Harold - the T25 van (1.8T content)

**GeorgeMK1** · 31-08-2017, 09:03 AM

Was too lazy to do any work yesterday so did a bit of brainstorming. I think I found the best possible engine bracing solution.
I've searched all other ways people have done theirs.
Some are very simple, and others and engineering marvels haha.

I have found that If I move the moustache further back just past the engine, I can raise it and not have to cut it in half due to the engine hanging so low. Then I can add 2 more supports and bolt them to the front on the chassis legs. This is by far the best method for my application and probably overkill, but will be a piece of mind for me.
A very quick dodgy sketch to get an idea.

**GeorgeMK1** · 09-09-2017, 08:51 AM

Its been raining very heavily for the past week so havn't been able to get as much done as I like, however following the diagram above I started to make the bits for the engine brace.
The O.G engine brace needed to be spaced 1" down, and 3" back. The good thing about moving 3" back is that it is enough to clear the engine, and yet still use atleast one of the original mounting holes.

This is the initial spacer I made for it.

But while at work I thought of a better method, where I can re-use both of the old mounting holes to make it stronger. So re did the spcacer again.

Here it is in action.

You can get the idea from this picture.

At the moment this is more than enough clearance, but I'm afraid that once the engine settles correctly after a few weeks, that it will hit. So there's two things I can do, 1) raise the engine another 5-6mm, or 2) leave it and just ad spacers under the engine mounts are a few weeks.

Fitted the passenger side mount on again. This needed some touch ups in order o fit the AUDI rubber mount.

Due to heavy rain I couldn't continue with anything under the car these past few days, so luckily I had the template of the front support plates I needed to make. Working with cardboard is soo good

Finished product and installed for test fitting/some final trimmings needed.

Finally caught my break last night after work as it stopped raining. However everything was wet, messy and freezing, this is what I had to work with

Definitely not fun, but if you want something done no excuses can be made haha

Lots of measuring and trimming to get these support mounts perfect.

.....and here we are, the home run. This is what it will look like. Once these are welded in place, I can do the final plates to actually support the rubber mounts. Its so close to being finished now!!
I borrowed a buddies arc welder, but i hate arc, so really hoping the repairer gets my mig fixed soon. Either way, this Sunday the engine brace will be done and finished. Then we can move onto other things

Cheers for reading

**ericcs** · 09-09-2017, 09:52 AM

looking good George, how much ground clearance will you lose with the lower sump?

**GeorgeMK1** · 10-09-2017, 06:20 PM

Originally Posted by ericcs

looking good George, how much ground clearance will you lose with the lower sump?

Hey Eric, not too sure to be honest mate. I havn't measured yet but I know if will be a big loss. I'm guessing around 6" of loss.
It's not all bad though, this will be rectified with 15" rims and larger diameter all terrain tyres. Also to add in the mix I will be putting in lift springs, so all up it should raise it quite high.
I've read the only 4-5 build threads on these with 1.8t, and no one has had any major issues.

Perhaps a bash plate might be made up to help

**ericcs** · 10-09-2017, 09:22 PM

i guess with that engine, it will spin up any size rim/tyre you choose.
my son had a t3 with a 1.8 subaru leonie engine, man, was that slow!

**GeorgeMK1** · 11-09-2017, 12:16 PM

Originally Posted by ericcs

i guess with that engine, it will spin up any size rim/tyre you choose.
my son had a t3 with a 1.8 subaru leonie engine, man, was that slow!

Im sure it would have been gutless, the 1.9 wbx was bad enough haha!

Yesterday was an epic day. Weather was top notch and I was able to put in a solid 6 hours, resulting in me finishing the engine brace.
Was able to borrow my uncles mig, wowee was this thing powerful with plenty of penetration. However lifting it out of the car was a mission in itself haha.

Started by tack welding both arms in place.

Pulled it back out and welding everything solid. Now that this step was done, I could start getting the idea of how it will all piece in together.

Then back in it went to start measuring the mounting plates for the AUDI mounts to sit on. Once again cardboard was a big time saver. Cut the plates out and tacked them in place. I ended up raising the engine about 8mm before making the final tack welds, so that when it settles with time - it should all be at the correct height.

Top view of how much room is left over.

Once that was done, back out it came again - for like the tenth time

by now I was pooped lol.
I went ahead and started making support walls on each side of the mount just to be able to withstand the weight of the motor. This took some time to cut out, I used 6mm steel and then welded it all together.

Finished product

Once I was finished, I thought for a piece of mind I should add two 6mm plate gussets to each corner where the legs meet the moustache bar.

.. and what a day that was. Now I have to battle the brace again - but with painting. Will be going over it with a wire brush, and a flappy disc to get it looking pretty and ready for etch primer and subrframe black paint within the next few days.

Hoping to also have the engine back out by tomorrow to start on wiring and also intercooler/exhaust setups.

Thanks for reading

**Sunny43.5** · 11-09-2017, 02:02 PM

Do you think that the frame will flex a bit under the weight and torque ?

**GeorgeMK1** · 11-09-2017, 02:48 PM

Originally Posted by Sunny43.5

Do you think that the frame will flex a bit under the weight and torque ?

Hey Sunny. I highly doubt it mate, unless I am running over 280kw, I think the frame will cope more than enough.
I've been researching this for months and most guys in the U.S use only the moustache bar and nothing else to support the entire engine weight on its own.

So I think I've over engineered mine by a bit.

Here are some that I found online to compare theirs.
This fella only used the original moustache bar.

Here's another that has only used the moustache bar

This is a off-the-shelf kit you can buy, but costs too much to import from the U.S and it doesn't look to be overly engineered either.

I have actually based my design on this blokes own design. He is running a 1.8 TDI engine at 50deg. He made his custom mount using the original moustache bar, and I basically made my design from his.

So hopefully no problems come from this, but it might be worth my time to maybe add a few more gussets etc for added piece of mind? Hmm