I thought I'd share the project I'm working on. We're building a street legal Meyers Manx Manxter 2+2 S.S. Dune Buggy and we're using a donor WRX 2015 for the motor. It is mated to 2004 Impreza 5SP transmission with a reverse-cut ring & pinion from Subarugears.
Although Subaru EJ, Corvair, Ford Ecotech and even a few Porsche 914 motors have been used in these builds, we're only the 2nd to attempt using an FA20T in this buggy.
There are a few interference issues but we're working through them.
We started with a running 1971 Super Beetle and converted the front end to a Ball Joint for a Std Beetle. These buggies don't need to be shortened but we replaced the pans and sandblasted the whole frame. It was then painted with POR15.
We then sourced a wrecked WRX 2015 from Copart with 14,000 miles and imported it to Canada (for parts). We made sure the engine ran before we pulled it and we photo documented the whole disassembly. (Having access to the manuals really help). This car came with a CVT and it can't be reversed (and is too big to fit in the buggy) so we sourced a 2004 TY754 5SP from a friend. The input shaft bearing had seized so I replaced all the bearings, forks and synchros before installing the reverse-cut ring & pinion.
As I said earlier, there are some interference and challenges to deal with in this project. I got close by lifting the body 1" but the TGV and EGT were still hitting the back of the body so they had to go.
Next was cooling, since the motor is in the back and we opted to run 2 side pod radiators. The initial quote for custom race radiators came in at close to $1K/ea. I'm going to try to run RZR radiators. The ports are a little smaller but I'm hoping it won't be too much an issue. I'll report back later. Routing the radiator hoses will require some clever thinking. I'm hoping I can flip the pump output to point to the back of motor to help with routing the hose. The return on top of motor will need a 180° hose.
The intake will probably come straight up on the side of the valve cover. I'm not planning on running a shield but the whole area is exposed so getting clean/cold air should not be an issue. K&N makes a pretty simple intake that I'm hoping I can run right off the turbo inlet.
I'll be running the intercooled in the rear wing and the charge Pipe will need to come straight up. Looking at the different products, it looks like PRL's 2 piece may be the best option. I would only run the bottom piece and add a hose to connect it to the intercooloer. The output into the intake will need a 180° or 135° hose to clear the back of the buggy.
The exhaust also needs to make a 180° turn to exit the back. I've purchased the Killer-B 3" J-Pipe and plan to fab an exhaust out of 3" stainless exhaust tubing to mate up to a Greddy muffler. It may be a little loud, we'll see.
The last piece is going to be wiring... I've been studying the wiring diagrams for the past few months and getting familiar with where everything needs to go. The immobilizer is going to be challenging but I'm hopeful.
Here are some pictures of the project.
Donor Super Beetle
Beetle head end conversion
Some wiring required...