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Volks-Swap :: Conversion Pictures :: Starting my 1.8L EA81 subaru swap PICS!



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spikedbeetle
05:48:21 Sat
Jun 28 2008

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Starting my 1.8L EA81 subaru swap PICS!








I am taking a subaru EA81 and making it look like a german watercooled experiment from the fifties. Keeping it as simple as possible. I am just mocking things up now, ordering parts and making the neccessary custom parts. I am estimating 90 or so HP over 100ftlbs of torque and really good mileage. An interesting fact I just found out is that the suby 1.8 weighs only 8lbs more than the VW engine it came with. The radiator should take place of the fan shroud and as far as weight goes, this swap should only add 30lbs max. with coolant. My car will be a hair over 1500 lbs parked.

The radiator is roughly 10x36 it came from a jeep cherokee. I plan on running two 10"fans. I built an adapter plate that allows me to use the stock VW generator and stand. It uses two bolts to hold the plate to the engine. three bolts to hold the stand to the plate, and the plate and stand actually share one hole into the engine. The carbs are a common set of Kadron carbs used for Hot-Rodding VW's. I am going to have them modified to run hard vacuum lines to the distributor. I also modified the throttle linkages to run upside down to get everything to fit nicely. Comments or Sugestions are very welcome.


[3 edits; Last edit by spikedbeetle at 04:29:09 Wed Jul 2 2008]

  
spikedbeetle
04:26:00 Tue
Jul 1 2008

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Re: Starting my 1.8l build PICS!

Here are some more Mock up pics.






  
spikedbeetle
04:33:27 Mon
Jul 14 2008

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Re: Starting my 1.8l build PICS!

Okay, I really liked the idea of having the carbs spread apart like the VW engine would have, but I had a really hard time trying to find a way to make the intake runners clear all the bolts and make the necessary bends. I went to several shops that also said they could not do it without a lot of cutting and welding and a big bill. So, I decided to turn the carbs 90 degrees and make the intake runners straight. This will be much easier and provide better airflow.

If you can afford it, have someone laser cut custom flanges because using a drill press, hack saw and dremmell tool works, but is very time consuming.

Bolting the flanges on before welding everything together makes it REALLY EASY to port match! This things airflow will be very smooth.:jump:

The exhaust shop wanted to charge me $15 just to flare the ends of my intake runners. It was going to be a nasty squareish flare too.:razzgreen: So I put them in a lathe, used an oxy aceteline torch and got the ends red hot. Then while it was still spinning, used a steel bar to flare the ends similar to a velocity stack. The goal is ultimately similar to a typical VW thinker, or any hot rodder for that matter. Take what you have and make it as good as you can. That and simplicity is why I am making this EA81 breathe as good as I can.





I will probably shorten the runners by an inch or two.

  
cjs
04:07:06 Mon
Aug 4 2008

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Re: Starting my 1.8l build PICS!

I am very interested in this swap. How is the progress this far? What are you expecting for fuel mileage?

-Chris

  
spikedbeetle
04:46:55 Tue
Aug 19 2008

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Re: Starting my 1.8l build PICS!

Sorry it took so long to answer. I haven't been checking in on the site because I have been low on cash and time, so the project has not made much progress. When I got the KEP adapter, it came with an info booklet that claimed the vanagons got 26MPG with this engine. My car will have the dual carbs, I don't know how that will affect it. It actually gave the VW motor better mileage. My car also weighs half what the vanagons weigh or less. I am expecting at least 26 and hopefuly over 30MPG. I am also expecting that with the HP and torque ratings for this engine I am hoping for 14's, but will be happy with mid 15's in the 1/4 mile. which would be as fast as my dads old roadrunner was with 2-3 times the mileage. It may be a year before I can get to the track, but I will post times and video as soon as I do.
[1 edits; Last edit by spikedbeetle at 04:49:18 Tue Aug 19 2008]

  
spikedbeetle
15:53:56 Sun
Sep 14 2008

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Re: Starting my 1.8l build PICS!

Okay, I'm now in the process of creating a throttle linkage for it. It is bolted in now so I can plan for that and for radiator placement.






  
spikedbeetle
02:08:05 Fri
Oct 24 2008

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Re: Starting my 1.8l build PICS!

I thought it would interesting if my throttle linkage ran right through the middle of my oil filler tube. so I drilled a hole and welded a smaller tube in for the linkage to fit through.
[1 edits; Last edit by spikedbeetle at 02:12:50 Fri Oct 24 2008]

  
aaandrew
12:52:46 Sun
Oct 26 2008

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Re: Starting my 1.8l build PICS!

Nice project! Those carbs do take away the Subaru look. What are your plans for a radiator right now. When I was building mine I had held a fox, dasher, rabbit, Jetta II, and cabriolet radiator in place, with my setup the cabriolet fit the best. The dasher and fox ones are tall and narrow, it looks like you would have room for that type. The vanagon rear heater is the way to go for heat, it sits opposite the battery, has a 3 speed fan and can be tied in with the original heat channels.

  
spikedbeetle
16:30:54 Sun
Oct 26 2008

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Re: Starting my 1.8l build PICS!

Thanks. The very first picture in this thread is a clickable thumbnail of my radiator. It came from a jeep with a 4 litre in-line 6. My concerns are that it might be overkill. It is huge. 36 x 12 x 1-1/2". I would really like to mount it horizontally like you did, but under the luggage compartment. I am worried that the radiator might not take the stress of the weight if the fluid when laid down. I guess, ifI built a frame for it to sit in it might be anything to worry about. I really like your heater Idea. I was thinking about putting a heater core up front, but your idea is simpler. thanks

  
aaandrew
11:32:56 Mon
Oct 27 2008

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Re: Starting my 1.8l build PICS!

what is your plan for a fan? how are you going to separate hot air from cold air?

  
BLACKPINE
20:17:56 Mon
Oct 27 2008

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(No Subject)

[1 edits; Last edit by BLACKPINE at 18:54:15 Tue Oct 28 2008]

  
BLACKPINE
20:18:50 Mon
Oct 27 2008

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Re: Starting my 1.8l build PICS!

[5 edits; Last edit by BLACKPINE at 22:07:24 Thu Nov 6 2008]

  
spikedbeetle
01:53:18 Tue
Oct 28 2008

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Re: Starting my 1.8l build PICS!

Right now, I am planing to lay the radiator down flat above the tranny. I have raised my luggage area about 6 inches. I have 300 square inches of cooling surface and two 10" electric fans. I don't really have a plan to separate hot and cold air. Do you think if I made a new "firewall" that it would be good enough? Do you think I would get enough air flow through the luggage area? I may put on deck lid risers in the summer months, if I have to.

  
spikedbeetle
02:05:22 Tue
Oct 28 2008

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Re: Starting my 1.8l build PICS!

To BLACKPINE, I pulled the engine out of a mid 80's four door sedan of some sort. I believe it is a 1785cc engine. I got the adapter plate and flywheel from "KEP" Kennedy Engeneered Products. They literally make hundreds of adapters. To post pics, join an online picture database like "photobucket.com". It's free. Click on upload pictures. Once uploaded, select the pictures you want, scroll to the bottom of the page and click on generate html and img code. That will take you to another page where you will need to copy the code in the "image code for message boards" section and paste that here when you are typing up your posts. It should look something like this when you paste it and will look like a picture when posted.

[img/]allyouneedtodoispasteithere.photobucket/blackpine/[img/]

  
aaandrew
15:10:23 Sun
Nov 16 2008

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Re: Starting my 1.8l build PICS!

I think as long as you are pulling air from one spot and ducting it and sending it to a different spot the radiator and fan set up should work. On my bug I made that piece of metal that seals against the engine cover when it is closed that way the fan blows all the air out of the vent holes and pulls it all from the bottom. Without it the air would just go around in a circle.

  
tuoppi
04:39:52 Sun
Dec 7 2008

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Re: Starting my 1.8l build PICS!

Hello everybody,

Looking nice! I just bought ea81 engine and have search information how to install it to my beetle 1300 -72 and this helps a lot.

have anyone made those adapters (kep) by themself? or have pictures in cad or something?

Spikedbeetle or someone else can you tell me how big valves is in ea81? have haven't found the answer from web. and if someone knows good place to get information and pictures and all kind of material about this engine I would be very hapy.

[1 edits; Last edit by tuoppi at 05:49:50 Sun Dec 7 2008]

  
spikedbeetle
23:40:34 Fri
Dec 12 2008

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Re: Starting my 1.8l build PICS!

I don't remember what the valve size is, but there are a lot of people who will know and have a lot more info on this engine. It is a popular engine to use in light aircraft. You might try searching that way.

  
spikedbeetle
02:03:34 Fri
Aug 21 2009

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Re: Starting my 1.8l build PICS!

Progress has been slow, but good. Here you can see my new aluminum radiator for a 1987 jeep cherokee and my frame I built to hold the radiator and fans. The first picture is looking straight at the bottom of the radiator. The second picture shows the radiator in the car. You can also see my filler tank about half way done. The third picture shows the engine sitting behind the car just waiting for the new flywheel bolts to come. It looks kind-of volkswagen-ish.:biggringreen: I was planning on making the exhaust system look like a performance VW header, but I think I have decided to run the pipes forward into a muffler of some kind and then run them back out the stock location for the exhaust tips.


[2 edits; Last edit by spikedbeetle at 03:05:37 Sat Aug 29 2009]

  
spikedbeetle
22:45:48 Sat
Sep 5 2009

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Re: Starting my 1.8l build PICS!

Here is the exhaust system almost done. I may make a single 2" style as well so I can swap them out when I want.




  
spikedbeetle
14:27:46 Sun
Sep 13 2009

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Re: Starting my 1.8l build PICS!

I am almost ready to start it up! I only have a few bolts, wires, and a fuel pump to hook up. A few hours this week should do it. My next update should be a video of this thing running again!




  
spikedbeetle
01:34:22 Mon
Sep 21 2009

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Re: Starting my 1.8l build PICS!

IT'S ALIVE!

Now I just have to figure out how to tune it correctly.


  
spikedbeetle
02:09:52 Thu
Sep 24 2009

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Re: Starting my 1.8l build PICS!

Here it is running on four cylinders instead of two. I also fixed the fuel delivery issue. Sounds much better. I let it idle in the driveway for about ten min. then took it around the neighborhood and let it idle some more in the driveway. It held steady at 195 degrees and my fan didn't even turn on.

[1 edits; Last edit by spikedbeetle at 18:11:03 Sat Sep 26 2009]

  
56_Oval
00:59:17 Mon
Oct 26 2009

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Re: Starting my 1.8l build PICS!

I love it - how did the radiator work out - is it cooling the motor enough

  
spikedbeetle
21:57:17 Sat
Oct 31 2009

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Re: Starting my 1.8l build PICS!

Thanks. The radiator is working out fine so far. I had it running and driving for 45 min or so and it didn't get over 190. I may build some duct work in the summer if it needs it; but for now it's working good.

Here is a short video I made. I will remake it for youtube after I get a few more parts. It is running a little rich here and the plugs are black, but you get the idea. I'll lean it out , get some more power and spin the tires some more...


[1 edits; Last edit by spikedbeetle at 21:58:46 Sat Oct 31 2009]

  
spikedbeetle
17:27:02 Sat
Apr 17 2010

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Re: Starting my 1.8l build PICS!

Well, I heard there could be corrosion caused by using an electric temp gauge. I swapped to a mechanical gauge with a 144 inch capillary tube. The temps with the new gauge read a little higher. My 195 degree fan comes on at 212. I have been driving it all over. Today's temps are in the 70's. I drove it over an hour to the drag strip so I could race it to see what it would do. The event was cancelled, so I turned around and drove home. About 2-1/2 hours on the freeway doing 60+ and the temps stayed at 215-220. Once off the freeway, the temps dropped to 210. My other gauge would have read 190.

A really big radiator in back works!
[1 edits; Last edit by spikedbeetle at 17:30:48 Sat Apr 17 2010]

  

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