ChaosMotorSport MKII Buggy Engine Swap

ChaosMS

Active member
Thought I would start a new thread for the engine swap on the MKII buggy, that way I can keep the MKIII design thread clean from any MKII updates - if that makes sense :)
 

ChaosMS

Active member
Here we have the recently removed engine from its host - a 2001 vw golf MK IV 1.8T 20 Valve GTI engine :)

86e03aea-cf17-45eb-bdec-a1f0a0d74e7d.jpg
 

ChaosMS

Active member
It was a hell of a job extracting the engine and the full engine bay loom and the loom from the front of the car behind the dashboard, including the instrument pod, Accelerator pedal (its drive by wire), ignition barrel and fuse boxes, in all a very long day which would of been impossible if I hadnt had the help from Steve!!
 

ChaosMS

Active member
A few more pics of the engine - this time with the loom totally removed still have aircon compressor and steering pump to remove then its clean up time!!

7b8216e9-b4d7-4565-b0c2-3318f376ee89.jpg


a9b0c544-87d3-42ea-ca9e-23b6efb26f62.jpg


9257fc7f-8127-405d-9280-dad79bf3c6fa.jpg


322e0c51-6efd-4ded-efe2-37023abb1faf.jpg


0d7cf5db-d4ff-4c93-f702-522a502a2f9f.jpg
 

ChaosMS

Active member
So been testing some 3d printed parts out for the engine - specifically the crankcase and head breather pipe - the one I have on the engine is knackered so I need a new one but rather than using the standard golf unit I would like to use the silicone hoses (with the Fluoro coating to stop oil vapour ingress) instead and so I need some odd shaped joining bits to make up the system, so is the first attempt just for testing

f792ff95-004b-4e97-9d99-23b050118057.jpg

1e506aad-1259-4a37-f314-fe5c7771cf42.jpg


I am going to add a collar to the next design so the tube has something to push up to and also a mounting lug, Overall it seems to work really well and its as hard as nails!!

Printed it in E3D Edge with is a PETG variant and is supposedly resistant to just about everything - we will see

Rich
 

ChaosMS

Active member
Hi all - been busy cleaning the engine off and stripping the old engine out of the buggy, found that the best thing to clean an engine with is not gunk its WD40 about 2.5 litres of it actually, its done an excellent job of getting rid of the thick layer of filth on the block!!

Anyway here are a couple of shots of the buggy as she is now minus the cooling system and all the electrics disconnected from the ecu
219dd5f4-5942-4b57-9a5f-38f8ce030808.jpg

72259f43-6720-4778-8310-24acca791840.jpg


Anyway should have the engine free this weekend with a bit of luck, then i need to strip the fuel tank and panels off then I can set to with the angle grinder and welder!!
 

ChaosMS

Active member
Well been busy again this weekend the back of the buggy now looks like this:
e4d620a4-55f1-46af-9ef6-75a91f0814f4.jpg

da4d6d76-a7b7-4452-fbc5-5ec04aea384c.jpg


And the engine is now sat here looking a little sad:
f94c9001-9525-491c-ea9a-8f67669af533.jpg


And the new engine is gonna take a little work..... actually a lot of work :D
7d706e6e-a812-4c33-937e-0e15d5d67841.jpg

c1c8f261-5bf4-4c66-aaf9-b99245962cb7.jpg

ffe42b37-52b7-4bf4-b3ac-00218977cd1f.jpg


Have also stripped out the side panels, will be taking the seats out next so I can remove the rear bulkhead and then remove the tank, then the real fun begins!!! ;D ;D ;D
 

ChaosMS

Active member
So quick update........

All the back end of the buggy stripped out, All of the Suzuki loom and the separate buggy loom removed, suspension off, seats out, brakes stripped old driveshafts binned, crap from VW engine I am not using binned.... Set to with angle grinder.... oh dear!!
f3b5126c-f75d-4601-eb91-628920c5b11a.jpg

All stripped out ready for cutting

8022b15e-80ec-45b3-aa0b-640f5fa946a8.jpg

Back end chopped very very carefully !! (I need most of it)

ecbe1803-ae9d-44a5-f0c7-a10d6d49890b.jpg

What I'm left with!!!

lined up the engine behind the frame with the mounts bolted on and looks like my mounting plan should work, just need to pick up a couple of brace points from the upper cage to support the new engine mounting frame (will post render of what I mean shortly

Rich
 

ChaosMS

Active member
Well been working on the buggy engine mount design again, built a dummy engine model to get it roughly correct then fine tune it later this is the back of the buggy with the rear frame removed:
1f32d66c-18a0-46b3-a8ae-36f8816c5895.jpg


The plates under the engine are placeholders for the final water cut parts that will make up the engine sub-frame - still working on it but should get more done this week as im on holiday now till the new year!

Oh and Father Christmas popped round with a few shiny bits (new intercooler and a remote oil filter mounting and sandwich plate, with a re-usable oil filter)
29b74f96-3a34-4442-b683-a3ef01fa8459.jpg

19cb205c-f492-472d-dc7c-0516063b81e3.jpg


Intercooler is a toyosport with a 2.5" inlet and outlet
d509234c-33a8-4b40-9172-cb180582a65b.jpg

3ef74caa-593b-4bb9-a862-08be788ee55e.jpg


anyway got to try and get the sub frame design finished then I can get it off to the local water cutting company will post more pics soon
 

ChaosMS

Active member
Hi Wagon, I booked this week off to work on the buggy and guess what the bleeding storm last week brought most of my fence down along the side of the house so all I've done so far is work on that (dodging the rain) - I should have most of it sorted by the end of this week then I might get a couple of days to work on the buggy.

I am just wondering if I should re-build the lower suspension arms at the moment I have a clearance issue with the starter motor so I will need to widen both upper and lower suspension arms, so though it might be a good idea to beef up the lower arms a little

Other than that diddly progress on the buggy front - very very frustrating!!
 

ChaosMS

Active member
Busy weekend this weekend got the new engine mounts built;
27bc5b4b-bf88-40b7-907f-1a7970e2d2b1.jpg


47cf73f3-4a09-48b2-b198-df9b5b01ef19.jpg


Still need to finish the seam weld on the flat mount but ran out of gas so had to prop stuff in place to check for fit;
be16807f-bf66-4188-9073-7513605761e5.jpg


dc35345f-20d4-448e-f0e9-3568de5e4f5f.jpg


8b7050a4-4986-4b73-de63-c1748cc4ad46.jpg


d045852f-5dd2-4de9-a785-03395ce3809d.jpg


next need to add the bracing to the upper frame to support the load on these mounts, hopefully should have a new gas bottle later this week and i can then crack on this coming weekend!!!
 

ChaosMS

Active member
Busy weekend got the engine mounts in and braced to the upper cage and now the engine sits happily at the back so here are a few more pics:

e938f10c-dd07-4e4d-c0c7-a87acbe530e5.jpg

main mounts tacked in place to check for fit

ff97575f-ac22-497e-b906-9aead2775f19.jpg

Brace tubes in place and welded in

a80e23bd-1345-4c9d-e9e3-93f861163e38.jpg

6ea3e405-5741-4916-f8f3-d878255645ab.jpg

19b96a2e-91f8-4655-a052-affdcebe8cda.jpg

I put the cover back on in the last shot as still dont know if im going to use it - my thought was that it might stop little fingers from messing!!!

next job is to sort the subframe design out and get it water cut so I can get that in place
 

ChaosMS

Active member
Copied this info over from Baloo's thread so as not to pollute his build thread!! ;D

The little side project I am working on is a buggy scissor lift!! - I needed a way to move the buggy out of the garage when it has no wheels, originally I was just going to build a table I could drop the buggy on that had big castors, then one night I saw a video of a guy in the US that had built a adjustable welding table - not quite what I wanted but gave me the idea so I drew it up I and added a manual hydraulic cylinder to do the lifting. The plan was to make it as low as possible then I could leave it in the middle of the garage and just drive over it when not in use, and if I made the top large enough it could become a build table for the next buggy !!

So after a bit of head scratching I came up with this:-
ab0b5be5-f68d-4705-8b6e-e92054f42809.jpg


over the last few weeks I sourced all the parts (160mm 500kg load castors, 8 ton hydraulic cylinder, steel, nuts bolts and odds & sods!) and set to - this is the build so far:

ca755481-1848-4b53-ebea-443f46f90d97.jpg

b78aa3a2-efca-43a7-8a33-ab2f72cd6f12.jpg

efd0a6fd-a055-4dda-a0c4-c7172162e6e7.jpg

fe316b3e-099c-4a85-d14b-8c5ea0d92b4b.jpg

5f31e4c6-3d63-4ef2-873f-556b983abaab.jpg

4f27b8f6-d38a-4421-aac2-e10bd6de526a.jpg


so its coming on quite well I just ordered the final parts laser cut from a local company as A- they need to be accurate and B- I wanted to see what they would be like with a small set of parts before sending the parts for the buggy to be cut!

another weekend should see it just about complete

Rich
 

ChaosMS

Active member
So more progress on the scissor lift this weekend (I need to get it done so I can continue on the buggy)

I got the laser cut parts back (awesome job by AK Stainless near Preston)
96d62a27-6dfb-4a18-c82d-87ee24f98a5a.jpg


finished up the wheel carriers:
541d9d76-69d5-480b-bd76-0fb69f1cb655.jpg

47fd9ce9-fbc5-441a-d5ee-44514fa048cd.jpg


Added the hinge box and additional strengthening to the wheel mounting plates:
012c226c-614b-4767-a51b-c463b1cc3ca4.jpg


A little test fitting with the scissor frames:
3e438129-f193-4c0a-9c3e-94870e53731c.jpg

abcbdd96-f425-4c12-930d-08c1a9e98a81.jpg


Added the torque tube to both wheel carriers:
d14c27b3-83d0-4ef0-fd9a-9917cfbde376.jpg


And assembled both carriers and the frames:
f82192d4-0d41-4463-dbc2-97fc422f4667.jpg

fbc64b04-5fc2-404b-80c7-bdaeb770c21d.jpg


I've welded in the lower mount for the hydraulic cylinder now need to build up all the other laser cut parts, fit them and then mount the top table!!!
 

ChaosMS

Active member
OK so finally got the whole lift to work and got the buggy on it - it was surprisingly easy to wheel about with the chassis on so here are a few more pics

6781427c-0fb7-4483-8c16-d93c8c1517f5.jpg


88428f0c-9fdb-4ecc-8f91-e626f9b89626.jpg


3824fa61-1dc7-4353-8f2c-4a487e1ef3f6.jpg


9f1aa7ec-b019-434d-b2e5-602e60c34dac.jpg


47902ac0-ddee-4cbb-9fcc-f04508aa8373.jpg


65d4e999-5676-4dc1-8983-e7ddd8d32e22.jpg
 
Top