 

CJ3b Beastie

 

There it is.

 

Very cool build Browncoat! Looks like fun!

I just finished making my own timing tools.I couldnt bring myself to pay for the tools when I knew I could make them.

Homemade TDI timing tools.










Since the timing belt is done I decided to get to work on the firewall. I Primed and painted it today. There is a painted cover plate that fills the space and provides a place to mount my accelerator pedal. Since the TDI is drive by wire, I am stuck using the VW pedal. Its not ideal but I was able to cut it down and get it to fit without looking to ridiculous. Im not a fan of having to cut the firewall, but it is what it is. You cant see it when you're sitting in the front seat, or from the outside....so Im ok with it.

 

HA! I made my own tools to do the timing belt on my wife 2004 VW Jetta TDI wagon. They just weren't nearly as nice as your though! Just could not justify shelling out all the money.

A couple suggestions.... I see you have disk brakes up front. If you don't have a double master cylinder, install one now. You will need to fab up a bracket, but that will be pretty easy for you.

Another thing is to either rebuild the ross box, install an M38-A1 one or a V6 model, or the best option is to go saginaw a this point. Power steering and modern brakes will make a 2A your daily driver. Mine is.

I love what you're doing, seriously.. this is top notch!

 

Thanks! Yes, I plan on doing some brake upgrades. The PO didnt do a very good job So I will likely being going through everything. The steering will be rebuilt but staying stock for now. With the small tires im running it should be ok for what I plan on doing with this jeep. Im getting tired of fabricating stuff anyway! haha!

 

Just been working on little things lately. The engine is ready to go back in.... Tonight I made a little bushing for my coolant lines so I can hook up the factory willys temp gauge. I made a bushing out of brass to accept the temp probe. I soldered it into a copper T that will go in-line with the pipe the leaves the head and goes to the rad inlet. The TDI has an electronic temp sensor, but I want the mechanical gauge to function. It will be towards the upper end of the sweep because these engines run at 190.

 

Ive made quite a bit of progress over the past few days. I finished painting everything. got installed the grill/fender. Ive been working on wiring and plumbing. Just getting everything back together. Fired her up backed it out of the garage and snapped some pictures and a video. Antique plates are on their way so hopefully with have this thing on the road soon!



















Here is a running video from today!

 

Listen to that turbo spooling up.

It's looking real good.

Your body seems to be reasonably straight, mine is full of bumps and bruises which are more obvious now it has a glossy top coat on.
Your tub looks a lot better.

 

Thanks! Yeah the turbo makes a lot of noise with the open exhaust. I guess the body looks decent in the pictures, but it has tons of dings/bumps/bends. I didnt waste time with bondo. I got rid of the rust and got it as straight as I could with a hammer and dolly....then I painted it. I am not a body man, and I plan on using this thing. Its good enough for me! haha!

 

First thing I watch that video this morning and instantly a smile happens on my face. Haven't even had coffee yet. This is amazing!

I tried hard on my body, but i think it got thrown out of a dump truck going 65mph into a salt mine.. My jeep tub looks even worse!

 

Yeah I knew if I tried it would still look like crap. Bad bondo job looks worse then dents in my opinion. Haha!

 

Agree about the body filler. Although I will come clean and admit to just now putting some in the weld divots on the hood of mine.

I reckon these old things need to have the bumps and bruises from their past lives out and proud.

A perfectly straight flat fender Jeep wouldn't look right.

 

Agreed! I love the spot welds and seams. I would be too scared to use it if it was perfect. Plus, I would never finish it if I tried to make to nice...... I would be chasing dents for the rest of the summer.

 

sorry for the lack of updates....... I have been working on the jeep here and there.

Rolled it outside for some photos with the hood and fenders on.









I got the hood blocks done and headlight buckets done....





I wired up my marker lights.







I took it for a spin around the yard. It ran great, but anytime I gave it a little throttle only one wheel would peel......So I knew something was up! Pulled it back in the shop and jacked it up.... Spun the the tires and I knew some thing was broken..

Pulled the diff cover and confirmed it had a broken axle! Thank you previous owner. Ahh the joys of buying a vehicle you cant test dive! haha! So I spent the day beating with a hammer to get the broken axle out of the housing and another day disassembling the locker to extract the broken off nub out of the carrier and stoning all the burs. Now its mostly back together but I am redesigning the rear caliper brackets. they ones it came with we poorly designed and in my opinion dangerous. So im a few days behind schedule. I have to get this back together and wire up the turn signals and tail lights. My plate should get here in about 10 days. My goal is to have the jeep done and waiting when it gets here. We will see if I can make it happen.


Here is the damage.








I have some videos from the maiden voyage. I will upload them to youtube and post soon!

 

Looking good. Sucks about the axle.

 

Talk about glamor shots! That jeep is hot Hot HOT!!

Is that a 10 spline axle?

 

Thanks. Yeah it’s a 10 spline Dana 41 with a lock-right. I have a 19 spline Dana 44 with a lsd in that I plan on building a installing later this summer. Just putting a spare axle in the 41 to get it on the road for now.

 

Total sleeper. Love it.