{"id":1449,"date":"2025-08-09T23:06:19","date_gmt":"2025-08-09T23:06:19","guid":{"rendered":"https:\/\/robonza.com\/beetle\/?p=1449"},"modified":"2025-08-10T00:56:33","modified_gmt":"2025-08-10T00:56:33","slug":"baby-come-back","status":"publish","type":"post","link":"https:\/\/robonza.com\/beetle\/index.php\/2025\/08\/09\/baby-come-back\/","title":{"rendered":"Baby Come Back"},"content":{"rendered":"\n<p class=\"wp-block-paragraph\">The finish line is near! Actually I was supposed to have the baja yesterday, but as they were loading it the alternator light came on and would not go off. So, with that we delayed it to add a new alternator. Which is kind of funny, because that was the <a href=\"https:\/\/robonza.com\/beetle\/index.php\/2023\/11\/15\/replacing-the-beetle-alternator\/\">problem I had when i first bought this 2 years ago.<\/a> When I replaced it 2 years ago I put in a Bosch 55 amp alternator, but this time I went for a 90 amp, because it is not like the Bosch lasted a long time. <\/p>\n\n\n\n<p class=\"wp-block-paragraph\">But in the meantime here is an update. <\/p>\n\n\n\n<figure class=\"wp-block-embed is-type-video is-provider-youtube wp-block-embed-youtube wp-embed-aspect-16-9 wp-has-aspect-ratio\"><div class=\"wp-block-embed__wrapper\">\n<iframe loading=\"lazy\" title=\"Baja Beetle After Engine Break In\" width=\"640\" height=\"360\" src=\"https:\/\/www.youtube.com\/embed\/9FLnUKYZCrM?feature=oembed\" frameborder=\"0\" allow=\"accelerometer; autoplay; clipboard-write; encrypted-media; gyroscope; picture-in-picture; web-share\" referrerpolicy=\"strict-origin-when-cross-origin\" allowfullscreen><\/iframe>\n<\/div><\/figure>\n\n\n\n<p class=\"wp-block-paragraph\">What has been done, so god damn much! <\/p>\n\n\n\n<p class=\"wp-block-paragraph\"><strong>Rear Axle and Disc Brake Assembly<br><\/strong>-Installed stock rear axles with modified(chamfered corners) fulcrum plates.<br>-Installed solid boots on axle tubes, and installed axle tubes with with re-enforcement plates.<br>-Painted rotors and caliper bracket from the Empi disc brake kit.<br>-Installed new axle seals into the bearing caps.<br>-Installed new OEM axle bearing and caps.<br>-Installed rear disc brake kit with new lines and hoses to the calipers.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\"><strong>Case Machine and Cleaning.<br><\/strong>-Drilled + taped for full flow oil system.<br>-Drilled lifter oil galley for &#8220;hoover mod&#8221; Connected rear lifters to main oil galley.<br>-Modified lifters for &#8220;Hoover&#8221; oiling ports.<br>-Drilled + taped oil suction tube access to wedge into the case. &#8211; Was loose upon tear down inspection.<br>-Drilled + taped main oil galley access to clean with a wire brush.<br>-Stripped paint and acid etch cleaned the case. Ready to assemble.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">-Fit and welded transaxle mid-mounting plate between the frame horns. Painted black.<br>-Installed transaxle with solid mounts and hold-down strap.<br>-Removed hard start relay, not needed.<br>-Installed RossWulf derlin shift rod bushing and empi H.D. shift coupler.<br>-Bleed brakes. Good.<br>-Installed emergency brake cables + modified ends.<br>-Modified chrome emergency brake handle to stop in the o\ufb00 position and not rest against the chassis.<br>-Installed front tube nerf bumper and KC lights, routed + zip tied wires.<br>-Installed caster shims behind the beam to correct front suspension angle and give a little lift.<br>-Installed Bilstien shocks front and rear.<br>-Re-splined torsion bars to lift and level the rear suspension.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">Engine Assembly 69.5mm x 90.5mm 1788cc<br>-Fit and welded windage tray in the bottom of the case to control oil splash.<br>-Installed oil control pistons and chamfered to correct seat angle.<br>-Fit Engle 100 camshaft to case and checked bearing clearances<br>-Installed distributor and timing gears.<br>-Assembled 69.5mm crankshaft and empi super stock rods.<br>-Glued and bolted the case half together and torqued to spec.<br>-Measured + adjusted crank end play to .004&#8243;, Installed lightened flywheel and main seal.<br>-Installed oil cooler with new seals, fuel pump block-o\ufb00, alternator stand, and full-flow oil pump.<br>-Fit 90.5mm piston rings to cylinders, set ring gaps to .015&#8243;<br>-Measured deck height and head cc to determine compression ratio at 8.8 : 1 with .047&#8243; deck height and 50cc combustion chambers.<br>-Assembled Mahle forged pistons, cylinders, and Empi class 11 heads.<br>-Installed solid shaft oil ported rocker shafts + arms with swivel &#8220;elephant&#8221; foot adjusters. Checked + adjusted geometry.<br>-Aluminum pushrods *adjust valves to .006&#8243;<br>-Cleaned and installed chrome cooling tin, intake, and exhaust with new gaskets and boots.<br>-Ran break-in on run stand. Went great, no leaks, sounds good.<br>-Drained break-in oil while hot to flush out contaminants.<br>-Let cool and checked valve adjustment. Good, no excessive play.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\"><strong>Engine and Accessory Installation<br><\/strong>-Installed engine breather canister\/filter on the firewall. Drilled Holes and mounted with nylock hardware.<br>-Installed oil filter housing mount on the driver&#8217;s side of the engine bay and re-located the coil further back. Drilled hose and mounted with nylock hardware.<br>-Measured, cut, and assembled oil lines to connect to the oil pump to the oil filter.<br>-8an fittings.<br>-Modified 40 Empi (Weber idf) carburetor for single carb use. drilled 2mm hole in throttle plates, zero by-<br>pass accelerator inlet valve, 28mm venturi, 60 accelerator jet, 70 idle jets, 115 main jets, f7 emulsion tubes, 160 air jets, set float to 13mm.<br>-Installed float bowl vent restrictor (keeps fuel in the carb on rough driving).<br>-Welded a barrel nut attachment to the arm for the throttle cable attachment.<br>-Installed accessory gauge radio mounting panel along with Smiths gauges -pres\/temp\/rpm.<br>-Pulled gauge wire harness though the chassis and routed along-side main harness.<br>-Installed engine and rear bumper tube cage.<br>-Routed wires, new fuel hose, and throttle cable, zip tied any\/everything.<br>-Wired the gauges to sensors, lights, and ignition power\/ground.<br>-Bad electric fuel pump replaced with new Carter rotary style pump.<br>-Test drove car and adjusted carburetor jetting with an exhaust gas analyzer. Jetting is as listed above<\/p>\n\n\n\n<p class=\"wp-block-paragraph\"><strong>Quaife LSD <\/strong><\/p>\n\n\n\n<p class=\"wp-block-paragraph\">&#8211; Modify Quaife differential to use 6 bolt 4.37 ring and pinion.<br>-Measured and drilled 4 holes in hardened steel flange to use early\/low ratio r&amp;p.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\"><strong>Transaxle rebuild and assembly with Quaife limited slip differential.<br><\/strong>-Replace 1st and 2nd gears.<br>-Replaced 1\/2 and 3\/4 sliders + shift forks with late\/wide style.<br>-Preloaded diff in housing .003&#8243; with tight mesh to pinion. Good contact pattern.<br>-Installed Weddle racing reverse gear.<\/p>\n\n\n\n<figure class=\"wp-block-image size-large\"><img loading=\"lazy\" decoding=\"async\" width=\"768\" height=\"1024\" src=\"https:\/\/robonza.com\/beetle\/wp-content\/uploads\/2025\/08\/IMG_0327-768x1024.jpeg\" alt=\"\" class=\"wp-image-1451\" srcset=\"https:\/\/robonza.com\/beetle\/wp-content\/uploads\/2025\/08\/IMG_0327-768x1024.jpeg 768w, https:\/\/robonza.com\/beetle\/wp-content\/uploads\/2025\/08\/IMG_0327-225x300.jpeg 225w, https:\/\/robonza.com\/beetle\/wp-content\/uploads\/2025\/08\/IMG_0327-1152x1536.jpeg 1152w, https:\/\/robonza.com\/beetle\/wp-content\/uploads\/2025\/08\/IMG_0327-1536x2048.jpeg 1536w, https:\/\/robonza.com\/beetle\/wp-content\/uploads\/2025\/08\/IMG_0327-scaled.jpeg 1920w\" sizes=\"auto, (max-width: 768px) 100vw, 768px\" \/><\/figure>\n\n\n\n<figure class=\"wp-block-image size-large\"><img loading=\"lazy\" decoding=\"async\" width=\"768\" height=\"1024\" src=\"https:\/\/robonza.com\/beetle\/wp-content\/uploads\/2025\/08\/IMG_0328-768x1024.jpeg\" alt=\"\" class=\"wp-image-1452\" srcset=\"https:\/\/robonza.com\/beetle\/wp-content\/uploads\/2025\/08\/IMG_0328-768x1024.jpeg 768w, https:\/\/robonza.com\/beetle\/wp-content\/uploads\/2025\/08\/IMG_0328-225x300.jpeg 225w, https:\/\/robonza.com\/beetle\/wp-content\/uploads\/2025\/08\/IMG_0328-1152x1536.jpeg 1152w, https:\/\/robonza.com\/beetle\/wp-content\/uploads\/2025\/08\/IMG_0328-1536x2048.jpeg 1536w, https:\/\/robonza.com\/beetle\/wp-content\/uploads\/2025\/08\/IMG_0328-scaled.jpeg 1920w\" sizes=\"auto, (max-width: 768px) 100vw, 768px\" \/><\/figure>\n\n\n\n<figure class=\"wp-block-image size-large\"><img loading=\"lazy\" decoding=\"async\" width=\"768\" height=\"1024\" src=\"https:\/\/robonza.com\/beetle\/wp-content\/uploads\/2025\/08\/IMG_0329-768x1024.jpeg\" alt=\"\" class=\"wp-image-1453\" srcset=\"https:\/\/robonza.com\/beetle\/wp-content\/uploads\/2025\/08\/IMG_0329-768x1024.jpeg 768w, https:\/\/robonza.com\/beetle\/wp-content\/uploads\/2025\/08\/IMG_0329-225x300.jpeg 225w, https:\/\/robonza.com\/beetle\/wp-content\/uploads\/2025\/08\/IMG_0329-1152x1536.jpeg 1152w, https:\/\/robonza.com\/beetle\/wp-content\/uploads\/2025\/08\/IMG_0329-1536x2048.jpeg 1536w, https:\/\/robonza.com\/beetle\/wp-content\/uploads\/2025\/08\/IMG_0329-scaled.jpeg 1920w\" sizes=\"auto, (max-width: 768px) 100vw, 768px\" \/><\/figure>\n\n\n\n\n\n<p class=\"wp-block-paragraph\">Also, because this song is amazing: <\/p>\n\n\n\n<figure class=\"wp-block-embed is-type-video is-provider-youtube wp-block-embed-youtube wp-embed-aspect-4-3 wp-has-aspect-ratio\"><div class=\"wp-block-embed__wrapper\">\n<iframe loading=\"lazy\" title=\"Player - Baby Come Back\" width=\"640\" height=\"480\" src=\"https:\/\/www.youtube.com\/embed\/NmEyGiaqm7k?feature=oembed\" frameborder=\"0\" allow=\"accelerometer; autoplay; clipboard-write; encrypted-media; gyroscope; picture-in-picture; web-share\" referrerpolicy=\"strict-origin-when-cross-origin\" allowfullscreen><\/iframe>\n<\/div><\/figure>\n","protected":false},"excerpt":{"rendered":"<p>The finish line is near! Actually I was supposed to have the baja yesterday, but as they were loading it the alternator light came&#8230;<\/p>\n","protected":false},"author":1,"featured_media":1450,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"footnotes":""},"categories":[1],"tags":[],"class_list":["post-1449","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-uncategorized"],"_links":{"self":[{"href":"https:\/\/robonza.com\/beetle\/index.php\/wp-json\/wp\/v2\/posts\/1449","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/robonza.com\/beetle\/index.php\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/robonza.com\/beetle\/index.php\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/robonza.com\/beetle\/index.php\/wp-json\/wp\/v2\/users\/1"}],"replies":[{"embeddable":true,"href":"https:\/\/robonza.com\/beetle\/index.php\/wp-json\/wp\/v2\/comments?post=1449"}],"version-history":[{"count":2,"href":"https:\/\/robonza.com\/beetle\/index.php\/wp-json\/wp\/v2\/posts\/1449\/revisions"}],"predecessor-version":[{"id":1456,"href":"https:\/\/robonza.com\/beetle\/index.php\/wp-json\/wp\/v2\/posts\/1449\/revisions\/1456"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/robonza.com\/beetle\/index.php\/wp-json\/wp\/v2\/media\/1450"}],"wp:attachment":[{"href":"https:\/\/robonza.com\/beetle\/index.php\/wp-json\/wp\/v2\/media?parent=1449"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/robonza.com\/beetle\/index.php\/wp-json\/wp\/v2\/categories?post=1449"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/robonza.com\/beetle\/index.php\/wp-json\/wp\/v2\/tags?post=1449"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}