Braveheart Build -R2.8

[Napalm00]

It was originally blue, PO painted it white. Country it originally sold in - Scotland.
Wife came up with the name.
Now I need some tartan for the seat insert reupholstery

Look for fabric for a euro model vw rabbit or late model us gti . Would look.great

 

[MountainD]

Porsche had some factory tartan too, worth looking at. Try Elite Auto Fabrics-- https://m.facebook.com/Elite-Auto-Fabrics-307392529642135/

 

[Ephry73]

I decided to finally begin my build thread. I wanted to wait until My Cummins R2.8 arrived….but still waiting.
My wife named it BraveHeart (her favorite movie) because the 90 first sold in Scotland, was originally Blue, now repainted White.
I purchased my ‘88 Ninety, RHD in late February. It had 171K miles on it, but body was IG good condition, and the previous owner had invested in coils, shocks, tires and interior refinish.
Knowing the 19J had lots of miles on it, I had figured on a 200/300TDI swap - that quickly turned into placing my order with QuickDraw on March 12th.
There were a “few” things that needed to be addressed (other than the engine), so I set out learning and ordering parts.
Clutch - previous owner had noted the ‘weeping clutch’ - a new master cylinder and bleeding - now I can shift gears! I noticed the brake fluid reservoir had the appearance of broken tempered glass, I figured I would replace that prior to it giving out completely.

Doors - passenger only opened from inside, driver only opened from outside, latching was a problem and neither locked. I connected a few linkages, replaced a few clips and latch - work like champs now.

Lighting - I quickly learned about Lucas - prince of darkness, as well as fixing incorrect connections and bad grounds. After troubleshooting, I decided to upgrade to all LED - I can see at night now!

Steering - lots of play!!! I began by replacing (probably original) bushes - this helped but while under the 90, I noticed torn boots on tie rods. I figured these were likely just as old and replaced all tie rods and linkages, including steering drop arm. All this helped, but still had play so dig into the swivel balls - full bearing and seal overhaul. It’s amazing how much more relaxing it is to drive when your vehicle maintains its lane.

Engine - still waiting on the r2.8, I figured I should keep the 19j running. After my turbo was spewing “oil”, I stumbled on some articles about boost diaphragm - turns out it was diesel as the diaphragm had a hole in it - explained the pressurized fuel tank at full up and (some) smoke issues. Engine now running noticeably better, went into limp mode…fine idling, didn’t like any acceleration- turns out the intake hose had collapsed, so I replaced that

I will add to this with some of the other items I have been working on, but will leave you with the most recent photo - r230 in 1.2, with Ashcroft ATB and HD goodies, in blue.

Still love the badge. Great build

 

[dkemm]

Engine arrived mid October
Took longer to get across the country than to get half way across the city.
Add the Ashcroft HD R380 and 1.2 Lt230 (in BraveHeart Blue).
Thanks for the suggestions for tartan upholstery…gotta focus on engine for now…

 

[dkemm]

The fun part -fitting!
I had to split the R380/lt230 as the original hoist didn’t like the weight.
Turns out I was shipped the wrong transmission- got a stumpy, so I had to do a little trimming of my passenger footwell.

 

[Napalm00]

I'm 99% sure the the difference between a standard TDI r380 and a stumpy r380 is just the bell housing.

You have a TDI r380 with a QuickDraw adapter housing that's really neither but the length is the same as a stumpy.

 

[dkemm]

I'm 99% sure the the difference between a standard TDI r380 and a stumpy r380 is just the bell housing.

You have a TDI r380 with a QuickDraw adapter housing that's really neither but the length is the same as a stumpy.

I had/have the lt77 (1988 D90 RHD), so I chose non-stumpy r380 - based on research of others.
I ordered the QuickDraw (Ashcroft) HD R380....but received the stumpy R380 & bell housing.
So, with the shorter bell housing, I had to clearance for the R2.8 fuel pump and starter. It wasnt major, but took a little sheet metal work.

 

[Napalm00]

So the issue here isnt the transmission, it's that your quick draw bell housing is the short version?

Stumpy r380 and a standard r380 next to each other without a bell housing are exactly the same, that's what I'm trying to say.

 

[dkemm]

So the issue here isnt the transmission, it's that your quick draw bell housing is the short version?

Stumpy r380 and a standard r380 next to each other without a bell housing are exactly the same, that's what I'm trying to say.

now I get it. Thank you for the clarification. But, to support the longer bell housing, transmission would also need the longer shaft correct?

 

[abraded]

Yup regular TDI R380 has a longer input shaft than the stumpy.

You just went with an unusual combo of r2.8, transmission and positioning. Seems like the intention of the quickdraw bellhousing options are to either use the stumpy with usual 300tdi transfer case position (need later r380 tunnel, floors, seatbox tunnel adapter) or use the long bellhousing with 200tdi/earlier 4cylinder transfer case position (can keep earlier tunnel, floor panels, etc). I guess by cutting the LHS footwell you're making it work but makes me wonder if you're gonna have other packaging issues to solve.

 

[dkemm]

Yup regular TDI R380 has a longer input shaft than the stumpy.

You just went with an unusual combo of r2.8, transmission and positioning. Seems like the intention of the quickdraw bellhousing options are to either use the stumpy with usual 300tdi transfer case position (need later r380 tunnel, floors, seatbox tunnel adapter) or use the long bellhousing with 200tdi/earlier 4cylinder transfer case position (can keep earlier tunnel, floor panels, etc). I guess by cutting the LHS footwell you're making it work but makes me wonder if you're gonna have other packaging issues to solve.

yup, I didnt order the stumpy from QuickDraw...but that is what they shipped. Didnt realize or consider validating until it was in. LH footwell was only mods - build coming along fine...pics are about 2 weeks behind.

 

[Napalm00]

Ok we are all straight and yea I forgot that the full length r380 TDI had a longer input shaft.