24) Front apron grill

So after thinking (read: worrying) about air flow the other day, I finally bit the bullet and decided to add some venting to the front apron. This was hard for me because I really wanted ALL of the body work on this car to be stock, and this would change the attitude of the car a little. But I want to be functional above all, and I really don't want to be caught 100's of miles away and have this thing over heat :)

I finally came up with the idea of using a grill just like a super beetle. The problem with the super beetle is the grill up front is very rounded, and it just wouldn't work in this virtually flat apron. Then it hit me, I have a spare hood, and it's got the fresh air vents up top! Sure enough, I cut it out and it fits perfectly! I really like how this is going to look, because it will match the one of the hood!





Here are the first few welds. I'm being super careful here about heat and burn through. I don't want to alter these perfect vents. I couldn't only imagine how hard it would be to fix them.





A few more welds, slowly...





The finished product. I'm in love!

22) Planning for the trunk

So the trunk will no doubt be a bit different on this Beetle. First of all since this will be a water cooled car now (I know, the purists are cringing) I will be placing the radiator in the spare tire wheel well. This shot is where I'm thinking about putting the spare tire. I'll make a nice sturdy bracket / brace for it. I'm also on the prowl for a lighter Porsche collapsible spare. This will give me more room to work with. I think I can say that I'm going to give up any trunk space here. Next I'll show you what I'm thinking for my radiator!

2) The plan

I love everything about my bug, but there are always areas for improvement, right?! My vision is to have a beetle that looks like it was taken off the showroom floor, then modified in a way that still says stock, but drives like a new car. A little lower, a little better handling, a little more power under the hood, a little more (OK so maybe a lot more) stopping power*, and some subtlety upgraded wheels and tires. This is by no means a complete list, but it's a start! : )

Suspension

• I will be using rear torsion bars from a '86 944 Turbo.
• I will be using adjustable shocks all around. (have to research, Bilstien or Koni)
• The rear will also utilize '86 944 Turbo aluminum trailing arms (the narrow ones)
• I'm planning on lowering the rear one notch.
• Up front I will have CB dropped spindles (2.5')
• Adjustable beam with the adjusters welded in at natural so I can fine tune up or down.
• The front beam will be narrowed 3"s to accommodate the wider wheels and brake setup.
• I want to have good bushings either eurothane or something similar that won't squeak!
• Rear sway bar will be an 18mm bar from a 944 Turbo.
• Front sway bar: TBD (It will have to work with the narrowed beam, etc...

Brakes

• I will have '86 944 Turbo brakes all around (Black 4-pots)
• I will have the front hubs machined to work with the CB spindles and late offset wheels.
• I will include a rear brake bias device so that I can fine tune the brake distribution.
• The E-Brake will be adapted to use the 944 setup.
  

Engine / Transmission

• I will be installing a stock EJ22 (2.2L) '96 Subaru Legacy motor.
• I will be using a KEP adapter plate w/ a stage 1 clutch setup.
• I will make my own wiring harness out of the Subaru harness.
• I will use an after market fuel delivery system with new tubing running from the gas tank.
• I will use the stock gas tank, but add a swirl tank, and bungs for send / return lines.
  
• I will be using a stock Beetle transmission at first, then later on, upgrading it to use better gear ratios and stronger 3rd and 4th gear.
  

Cooling (I'll be taking a leap of faith from the old air-cooled world)

• I will use a front mounted all aluminum performance radiator.
• I will scoop air from under the car, plus provide a means for a little direct airflow to the radiator. (I'm thinking welding in a vent taken from the fresh air vent of a donor hood)
• I will use aluminum tubing running under the car protected by some sort of channel built into the floor board.
• I will be using a tubing beader to make sure all connections between tube and hose will be secure.
• I will be utilizing a heating system under the back seat that will pump air to the front via the stock heater channels.
  

Wheels / Tires

• I will be using 16" 944 "Phone Dials" in their stock finish. (They are 53mm offset)
• I will be using aggressive tires, something like a Kumho MX, Falkin Azienth, or similar.
  

* I'm sick of the years and years I've dealt with drum brakes!! Time to not worry about stopping! : )