T4 Eurovan Coolant Bottle Bracket Adapter

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T4.5 Eurovan Coolant Bottle Bracket Adapter

We had to make a custom adapter for a T4.5 Eurovan Coolant Bottle Bracket Adapter the other day. We needed a new coolant reservoir for our customer’s 2001 Volkswagen Eurovan VR6 MV. The warehouse sent me the wrong reservoir (Ver C, and not a Ver E). (701 121 407 E). The Ver C is for 1999-2000 Eurovans with a 12v VR6 engine, however all the connections and hoses are the same. It’s just 180º off from the one we needed. Apparently the Ver E coolant reservoirs are no longer available (NLA) and virtually impossible to find. We searched Classic VW parts, eBay and other sites and came up with zero results. Ver C is still available, however it is also hard to find, but they are available special ordered new from Europe. If you need a Ver C reservoir, we can get one for you.

Instead of wasting time trying to find a new one, or installing a used part, we drafted a file in Fusion 360. Then we 3d printed this bracket. Printed with PA12-CF Polycarbonate Carbon Fiber (25%CF/75%Poly). The bracket is safe up to 220c / 428ºF. This will adapts the older C style bottles with the overflow return on the left / drivers side. These other tanks are readily available. Furthermore, this will fit so the left / drivers side electrical connection (coolant level sensor) fits the configuration for Eurovans with the Ver E bottles. Fits 2001+ T4.5 Eurovan / Transporter / Caravelle – 24v Engines, with the bottle that mounts to the core support. We also installed some brass inserts so we can just bolt it right in and the tank can be replaced it in the future, if need be.

VW Eurovan Functional Application

Version 2.0

We revised our design a little to make it both easier to print and use less material. It’s just as strong as Ver 1.0.

VW Eurovan Coolant Bracket

 

More Info

For more information on how to get your Volkswagen Eurovan Repaired, please call 425-254-0627. You can also email us by clicking here. Meister Werks European & Import is located one block south from The Renton Landing in Renton, WA, across the street from the former Boeing Store and on the westside of the Paccar / Kenworth plant.

Purchase

If you would like to purchase one of these. You can do so by clicking the link below. These are made to order, so the turn time on these is approx 3-5 days to ship + shipping time.

Click Here to go to the shop site.

 

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1984 Porsche 928 S Bumper Grill Restoration

This 1984 Porsche 928 S has been in the shop for some repairs, service, and minor restorations. It was a gray market car, imported to the USA and originally sold in Germany.  Some modifications had been performed at different shops previously that was not to our customer’s liking.  One of the items we repaired in house was rebuilding the transmission and repairing the broken gauge cluster. Another item was trying to find a new old stock OEM exhaust to replace the awful sounding aftermarket exhaust – which to our amazement, we did. Another item on our customer’s wish list was to source a original lower center, 928 S bumper grill.

Sourcing the Grill

We were able to source a complete unit, in decent shape, which was not inexpensive even in this poor condition. We looked over the product listing photos and knew a thorough restoration was going to be necessary. This was definitely something we knew we could tackle in house. These photos below show the condition when the grill arrived.

When we received the grill we noticed all the hardware was rusty, so that would need to be refurbished or replaced. Also, the plastic brackets that hold the aluminum grill inserts were painted. They were also on the brink of breaking and extremely flexible. Those would also need to be replaced. Even though the brackets are still somewhat available on some specialty websites, we had an idea on how to upgrade these while still retaining the OEM look. Since we have multiple 3d printers in house, this technology was first thing that came to mind.

Disassembly

First, we started by disassembling everything and bagging and inventorying all the hardware. We took the metal grill inserts to our in house powder coating department to get stripped, blasted and coated.

Drafting the CAD Files

While the grill inserts were in powder, we took the brackets and scanned the profile them on a flatbed scanner. Since flatbed scanners, scan to a 1:1 ratio, we knew the profile sizing and dimensions on screen would be 100% perfect. We took the scans into Adobe photoshop and manipulated the contrast to make it easier to see the profile. After that, we saved the file and imported it into Adobe Illustrator. This is where we created vector outlines of the center and outside brackets. After the profiles were established, we deleted the imported scanned image and exported the file to a CAD format. We imported that into Fusion 360, where we drew up our 3d model for printing.

While in Fusion 360, we added additional supports, removed all the recesses that the OEM bracket have and pocketed each of the 5mm screw holes. Below is the transition of the files, from start to finish.

Flatbed Scans 1:1 Ratio
2d Vector Profiles Drafted
Final CAD Drawings Rendered
CAD Drawings Top

After the Fusion 360 CAD drawings were complete, we exported these to a .STL file and sent them to the 3d Printer. Our AnyCubic Kobra Max is capable of printing 15.9″ x 15.9″ x 17.7″ Tall. We can print a wide variety of materials such as PLA, TPU, and for more industrial applications, carbon fiber nylon blend.

Once the parts came off the printer, we mocked up the grill inserts to the brackets. To our amazement, the brackets fit really well, directly off the printer. Immediately we noticed how much stronger these were compared to the OEM brackets. Furthermore, the reinforcements allowed for very little flex to the upper grill section. We performed some minor finish work and deburred the pieces. When the grill sections came out of powder coating, they would be ready to assemble.

Assembly

At this point in the project, the grill inserts were out of powder coating and ready to go with a fresh coat of Cardinal Powder Semi-Gloss Black T002-BK08. We now started assembling the grill. However, one thing that was not compensated for while designing the brackets was the thicker tolerances.  When we reinforced the brackets joints in programming, we made them thicker than the OEM measurements. Our hardware was a little too short. We sourced some metric black oxide socket head screws that were 3mm longer.

Polycarbonate Carbon Fiber Grill Supports – Porsche 928

While installing the bumper grill, we found out a interesting thing. The North America (NA) bumpers grill brackets are different than the European E-Code bumpers. The brackets have a slightly different mounting location due to the fact that they are slightly shorter. To sold this, we had to modify the lower mount to be able to accept the NA brackets. It wasn’t worth printing new parts as we just had to drill a hole in each lower bracket and trim off the bottom tab just a little.

This is how it looked after installing the grill:

Porsche 928 Grill Supports
Porsche 928 Functional Application

In conclusion, the assembly went perfect after sourcing those. Overall the project turned out really nice.  We believe our customer will be really happy with the final outcome. Stay tuned for our next post where we remove and install the rear Porsche 928S decals and repair the gauge cluster using 3d printing technology again.

For more information on how to get your Porsche back to OEM condition, please call 425-254-0627. You can also email us by clicking here. Meister Werks European & Import is located one block south from The Renton Landing in Renton, WA, across the street from the former Boeing Store and on the westside of the Paccar / Kenworth plant.

 

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1960 Porsche 356b Shifter Rebuild

1960 Porsche 356b Shifter Rebuild

Last week our tech Jonathan and I were able to repair Craig’s (Rennfilms), 1960 Porsche 356b shifter. When driving this beautiful Porsche, It was difficult to find gears and made very sloppy shifts. This was due to the fact that it was missing the main lower ball pivot. It also had some poorly fabricated sheet metal, installed from the previous owner, which was not helping the situation. We had talked to Craig about this concern the last couple times he was in for service and seat bracket fabrication. We decided now was the time to do this.

Starting the project

First, I found a photo off the internet of the exact part we needed. This is really all we had to go by. Since we only had the shifter itself. The other measurements I had were the spring size and the dimensions for opening of the lower stick. I brought the photo into Adobe Illustrator and resized the photo so the hole size slightly larger that the known lower stick size of 20mm. Based off of that, I extrapolated the degree in which the photo was taken. After that, I calculated the outer ball perimeter, ball height and overall height. 

Next, I opened up Fusion 360 to start drafting our CAD file. Using our notes from the internet JPG image dimensions, I was able to come up with this drawing.

The 3d Printer

Since we print replacement parts with high temp resin, we must calculate the shrink rate. This is typically between 1-3%. Using a little simple math, that number needed to be around 103%. For safe measure, we printed 100% through 104%. Furthermore, there was going to be some margin of error. It takes about and hour to print these, so we wanted every option when we started assembling the shifter.. The 104% part fit best, although the 103% would have worked, we wanted some tolerance.

After the part came out we post processed it in a wash / cure station. Washing it with 99% isopropyl alcohol for 10 minutes and curing it with high intensity UV light for 6 minutes. This will harden the resin and prevent it from failing in the future.

While I was drafting and printing the parts, Jonathan media blasted the shifter housing and put a light coat of satin epoxy paint on it. We would have powder coated this in house, but the customer was picking up the same day. Powder coating will add a few hours to the project. If we need to make any adjustments in the future, we will powder coat it. Disassembly is fairly simple so it shouldn’t take too much addition time.

Assembly

After post processing the parts, Jonathan and I took them to the bench to test the sizes and fitment. You can see from this photo that the fit was spot on at 104%.

Parts all layed out
BottomPorsche Speedster Parts
Top fitment
Porsche 356 Speedster Parts
Close up of the assembly
Jonathan installing the shift linkage dry

From here, we performed a dry fit before lubricating the mechanism. They dry fit felt night and day better, and that was without any grease. We removed the shifter for the last time, greased up all the components and reinstalled the shifter assembly. The feel was 100% OEM and each gear was defined, with no lateral movement while in gear. Reverse felt so much different than before, which might take a little getting use to for the customer. (In a good way)

In Conclusion

Overall we were very pleased with how this shifter turned out. The customer was very pleased with the results. Considering the short wait time to make the part and its functionality, It’s pretty amazing that we can replicate parts like this. 15 years ago, this was mythology.

Since we have six different 3D printers (SDA resin and FDM filament), we have the ability to print polyurethane and other synthetic components. With build plate dimensions from 4-1/2″ x 2-1/2″ x 6″ tall all the way up to 16″ x 16″ x 17″ Tall – The possibilities are almost endless.

Information / Schedule

For more information on how to get your classic European vehicle or Porsche repaired, please call 425-254-0627. You can also email us by clicking here. Meister Werks European & Import is located one block south from The Renton Landing in Renton, WA, across the street from the former Boeing Store and on the westside of the Paccar / Kenworth plant.

 

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Ayala – Audi A3 – J008257

Disassembly Begins
Saturated Hoses at Oil Cooler Cylinder Head Left
Valve Cover Oil Leaks at Cap
Spark Plug Hole Oil Leak
Rear Valve Cover Oil Leak
Lower Intercooler Hose
Intake Hose Satuated
Old PCV – Showing Blow Oil By (Green Gasket)
Ignition Coil Oil Saturated
Side Valve Cover Oil Leaks
Upper Side Valve Cover Oil Leaks
Valve Cover Oil Leaks
Camshaft Valve Cover Oil Leaks
HPFP Fuel Pump Oil Leak
HPFP internals
Cam Position Sensor
Repair Progress
Upper Timing Cover Seal Cracked
New PCV
Old Timing Cover
New Coil Packs
Assembled & Sealed Valve Cover
Oil filter crushed
Oil filter crushed
Oil filter crushed
Complete
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Porsche Squeak Brakes – Explained

Porsche Brake Pads Squeak – Explained

Squeaky Porsche brakes is a topic that comes up a lot here at Meister Werks. In some instances, days or weeks after the pads and rotors were replaced. There are many reasons that cause this. According to Porsche it’s not a bad thing. We fully understand where Porsche is coming from. Here is a very scientific TSB (Technical Service Bulletin) video on why your Porsche brakes may squeal…. sometimes.

At Meister Werks, we use high quality components when servicing your brakes. Sometimes even the highests quality parts will squeal from time to time. Here is a list of the reasons why you may be getting brake squeal.

Glazed Rotors

Porsche brakes are designed to be used. Since they are classified as performance brakes, they need to be used this way. If you are very light on the brake pedal, aka brake far before you should, this will leave a very minute amount of dust on the disc brake rotors. Furthermore, riding the brakes (having your foot on the brake pedal when you shouldn’t be breaking) will cause this to happen very rapidly. This unnecessary friction causes heat, coupled with brake pad dust, will cause it stick or bond tightly to the rotor. This is essentially making a sticky glossy surface causing the squeal. Think of a new sneaker on a freshly polished basketball court. Brake disc rotors must to be a slightly rough for brakes to perform optimally, without noise. To ‘deglaze’ the rotors, there are methods of braking to clean the disc from this coating. Later discussed in this article.

Corrosion on the Brakes

Do you experience squeaking or squealing first thing in the morning? Maybe while backing up or while driving for the for only a few minutes? One of the few reasons the brakes squeak is due to corrosion. Yes, hours, sometimes minutes after parking your Porsche, the raw steel rotors will start forming a very thin layer of iron oxide, aka rust. This is a chemical reaction between 2 elements. Iron, the material the disc brake rotors are made of, and the oxygen that is in the air. If rain or water is present, this will accelerate the corrosion process. Since water has 2 oxygen molecules, causing the reaction to take place more rapidly.  Furthermore, salt air or water will accelerate this process even faster, due to more of the dissolved ions. This means electrons can move faster. Since rusting is all about the movement of electrons, iron rusts more quickly with salt air or water than fresh water or air. Using your brakes 2-3 times will typically clear the discs from the corrosion or rust.

Cold Brakes

The same experience with squealing brakes, first thing in the morning, can also be due to cold brakes. Porsche brakes are performance brakes, just shy of what racing cars have. The compounds Porsche uses are designed to perform when they are warm or even hot. A cold brake pad or disc can cause squealing. Again like when corrosion is present, using the brakes will increase the heat, causing the squeaking to go away. This sometimes takes a little longer, 5 minutes of driving may dio the trick, but we’ve seen up to 15-20 minutes with some brakes. If you have glazed brakes, this will not go away and the deglazing process will be needed.

Deglazing Brakes

By now you are probably asking, “How the heck do I deglaze my disc brakes?” The process is quite easy and usually will yield results on the first or second pass. First, you’ll want to be traveling on a road that is void of any people, traffic, or cars in front or behind you. Second, you’ll need to have a safe stretch of road to get up to 20-25 mph. 1/8 of a mile or more is best. Accelerate your Porsche up to approx. 30-35 MPH and push the brake pedal hard. If you can get the ABS to kick on, this will also help the deglazing process. We highly suggest not performing this procedure in the rain or poor weather conditions. Furthermore, if you do not feel comfortable doing this, Meister Werks will be to deglaze your brakes for you during a test drive at your scheduled maintenance, free 30pt inspection or repair.

Here is a before and after video from the Tulsa, OK Porsche dealership:

Maintaining Your Brakes While Driving

We highly suggest using your brakes like they are meant to be used. I know this might sound weird. What we really mean is don’t brake 1/4 mile before you need to. Use firm brake pedal pressure when stopping. Riding your brakes or stopped well before you need to is probably the worst thing to do for your disc brakes. Keep this in mind when driving. Remember, your Porsche likes being driven. When you follow these rules above, your Porsche will be much happier and you can eliminate any brake noise in the future.

 

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Info about Fix-A-Flat tire repair

Fix-A-Flat tire repair is not good for the environment, your wheels or tires. It contains Hydrocarbons (Tetrafluoro), similar to the air conditioning refrigerant in your vehicle. When exposed to moisture, it becomes corrosive.

It can corrode the paint inside your wheel, the aluminum wheel itself, and/or any electronics inside, such as tire pressure monitor sensors (TPMS).

Tire repair with Fix-a-Flat Is not permanent and is not a permanent tire repair. If you choose to use this, the product is only meant to keep you rolling up to 100 miles. This will let you repair the tire properly. It will not help you in a “blow-out”, which usually involves separation of the tread from the tire and large, gaping holes in your tire.

If you have a spare tire, please opt to use that rather than a quick fix. It may save you hundreds, and in some circumstances – thousands of dollars.

Click here for directions to our shop. To schedule an appointment, click here.

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Protected: Carrasco – J007937 – 2004 Porsche 911 Turbo

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Automotive Tech / Mechanic

Hiring Automotive Tech / Mechanic

About Us:

Meister Werks European is hiring a Automotive Tech. We specializes in European vehicles and was established in 1997. We are located in Renton, on the south side of Lake Washington, next to Boeing. Meister Werks is dedicated to high end customer service. After all, we go above and beyond for our customers. For instance, free inspections, washing and vacuuming are some of the service we provide.

About the Automotive Tech Position:

High end European automotive facility is seeking a reliable Automotive A Tech / Mechanic. Above all, a positive attitude is a must to join our team. Firstly, a qualified candidate will be team oriented and have the experience necessary to provide our customers with optimum service and repairs. Secondly, we require our candidates to work with care and provide a high attention to detail, which are critical. VW / Audi, BMW / Mini, Mercedes-Benz, Porsche, Ferrari, Bentley, Maserati, and Aston Martin. Furthermore, any extensive knowledge and experience with these vehicles are a plus.

Duties include performing service, maintenance, and repair on European vehicles. Custom suspension experience and wheel / tire mounting and balancing a plus. You will be working with master tech from Germany who will help with workflow and teach you our systems. Another item may include custom work, electrical and mechanical diagnostics, performance flash tuning vehicles, and updating software on vehicle ECM/TCM and modules. You will be expected to know how to repair, service, and perform maintenance on vehicles without assistance. Furthermore, you must be able to read, write and comprehend specific directions on job tickets and have good communication between shop manager and service writers.

About the Shop:

Our shop is fully loaded with new, high end equipment. Such as, Gas heated shop (66-68º most of the year / summers a little warmer), co2 evacuation system, 175 psi air and 120v power cords on every rack, & 55 gallon drum engine oil dispenser systems. Additionally, other equipment include, a Snap On tire machine and balancer, Flo-Dynamics coolant machine, Snap On transmission machine, Snap On AC machine R134 & R1234yf, recently installed Hunter Hawkeye in ground alignment racks, 3 – 2 post Rotary racks, 30 ton press, wall mounted spring compressor machine. Also, we have a media blaster, manual parts washer, automatic parts washer, Jet upright knee mill for machining, Lincoln MIG welder / aluminum spool gun welder and many more speciality tools. In other words, if we don’t have it, the owner will get it.

Qualified Automotive Tech Application Requirements:

  • Minimum 5 years of experience in a professional shop – REQUIRED.
  • Strong diagnostic skills.
  • ASE certified or certified dealer training.
  • Ability to work and maintain a very clean area and work environment

Benefits:

  • Medical, Dental, Vision and 401k options.
  • Performance bonuses – based off sales and efficiency.
  • Free daily coffee / drinks at a coffee stand located in our parking lot.
  • Use racks for personal use after hours and weekend.
  • Wholesale + 10% on all OEM and Performance Parts.

Earnings:

$30-40 per hr DOE
90 day / 6 moth and 1 year reviews. Furthermore, a potential raise will be considered based off performance, skill and abilities.

Appling Info / Applications:

Download an application here. E-mail: meister@meister.us.com with your resume and application. Without delay, pick up and application and apply in person. Our address is:

Meister Werks
618 Park Ave N.
Renton, WA 98057

 

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Custom Vehicle Rendering

Custom Vehicle Rendering

Here at Meister Werks we want you to see a Custom Vehicle Rendering. This will show you exactly how your vehicle will look after receiving our custom treatment. We can manipulate a photo of your vehicle to have different wheel sizes, colors and styles. Another thing we can do is show you different colors of powder coated brake calipers. Furthermore, we can even lower the vehicle to mimic the exact look of springs, coilovers or airbags on your vehicle.

To get a rendering of your vehicle, we will need a parts deposit before starting on a render. After which, we will provide you with an animated gif photo. Just like the one seen here, private link and password to our website to show you – and only you – exactly what it will look like.

Even though we do not provide the following services in house, we can also apply a wrap color, window tint and more. See out custom shop page for just a fraction of what we can do for you. Contact us to find out more about what we can do for your car.

About Us

The owner and of our company, Dave Meister, has always been a car enthusiast. Since age 16, he’s had a passion for modifying and working on European cars.  What is now Meister Werks began in 1997. With Dave manufacturing and selling custom gauge faces to fellow car enthusiast friends with VW, Audi, and Porsche vehicles.

As our business has grown over the years, our products and services have expanded as well to keep up with customer demand. Now a full service shop, Dave and his staff will take the time to explain your vehicle’s needs to ensure you have a confident and positive experience. To provide you with the best experience possible, we only hire staff with the widest knowledge and best work ethic. Dave and his staff have a passion for excellence has resulted in satisfied customers. Customer service is our number one goal— Dave always says, “if you’re not happy, we’re not happy”. If you live in the Pacific Northwest, this is your go-to shop for European automotive service and repairs.

Dave grew up in Redmond, WA and is a resident of Renton, WA and has lived in the Seattle area his entire life. He has deep roots in Seattle’s history and area. His Great Great Great Grandmother and father moved to Seattle here from Germany. In 1907, they were one of the only German families in Ballard area and the house that his Grandmother was born in still stands to this day.  Dave enjoys working on his 1980 VW Scirocco, spending time with his wife, 2 kids and Chocolate Lab, ‘Blue’.

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