Custom Engine Parts from a Backyard Foundry

Building a car engine can be a labor of love. Making everything perfect in terms of both performance and appearance is part engineering and part artistry. Setting your creation apart from the crowd is important, and what better way to make it your own than by casting your own parts from old beer cans?

[kingkongslie] has been collecting parts for a dune buggy build, apparently using the classic VW Beetle platform as a starting point. The air-cooled engine of a Bug likes to breathe, so [kingkongslie] decided to sand-cast a custom crankcase breather from aluminum.

Casting solid parts is a neat trick but hardly new; we’ve covered the techniques for casting plastic, pewter, and even soap. The complexity of this project comes from the fact that the part needs to be hollow. [kingkongslie] managed this with a core made of play sand and sodium silicate from radiator stop-leak solution hardened with a shot of carbon dioxide. Sure, it looks like a Rice Krispie treat, but a core like that will stand up to the molten aluminum while becoming weak enough to easily remove later. The whole complex mold was assembled, beer cans melted in an impromptu charcoal and hair-dryer foundry, and after one false start, a shiny new custom part emerged from the sand.

We’ve got to hand it to [kingkongslie] – this was a nice piece of work that resulted in a great looking part. But what we love about this is not only all the cool casting techniques that were demonstrated but also the minimalist approach to everything. We can all do stuff like this, and we probably should.

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Volkswagen Beetle – The Most Hackable Car

If you build a better mousetrap, the world will beat a path to your door. Of course it helps if your mousetrap is reliable, simple, cheap, and easy to work on. In the car world, look no further than arguably the most successful, and most hackable, car in history: the Volkswagen Type 1, more commonly known as the Beetle. The ways in which this car was modified to suit the needs of a wide range of people over its 65-year-long production run proves that great design, ease of use, and simplicity are the keys to success, regardless of the project or product.

Built by Ferdinand Porsche in 1930’s Germany, the Beetle was designed to be a car for anyone and everyone. Its leader at the time wanted a true “people’s car” (i.e. “Volkswagen”) that was affordable for a German family, could reliably travel at sustained highway speeds on the new German autobahns, and easily be repaired by its owners. The car features an air-cooled engine for simplicity and cost savings: no radiator, water pump, or coolant, plus reduced overall complexity. The engine can be easily removed by disconnecting the fuel line, the throttle cable, and the four bolts that hold it to the transaxle. The entire body is held on to the chassis by eighteen bolts and is also easy to remove by today’s standards. There’s no air conditioning, no power steering, and a rudimentary heater of sorts for the passenger cabin that blows more hot air depending on how fast the engine is running. But possibly the best example of its simplicity is the fact that the windshield washer mechanism is pressurised with air from the over-inflated spare tire, eliminating the need to install another piece of equipment in the car.

It’s not too big of a leap to realize how easily hackable this car is. Even Volkswagen realized this and used the platform to build a number of other vehicles: the Type 2 (otherwise known as the bus, van, hippie van, Kombi, etc.) the eclectic Karmann Ghia, and the Types 3 and 4. Parts of the Type 1 were used to build the Volkswagen 181, commonly referred to as “the Thing”. Ferdinand Porsche also used design elements and other parts of the Type 1 to build the first Porsche, essentially making a souped-up Beetle. The rear-engine, rear-wheel drive layout of modern Porsches is a relic of this distant Beetle cousin. But the real magic is what people started doing to the Beetles in their backyards in the ’60s and 70s: turning them into buggies, off road machines, race cars, and hot rods that are still used today.

At some point around this time, a few people realized that the Beetle was uniquely suited to off-road racing. The type of suspension combined with the rear-engine, rear-wheel-drive layout meant that even without four-wheel drive, this car could excel in desert racing. There are still classes in this race for stock Beetles and modified Beetles called Baja Bugs.

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Introducing the Flux Buggy — A Serious Electric Dune Buggy Conversion

Believe it or not, the writers here at Hack a Day do their own projects too, we don’t just write about yours! I’ve just started a new project, and I want your advice! A few friends and I are converting a custom-made dune buggy — to electric.

The project will be chronicled over on Hackaday.io, with (hopefully) weekly updates on our progress. If you’ve been perusing Projects, you may have noticed my Electric Car conversion from a few years ago. First year of my engineering degree, my friend and I converted a 1993 Honda Del Sol to electric, using the guts of an electric forklift.

We got it going over 100km/h on used batteries our school donated to us. Unfortunately, there was a bit too much red tape and bureaucracy for us to get it on the road legally. That and we were poor university students who couldn’t afford new batteries, or the ridiculous amount insurance companies wanted to put it on the road. The project got scrapped after sitting in the backyard for a few years.

Fast forward to today, and we’ve both graduated and are working our “cushy” engineering jobs, and for the first time in our lives, we have some disposable income. We needed a new project to work on.

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