| [ Total Views: 307016 | Total Replies: 964 | Thread Id: 66140 ] |
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 cam070
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| posted on December 30th, 2009 at 09:39 AM |
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One word, MASTERPIECE!
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063bug
A.k.a.: Alan
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| posted on December 30th, 2009 at 09:42 AM |
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Constantly amazed by the quantity of work and level of detail on this project   |
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Flintstones
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| posted on December 30th, 2009 at 10:11 PM |
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impressive Ian.
I'm a bit concerned about the oil lines going under the spare wheel well though. You couldn't have run it behind?
Cheers
D
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2443TT
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| posted on December 30th, 2009 at 10:18 PM |
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There isnt going to be a spare wheel?
Another update.
I finished the mount for the crank angle sensor today. The sensor is actualy an ABS sensor from a porsche 944 so im keeping it german. The sensor
will detect 2 bolts that are screwed into the back of the crank at 60 degrees BTDC.
I also finished off the dump pipe for the drivers side turbo, mounted the wastegate actuator, and added some aluminium heat shielding. The heat
shielding is a folded/laminated mix of aluminium and some sort of fibrous heat shielding material (looks like asbestos so im sure its not). They use
this stuff in the XR6 turbo's from factory and its very effective. While I am hopeful the ceramic coatings will do a good job to keep the temps
down, Im taking no chances with the paint being as close to the heat as it is.
Thats all for today.
Cheers,
Ian
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Sides
A.k.a.: Dave Sidery
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| posted on December 31st, 2009 at 07:46 AM |
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Looks awesome Ian, and getting oh-so-close... do you have the "startup party" planned yet ???
Any chance you could post some pics on the oil lines back to the engine ??? I'm thinking of putting my oil tank up front also, so curious to see
how/where you've run your lines... the feed one mainly...
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Flintstones
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| posted on December 31st, 2009 at 09:23 PM |
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| Quote: | Originally
posted by 2443TT
There isnt going to be a spare wheel?
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I can see that there's no chance of that with the dry sump tank claiming the area.
It's the below pic that show's the oil line under the wheel well. I'd be worried about the oil line getting damaged if it came into contact with
debris that was on the road. That's why I mentioned about routing the oil line behind the wheel well...
Cheers
D
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2443TT
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| posted on December 31st, 2009 at 10:01 PM |
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Ah... Now I see what you mean. Its nearly impossible to see from that picture, but the hose is actually cable tied on top of a steel plate (not to
the bodywork. Those stainless hoses will rub through anything too). Its this plate that is the lowest point on the car at the front, not the hose.
The plate also supports the oil coolers inside each guard and is itself attached to the body with 8mm high tensile bolts. I wouldnt use the plate as
a jack point, but the stee plate is as strong as hell, so it will take quite a hit to damage anything there. Even then the bodywork would be damaged
before the hoses would be.
Today's progress saw the completion of the wastegate actuator mount for the left side turbo, and fabrication of the air intake for that turbo. Heat
shielding is done as well. As has become my typical form it has turned out way better than the drivers side, so I may well be re-making the drivers
side again tomorrow. Im starting to think about air boxes and air filters now too.
If only I had oil lines and an ignition system! I cant wait to hear the car come to life.
Dave, no plans for a "startup party" as of yet. Sadly there are no local VW nutters that are as into modifying their cars like I am. There is a VW
club up here again now though but they arent very active. So I'll most likely just call Reub and give the engine a few revs over the phone and post
a bunch of video on the internet.
My usual tradition when starting up a new engine is get it running, do the cam break in, oil change, and then drive to the service station without the
engine lid on (hopefully avoiding police), and buy a coke. Then relax and watch passers by jaws drop when they see whats in the back of the car!
I'll be sure to post pics of the oil supply and return lines when I get to installing them.
Cheers,
Ian
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063bug
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| posted on January 1st, 2010 at 09:20 AM |
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....what no local competition and you build one of the most complex bugs in the country..... go figure  that can of coke will taste soooo sweet |
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Flintstones
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| posted on January 1st, 2010 at 10:14 PM |
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| Quote: | Originally
posted by 2443TT
Ah... Now I see what you mean. Its nearly impossible to see from that picture, but the hose is actually cable tied on top of a steel plate (not to
the bodywork. Those stainless hoses will rub through anything too). Its this plate that is the lowest point on the car at the front, not the hose.
The plate also supports the oil coolers inside each guard and is itself attached to the body with 8mm high tensile bolts. I wouldnt use the plate as
a jack point, but the stee plate is as strong as hell, so it will take quite a hit to damage anything there. Even then the bodywork would be damaged
before the hoses would be.
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Phew, that's a relief!!
| Quote: | Originally
posted by 2443TT
My usual tradition when starting up a new engine is get it running, do the cam break in, oil change, and then drive to the service station without the
engine lid on (hopefully avoiding police), and buy a coke. Then relax and watch passers by jaws drop when they see whats in the back of the car!
Cheers,
Ian
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The cops wouldn't even have a chance at catching you, with all that upgraded suspension, brakes and driveline
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LIFE IN THE LOW LANE
A.k.a.: Brennden Alder
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| posted on January 2nd, 2010 at 05:47 PM |
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I think i speak for most on here that if I lived close enough i certainly would book a front row seat for the start up party!! as for the drive to the
servo for a Coke there had better be video footage!!
[size=4] ACCEPT THAT SOME DAYS YOU ARE THE PIDGEON AND SOME DAYS YOU ARE THE STATUE[/size]
Alder Outlaws VW Racing - check it out on fb!!
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Sides
A.k.a.: Dave Sidery
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| posted on January 2nd, 2010 at 09:37 PM |
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| Quote: | Originally
posted by LIFE IN THE LOW LANE
there had better be video footage!!
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Oh yeah - I hope so too !!!
VWDCQ vice pres & web dude - vwdcqinc.org.au
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2443TT
A.k.a.: Ian
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| posted on January 2nd, 2010 at 11:18 PM |
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Maybe I should try do one of those webcasts! Broadcast the startup of the engine live... How much of a computer geek does that make me sound like?
I nade a little more progress with the car today. I have been working on the air intakes for the turbo's and came to the conclusion that I didnt
like any of the pressure side of the intake and intercoolling plumbing that I had already done. It basicly made it impossible to get good straight
airflow to the turbo's. So I have re-worked the whole intake system, moved the intercooler and changed the piping around a lot.
The end result is a VAST improvement over what was there before. Everything is solid mounted to either the engine or the gearbox, so it all moves as
one unit. Air intakes are 3" to 2.5" at the compressor housings and are virtually a straight line. Sorry no pictures as of yet as its all in pieces
again at the moment. I need to source some more 3" stainless tube so I can finish it all off properly, so its on hold till next week now.
Cheers,
Ian
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hellbugged
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| posted on January 2nd, 2010 at 11:49 PM |
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| Quote: | Originally
posted by 2443TT
I nade a little more progress with the car today. I have been working on the air intakes for the turbo's and came to the conclusion that I didnt
like any of the pressure side of the intake and intercoolling plumbing that I had already done. It basicly made it impossible to get good straight
airflow to the turbo's.
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o dear........chasing every last poofteenth of power now.............bloody nutbag, time to institutionalise Mr Swinkles i think
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BigWigRaceCars
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| posted on January 6th, 2010 at 04:05 AM |
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Wow. This is one of the best build threads I've seen. Great work! I just spent a full 1/2 day looking through this thread from the beginning (at
work). If I get fired, I'm blaming you. |
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Sides
A.k.a.: Dave Sidery
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| posted on January 18th, 2010 at 11:23 AM |
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Two weeks without updates... I'm starting to have withdrawal symptoms !!!
VWDCQ vice pres & web dude - vwdcqinc.org.au
Join a car club - get car peeps
My toys
'70 Hillclimb Bug 'Jezebel' w/- Haltech EFI - http://bit.ly/VwTNtQ
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2443TT
A.k.a.: Ian
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| posted on January 18th, 2010 at 09:58 PM |
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Hi all,
Ive been moving house for the last weeks but am finally in. The new shed is great too. Smaller but a lot better laid out.
I hope to be getting stuck back into the VW soon. I still need to order an ignition system and the main oil supply and return lines but thats about
all thats needed to get the engine started for the first time.
The main project at the moment is un-packing, and of course I also have a fair amount of minor house repairs to do as well. There isnt enough hours in
the day at the moment.
Cheers,
Ian
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cam070
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| posted on January 18th, 2010 at 11:52 PM |
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Where asre your priorities? Car first!
Just kiddin, but I know I am not the only one waiting for updates here. Hope the new place is good and you are in and unpacked soon.
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BigWigRaceCars
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| posted on January 21st, 2010 at 03:53 AM |
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What are you planning to use for the chargecooler heat exchanger, and where will you fit it? That car is getting full. |
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2443TT
A.k.a.: Ian
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| posted on February 11th, 2010 at 06:42 PM |
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Its been too long since being able to work on the car and post an update. After moving house I've had to make a few repairs to the new place, and
that then got all out of hand like many of my projects. What started with some gardening and some roof guttering repairs turned into replacing 1600+
roofing iron screws, pressure blasting and painting the entire roof, and replacing all the guttering and flashing. Fortunatly I will be finished this
weekend, so I hope to be able to spend a lot more time in the new shed in weeks to come.
Ive had another lot of earls fittings and a heap of -12 and -16 oil hose arrive for the oil supply and return lines, and have been able to finish all
the engines oil lines and cooler lines. Ignition coils have arrived as well, but I still need to source an MSD DIS4 CDI unit. Here are some
pics...
Earls oil thermostat attached to the return line from the oil pump diverts oil through the oil coolers if necessary and then returns to the tank.
Supply and return lines will hopefully be run this weekend. The tank has a diagonal brace to make the mounts more rigid too, not that you can see it
from that angle.
All the engine oil lines, turbo oil supply lines and returns are all done now too. Only pump supply and returns need to be finished now. That and
wiring the ignition system and Im pretty sure the engine will be ready to test fire.
This is the new setup for the intercooler. The heat barrel is mounted rigid to the gearbox, so it all moves as one unit with the engine.I've had to
use silicon bends all over the place to allow joins and tight radius's, but the result is acceptable and it shouldnt blow apart once the pipes are
flaired a little. This revised setup allows a 3" air intake directly into a 3" to 2.5" elbow to feed each turbo. Meaning virtually no intake
restriction at all.
This is the new shed! Car one side, workshop the other side. I stil need to unpack but that wont stop me from working on the car once time permits
again.
Hope to have another update on sunday night.
Cheers,
Ian
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reub
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| posted on February 11th, 2010 at 06:47 PM |
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Looks pretty serious dude. Man is this thing going to be scarey 
Reub
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vassy66T1
A.k.a.: Marcus Vass
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| posted on February 11th, 2010 at 07:51 PM |
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Ian, I shake my head in awe every time I see this car.
Great work and your perseverance is commendable/outstanding!!
Can't wait to see it one day.
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Sides
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| posted on February 11th, 2010 at 08:29 PM |
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Looks awesome Ian !!!
Any chance of some pics on where you've run your oil lines from the front to the rear... and have you gone braided for the full length, or hardline
for the majority of it with the braid just at either end ???
VWDCQ vice pres & web dude - vwdcqinc.org.au
Join a car club - get car peeps
My toys
'70 Hillclimb Bug 'Jezebel' w/- Haltech EFI - http://bit.ly/VwTNtQ
'60 KG Coupe - resto kinda started
01 New Beetle - gf's car, but I turn the spanners |
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 matberry
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| posted on February 11th, 2010 at 09:25 PM |
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Brilliant work Ian
Matt Berry Motorsports...air cooled advice, repairs and mods Ph 0408 704 662
OFF-ROAD,CIRCUIT,DRAG,STREET,ENDURANCE
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Ollie
A.k.a.: Ollie Clarke
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| posted on February 15th, 2010 at 12:40 AM |
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Woah...
Words can't describe how amazing this car is.
I just spent half of "Tango and Cash" (It's playing on Channel 9 - don't judge me!) flicking through this entire thread and can't believe this
car is coming together so well! The fact that you have my favorite car in the world (R34 GTR) and an insane bug makes me green with envy! I can't
wait to see the updates continue to filter through amongst the admiration from every follower on here.
On a side note, what mods have you done to Godzilla?
Cheers,
Ollie
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2443TT
A.k.a.: Ian
Fahrvergnugen
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| posted on February 15th, 2010 at 08:20 PM |
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Sorry but no update. I spent the weekend workiing on roof doing guttering and flashing, and am now very close to having it all sorted out. I dont
think I ever want to do this kind of work again though with any luck i'll be done with the house repairs before the weekend and I can start to play
with cars again.
| Quote: | Originally
posted by OMClarke
Woah...
Words can't describe how amazing this car is.
I just spent half of "Tango and Cash" (It's playing on Channel 9 - don't judge me!) flicking through this entire thread and can't believe this
car is coming together so well! The fact that you have my favorite car in the world (R34 GTR) and an insane bug makes me green with envy! I can't
wait to see the updates continue to filter through amongst the admiration from every follower on here.
On a side note, what mods have you done to Godzilla?
Cheers,
Ollie
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Thanks Ollie, glad you enjoyed the read.
My R34 is only mildly tuned at the moment. Its was a standard R34 GTR S-Tune which basicly means all Nismo factory options (S-tune suspension, carbon
fibre bits and v-spec aero parts, and side and front airbags). So its like a vspec but without the active LSD and with all the sound proofing.
Ive since added a tunable ecu, slotted rotors, wideband AFR system and a Nismo 80mm exhaust. Ive also built a pretty crazy 450kw engine upgrade for
it too, but that project is on hold till the VW is running. Have a look at http://www.odengines.com if your interested in it, thats my other sideline "project". Too many projects...
I race the R34 in sprint events occasionally. It is truely an awesome car to drive. There is nothing ive ever driven or been in that feels so planted
and controllable. They are a car that you can safely push beyond the limit. While a 2wd car would be off the track, the gtr just keeps on giving.
They do eat tyres though. 6 sprint events per year, 4 x 4 lap runs at each event and it will totally destroy a set of tyres.
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Ollie
A.k.a.: Ollie Clarke
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| posted on February 17th, 2010 at 12:26 AM |
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Hell yeah...
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Martin Taylor
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| posted on February 17th, 2010 at 10:09 AM |
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Awesome work, some fantastic fabrications going on!
Just a little info for you we used the largest PWR intercooler on one of the turbo cars over here, it was next to useless, air temps were over 85oC at
the top of the 1/4
switched over to a HKS unit and it never went over 21oC.
good luck with it, looking forward to seeing the results of twin turbos.
Regards
Martin
Martin
9.83 on street tires and 98 octane pump gas
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2443TT
A.k.a.: Ian
Fahrvergnugen
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| posted on February 18th, 2010 at 08:30 PM |
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| Quote: | Originally
posted by Martin Taylor
Just a little info for you we used the largest PWR intercooler on one of the turbo cars over here, it was next to useless, air temps were over 85oC at
the top of the 1/4
switched over to a HKS unit and it never went over 21oC.
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I ran a smaller PWR barrel cooler in my 2332cc turbo vw engine. I found the efficency of it to be very good, as over a 1/4 mile blast the air temp
would only rise about 4-6 degrees over ambient temps. I used a 10 litre coolant resivour as well though to help slow heat soak of the coolant though
too. Setup is everything.
If it was a front engined car you ar referring to that you then switched to a HKS core, then your 100% right. Its hard to go past the quality of those
units. I had one in my R33 GTR and it would always sit very close to ambient temps, provided you had some good forward momentum. Anything above 80km/h
and a good front mount is unbeatable.
Shame the VW's have no frontal area for mounting a decent size air-air intercooler. Unless you want to put in a core in a wing over the engine like
they do on the turbo/GT2 porsches.
I had a break from working on my roof guttering and flashing today (its still not finished), and instead started plumbing my oil lines at last. After
much consideration I have decided to not run the hoses through the heater channels. There is too much risk of kinking a hose. Instead they will be
running down the pasenger side of the car next to the heater channel.
Here are a few pics.
Bulkhead fittings. -12 return, -16 supply lines. I used black nylon hoses as the intention was to run them through the heater channels and stainless
braid tends to rub through everything it touches. Nylon wont damage what it comes into contact with.
-16 from the tank so there is as little restriction as possible on the supply side of the pump.
And finally how it looks with everything bolted back together.
More fittings are on order to finish the rest of it off.
Cheers,
Ian
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Martin Taylor
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| posted on February 19th, 2010 at 08:59 PM |
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The car in question was in a beetle. we convert the HKS intercoolers into charge coolers by welding a jacket on them
the turbo is a 40/94 hybrid from the the 40/88 Garret roller bearing unit. Running 28 psi of boost generating 540 rwhp.
the water pump for the intercooler is a davis craig 110 ltr/min pumping from a storage(ice) tank in the car. using -16 hoses
we were just disappointed with how it performed. the hks unit has nailed it now
Great thread by the way
Martin
Martin
9.83 on street tires and 98 octane pump gas
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Sides
A.k.a.: Dave Sidery
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| posted on February 20th, 2010 at 10:19 AM |
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Yikes... -16 supply lines, that's some serious flow you're gonna have !!! Very neat too how you've run them... more things to throw into the
thinking for mine.
Keep up the brilliant work Ian... tho we all know that you will... I for one am eagerly waiting to read an "it's alive !!!" post...
VWDCQ vice pres & web dude - vwdcqinc.org.au
Join a car club - get car peeps
My toys
'70 Hillclimb Bug 'Jezebel' w/- Haltech EFI - http://bit.ly/VwTNtQ
'60 KG Coupe - resto kinda started
01 New Beetle - gf's car, but I turn the spanners |
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