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DrBoost
DrBoost SuperDork
2/27/12 6:23 a.m.

This thread makes me giggle like a little girl.

thummmper
thummmper Reader
3/2/12 9:16 p.m.

thanks doc! I used to say that in the academy, they ran you until you either fainted, cried like a little girl or quit, and I never fainted or quit! glad you like it.

I just ordered $550.00 worth of halfshafts and cvjoints-- i had to order two pairs due to the different lengths, so I will have a set for the next one as well, sans joints. I found 2 hard brake lines on the shelf I can use on the rear trail arms. that saved me 80 bucks. but I could have gotten longer flexies and deleted other pieces and their costs. the second van will have more improvement.

thummmper
thummmper Reader
3/14/12 9:46 p.m.

I am experimenting with developing this and other conversions for junior colleges to give the kids a project they can frankenstein and start up at the end of the semester-- develop it into weekly chapters or learning domains. every week you walk in and see real progress. If they won't have it, then I will do it on my own--I see so many dumb-ass questions on the net from kids that something must be done

thummmper
thummmper Reader
3/17/12 12:36 a.m.

mockup 1/2shafts with the old 735i shafts cut in two and shortened and the right side and I got another donor car wednesday-- a 97 trep sport with the 3.5 and paddle shift-- only 45000 mi

Vigo
Vigo SuperDork
3/17/12 11:41 p.m.

Although you could easily hook paddles up to run Autostick since all it needs is momentary switches to ground two tcm pins... i still wouldnt technically call it paddleshift.

I really liked my 97 intrepid 3.5/autostick. I never would have gotten rid of it except for the years-long horribly difficult to diagnose intermittent performance problems that eventually made me hate it after loving it.

thummmper
thummmper Reader
3/18/12 12:14 p.m.

auto stick- I was going to say tiptronic but thats foreign-- although I would get paddled at the transmission shop if I abused it--

Karl La Follette
Karl La Follette Dork
3/18/12 1:37 p.m.

Great thread and very inspirational awesome work .

thummmper
thummmper Reader
3/20/12 11:56 p.m.

what sort of problems did you have vigo?

Vigo
Vigo SuperDork
3/21/12 6:07 p.m.

Well, i had a really intermittent overheating problem that took me like 2 years to figure out. Eventually found it to be steaming (not leaking, only when hot, not leaving a trace, wouldnt do it with a pressure tester) from one of the o-rings between the inner timing cover and the block (for the water pump, but BEHIND the inner timing cover), and the steam would VERY GRADUALLY escape from somewhere under the thermostat. I also had an intermittent connection problem at that fan module thing that's mounted to the fan shrouds on those cars.

The big thing that ruined the car for me was that it would randomly lose about 70 or 80 hp at the most inopportune times (like when i was trying to embarass mustangs.. it worked when the CAR worked..). I dont like to rest on my titles but suffice it to say im an ASE master-certified tech and couldnt figure it out for 2 years, nor could any of the people i worked for in that time, or any of the people i learned under at the trade school i got my automotive degree at. Literally noone i ever ran across while working full time as a professional tech, could ever figure it out. Eventually i got bitter (after 2+ yrs..) and sold the car. I think if i HADNT, my next step would have been replacing the entire engine bay harness, but id almost rather give up than fix anything by accident and not be able to say WHAT i fixed.

thummmper
thummmper Reader
3/21/12 9:08 p.m.

theres a guy that hosts "ask roland" that hates this engine for the mysterious o-ring problems--I have seen a lot of clist posts where "it sometimes overheats, but runs well'--seemingly mysterious I thought it was patently the intake manifold flat gasket failing at the coolant ducts and leaking coolant into the runners-- Mine was doing that and corroded the manifold bolts to the point of breaking off at removal, but 2" protrudes after the manifold is lifted off, so they can be torched cherry red and worked out. Behind the wpump...roland complained of the o-ring /tube ducting under the intake manifold of the 2.7 suddenly losing an o-ring--and the whodunnit that ensued-- seems total disassembly of the water system was the rx, but thats major activity-- and the fan cm malfunction with no code...and not a line mechanic with an answer to be found....those guys step backwards through the "mechanics only" door when I start asking about codes etc.,,, I knew rebuilding main street wasnt going to be easy.
did the gen 2's have as many problems? thanks vigo

thummmper
thummmper Reader
3/26/12 10:11 p.m.

this projects son--backburner for now--a toyota previa van with an ho 3.5 under the back seat, similar to the vw--theres a lot more room between the frame stringers to install it from underneath on a subframe--

MrJoshua
MrJoshua PowerDork
3/26/12 10:30 p.m.

In reply to thummmper:

I'm not sure if you are aware of this, but the JDM "Not Fat American Version" of the Previa/Estima has an IRS.

thummmper
thummmper Reader
3/27/12 9:59 p.m.

I was going to use the chrysler suspension as well, or bmw 7 series, until the X5's become available in the jy's. I would have to buy a "clip or back half of a previa/jdm model--never bought a jdm half before--It would be cheaper to use the chrysler hdw. donor is paid for.

thummmper
thummmper Reader
4/14/12 5:01 p.m.

true though-- initial equipment choices are the most important, and forsaking one for the economy of another is not always the best rule. an estima would be an interesting subject to review.

thummmper
thummmper Reader
4/18/12 11:12 p.m.

before any oil goes in, I must address the front engine seals, which I put off a year and a half. viton o-rings are a bitch to locate, and it all awaits them.

thummmper
thummmper Reader
4/19/12 9:06 p.m.

thummmper
thummmper Reader
4/21/12 7:43 p.m.

and the water pump is wrong-- too large diameter pulley from the later model--and the listing said that--duh, but I can use it for my 97 intrepid, so i have the RIGHT one coming thursday.

thummmper
thummmper Reader
4/29/12 7:42 p.m.

there-on my way back together

chandlerGTi
chandlerGTi HalfDork
4/30/12 6:29 a.m.

Nice.

thummmper
thummmper Reader
5/1/12 11:40 p.m.

all closed up-- it took 2 weeks to get here with these seals-- almost 3 weeks. ordering stuff- the next one will take 3 days with paint drying and all.

thummmper
thummmper Reader
5/3/12 12:58 a.m.

fuel access hatch and the little tool I made to tighten the ps outlet fitting

thummmper
thummmper Reader
5/5/12 10:36 p.m.

after almost 2 years, the fuel filler neck is installed, except for 2 little parts waiting for paint to dry and the fuel tank is in and final-connected. the vacuum hoses and wiring are next-- am I almost at the end of the list? can it be?

Nitroracer
Nitroracer SuperDork
5/5/12 11:02 p.m.

Take a video when it starts up and moves under its own power again. It has been great following your build.

thummmper
thummmper Reader
5/7/12 12:23 a.m.

thummmper
thummmper Reader
5/15/12 1:20 a.m.

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