So I am a proud owner of a 1977 vw beetle. It took me two years now and the car is finally fully restored with not a speck of rust on it. It has a rebuild motor with a few goodies in it,but the power is just not there. I have always loved the rotary motor and how different it is from the norm. So basicly my question is what is the best way to put a rotary motor in my beetle? I have read tons of forums and stuff on this topic and over all it does not seem too bad. A friend of mine has a very nice s5 n/a motor he will give me for next to nothing and it makes about 215hp so that would definitely step up the game a bit. My main concern is installing the radiator. Since the car was just redone it has a nice coat of fresh paint on it. So is there anyway I would be able to place a radiator in the car with out having to repaint part of the car. From what I have seen most people put it in the spare tire well and cut some luvers in the front apron of the car. Is there anywhere else i could possible put the rad and if not what is the best way to install it with out cutting up my car. Any advice is appreciated!!! And sorry for the long explanation.

 

Let me take you under my wing,
I am working on this project and have seen different setup's. I am also trying to minimize any destruction to my 64' bug. I am assuming you don't have to worry about smog, so this engine should not be an issue there. The first question is what is your budget? Second question is how much do you want to make this work??? I want to place the rad in the engine compartment, but that is abit optimistic. I believe that a good aluminum rad with adequate air flow should be good for a rotary pushing between 180-200 hp, but we'll see soon. I'm trying to round up all ROTARY TO VW convertions , and at the same time I'm trying to pull off the highest constraints under the lowest budget. So keep in touch and hit me back up with your plans and questions...

 

Alright man that definitely sounds awesome to me. Since I am getting the engine pretty cheap from a friend i figure my budget to be around 1500-2000 for everything. I think that seems pretty reasonable. I really would love for this setup to work. It would be such a thrill to have the power and sound of the rotary in my bug. Plus it is just an awesome feeling to have something so different from anyone else. How far are you into your project?

 

Cool!

I am in the process of customizing an exhaust, maybe intake too. Still trying to figure out where to place the radiator. I'm going to try running a rad under the trans just to see how that works out. Gotta make the exhaust first before I can make any more move's. I've done a run with a bypass hose on the cooling system and had just a header, and all I can say is WOW!!! I have a long way to go still, the hardest part is the budget I'm on. Can't afford to make many mistakes...Well I'll keep you updated...

 

Alright awesome man.. Im very excited to see how it turns out for you. As for me right now im just drawling up some designs on paper to decide what route I am going to take.

 

I'll try to give a little information to help as much as possible on the converseion. You may have seen my bug thread already and how far that is. First thing, it will cost a lot more than any expected budget so be prepared to spend a little extra if needed. Second, my giant v8 rad is in the spare tire well and I have to vent the hood as temps of 200 on my 13b-re tt are common after 10 min of cruising... There was another bug thread a while back (look at older posts) and the rad was mounted horizontal above the trans under the rear window compartment under the car. If that made sense. I have also seen rads mounted as wings, a smaller one could be used as airflow is great.

As for the conversion. Pick an engine, turbo is a tight fit as you can see on my thread. Carbureted is clean but sometimes the parts to build the setup are as much as efi setups. Look up kennedy adaptors and they have an adapter per engine you pick.

I have around 6 feet of exhaust warpped around my engine about the same length of a normal car exhaust. I have seen short exhausts from header to the back of the bug to be extremely loud. My exhaust setup is as quiet as a normal car with 2 mufflers. Keep cost and fab skills in mind.

Looking at costs... You have a bug with a built engine and tranny. Sel lthe engine off for say 1500 ish. Buy the convo kit from kennedy for 500. Buy an engine for around 1000 considering a rebuild for another 600 ish if needed. Big dollars now... Run the stock ecu on an efi motor (if not a jdm cosmo like my bug has :p) run carb, dist, manifold etc for around 1000 all done. Or go standalone efi for around 1000 to 15000 depending on the setup. Running stock efi motor its around 2000 with stock efi and rebuild. Selling your engine will bring your cost to 500. Or go carbed rebuilt version for around 3000 minues the engine is 1500. Either way you could do it.

Just remember the rad, intercooler, pipes, msd box, welding materials, paint etc into your costs. I would say 3000 could do it. Selling your engine can help reach your budget.

Hope any of this helps. Let me know if you have questions. I know just about all the setups for racing and street use after spending years calling sources... hahaha

 

This project can be had with a low budget, it all depends on what your aim is...

I am currently going to run my setup with what I have available and then sub out parts as I recieve them. My current budget is at only $800 so far and I have everything I need to make this a daily driver now!!! I just need to fabricate a few things. Luckily I work where there is a TIG welder that I have access to. I'm just going to run the Racing beat intake to HOLLEY that I have (using a motorcraft 2100 carb 1.21). I'm going to make my own alternator relocation bracket. I'm playing with the exhaust system right now, trying to see what length will get me the best over all power increase throught the entire power band. Then lastly and most difficult the radiator, is going to be an original FC rad just bolted to a frame above the engine. I'm hoping it will recieve sufficient air...

As I said I will replace things as they become available. My main goal is to have the deck lid closed so, I might run an electric water pump later, I want to make a custom intake that will be more flush with the engine top, and to figure out the best place for the rad...

And for even further in the future, turbo, EFI, maybe even A.C. but one thing at a time...

 

Alright so im going in a totally different direction then I originally anticipated. My friend has a late model super beetle ( Im not sure the year ) that is actually in decent shape. And I will be able to pick it up for next to nothing. So I am planning on picking the car up later this week or early next week. I want this to be a cheap swap so as far as looks I honestly dont care at this point. As long as the car is structurally good then im good with it. My friend with the N/A motor is getting is car turbo2 swapped as we speak and will get the car back in a month or so. So I have some time to kill before I get the motor. The only major problem I am having right now is that I am not sure what trans to use. Should I buy racing bug trans, Porsche trans, or a bus trans. PLEASE HELP!!!

 

I think you said you wanted this to be a cheap swap. Porsche 5 speed or a beefed bug trans will cost alot of $. Bus trans will work but you need to modify mounts. Also the bus trans are stronger but geared super low. You will go through the gears too quickly and have no highway cruise. Stock bug trans are pretty stout believe it or not with somewhat sane driving. Unless you plan to drop the clutch at 7000 rpm every day you should be fine with the trans that is in the car. What I learned from swapping a rotor into my bug on low budget is: keep it simple. I tried to modify everything all at once and I am finally finishing it now after 3 years. If you want to get on the road sooner than later, you minimize the modification and fabrication if you can. Good luck with the swap.

I'll be happy to help with whatever I can

 

is there anything I can do to the stock bug trans to make it a little strong such as weld stuff or anything like that. Something cheap I can do while the whole thing is apart.

 

My 2c,i've heard that ur best bet is a 68 vw trans known as a freeway flier.its said to have longer gears for fwy driving.still cheap if u can find one used.

 

On the vw trans there are some bolt on parts that generally help strengthen it. Freeway flyers are an option. Alot of vw parts places sell the freeway flyer trans for about 400 with a core exchange. So that isn't bad but if you want them beefed up then you will spend some more.

 

Alright your back,

A VW stock trans should handle about 200 hp (from what I heard from a lot of people that used to max these bugs out. I used to work at a place where we sold everything for VW's and there were a lot of people coming in with turbo'd this and oversized that.)

Like it's been said don't drop the clutch. My only worry is the 3rd and 4th gears. I hear that welding them (since there only pressed in ) is one mod that can be done to ensure you dont spin in those gears. But like I said don't drop the clutch and you should be fine.

There are some trans that are availible with welded 3rd n 4ths and optional gearing ( I.E. 3.88 rack n pin which is the freeway flier, and all sorts of different range shift gearing.) I havn't found anything that was under $750 with core around here (CA) so If you can that would be sweet...you could also have the work done your self, the rack n pin are only around $200 and you could just weld the gears, but that comes with a whole other set of problems. If you don't do it right it will pop out of gear...I might go this route, mostly beacause I know people that have done it and it's way cheaper than any other option for me...

The next bet in my opinion, it the rhino case trans. It's a stock replacement, the only difference is it can handle 400 hp+++ and you can drop the clutch at 9000 RPM (may be a little exaggerative ). If you have $3000 it should be no problem...

Then, there is the porche trans. Good luck locating one and hoping it's cheap, last one I found was used and the guy still wanted 3 grand... Damn good trans if you can get it. Imagine that, 5 speed cruising gear, power handling of 400 hp, and it's a porche trans!!!
On the down side you got to fab the install ( cut out the shift area, mounts, axle shafts, ect..) and don't forget the adapter plate to the engine...It has been done just not cheap.

And, the bus trans. In my opinion not practical, hard to make work and bad gear ratio, it was for a big *** heavy bus and 50hp engine. Need I say more...

What is really important is your intention. Do you intend on making this a racer of some sort, daily driver, emissions an issue, increasing HP later...and so on. Also does your intention match your budget??? Mine doesn't but I know how I will get by for now.

Like it's been said keep it simple and you can be running in no time, with the stock trans and a stock engine (rotary should be about 150-200 hp depending on setup) you can have an awsome bug...

As for me, Im almost done with my stainless exhaust system. I'm going to run the rad just on top of the engine to get me by for testing. Should have her running within the month but well see...

 

+1 to what 13b said. my freeway flyer ranny is awesome for the rotary. As long as you don't dump the clutch everyday at 8k you shouldnt kill it daily driving it. I can hit free way speed in 2nd gear and cruise at 70 mph at 3k in 3rd gear all day long. 4th gear isn't needed for me and almost sounds like it wants to be luggish if not going 80 plus :p I just paid the local bug shop to build me a freeway flyer for my standard bug and it was 650 fresh and built for my specific car/needs. Just my 2 cents