| [ Total Views: 306996 | Total Replies: 964 | Thread Id: 66140 ] |
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 2443TT
A.k.a.: Ian
Fahrvergnugen
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| posted on April 11th, 2010 at 10:23 PM |
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Na there is plenty of room inside those rear guards. Under the firewall inside the back of the car is getting pretty cramped though. I had the
intercooler, intake piping and plumbing etc all installed and its going to be a very tight sqweeze getting air cleaners in there, but I have a good
plan.
Gidday Slappa, definatly give me a call when you are back in town too.
So... update time.
I had the intake of the car all assembled at last (except air cleaners), and was plaing with the tune today when my starter motor shaft let go...
again. It didnt break at the welded join where I extended the shaft, rather it broke further along the shaft right under the outer bearing where it is
stressed the most.
After much swearing I decided it was time to fix the dam thing properly, as in the hard way. The new plan is to machine up an mount for a 2nd ring
gear that will be 15mm closer to the starter motor, thus solving my offset issue. I will use a standard 200mm flywheel to make the extension, and
basically machine the center out of it. Then it will attach to the main flywheel using studs or longer bolts that will replace the 6 standard flywheel
bolts. Because of how the clutch goes together, I can have the "ring gear extension" machined so it positively locates centrally over the pressure
plate very easily.
With any luck I can have this done before next weekend too. I was SO close to driving the car today, and to have the starter break was a right pain
in the ass.
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2443TT
A.k.a.: Ian
Fahrvergnugen
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| posted on April 15th, 2010 at 07:07 PM |
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Today I picked up my solution to my ring gear/starter motor woes from the machine shop. A new ring gear system that bolts on to the flywheel.
Basically I got a normal german VW flywheel and flipped it over so the ring gear is towards the gearbox instead of the engine. Then I went about
making it bolt back onto the existing flywheel using the 6 main pressure plate bolts. The ring gear mounts are notched so they positively center on
the edge of the pressure plate, exactly the same way the pressure plate centers into the flywheel. The whole lot was then re-balanced.
The new ring gear setup...
And the ring gear attached to the flywheel
I could have had the 1st ring gear removed from the main flywheel, but I like to keep my options open. I doubt it will affect the performance much
anyway.
I got as far as getting the engine back in the car again too, but still have to bolt on the header, turbo's and all the intake plumbing again. Thats
my mission for tomorrow afternoon. I'd like to be starting the engine again on saturday, and weather permitting actually get to go for a drive!
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dangerous
A.k.a.: Dave Butler Muffin Man
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| posted on April 15th, 2010 at 07:10 PM |
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Nice work ian, good solution!
| Quote: | Originally
posted by westi
That's mad Alan.
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vassy66T1
A.k.a.: Marcus Vass
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| posted on April 16th, 2010 at 08:09 AM |
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You are an excellent problem solver ... definitely a requirement for this project. Hope Saturday goes to plan for you.
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VoLkSuBaGeN
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| posted on April 19th, 2010 at 03:35 PM |
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Great project!!
I'm doing a superbeetle pan conversion to my 69 beetle project in Thailand.
Your car inspire me, very very nice car. :-)
PS. This is my car, I think it will be finished in 2 months.
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pete wood
A.k.a.: figure itout
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| posted on April 22nd, 2010 at 08:31 PM |
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awesome work volksubagen 
I have just shamelessly copied those pics. My buggy is definitely getting a strut front down the track. It's just sooooo much better than torsion
bar. 
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2443TT
A.k.a.: Ian
Fahrvergnugen
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| posted on April 26th, 2010 at 09:30 PM |
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Good idea using the superbug pan to update your suspension. It makes the whole process and parts compatability a lot less grief to deal with. The
only reason I went with the swing axel pan and then went for broke on it was the torsion horns arent as tall, allowing more clearance to the CV
joints.
Quick update....
The car is now back together again, wheels on and on the ground again. The new starter motor drive setup continues to work a treat. I wish i'd done
it that way from the start but thats part of the joys of having modified everything so much i guess.
Ive been playing with the tune a little and now have a base map that should be reasonably drivable, at least enough to get going on a street tuning.
The engine is finally running properly on all 4 cylinders now too, and with the twin exhausts operating it sounds cranky as hell. Not surprising since
the cam is a varient of a FK87.
I had a bit of a mission chasing oil leaks too, which all turned out to not be from the engine, but from 2 o-rings on the external pump.
I spent most of the weekend tidying up wiring and with finishing touches. Just have tail lights, seat belts, seats and number plate mounts to finish.
I hope to get to take the car for a lap before the end of the week.
Thats all for now.
Ian
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2443TT
A.k.a.: Ian
Fahrvergnugen
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| posted on May 2nd, 2010 at 07:32 PM |
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Hi Everyone,
Time for a long over-due update. Ive been busy tinkering on the car lately. The last finishing touches taking the longest to work out how to finish
properly... The car is now drivable, and only needs a horn and number plate to be mounted so its "legal". I think I need to re-bleed the brakes
again too as the pedal isnt as firm as i'd like it to be. I hope to finish that off tomorrow and go for the drive to the service station and get my
victory coke.
I've finally been able to finish of the ignition system now that my AEM 4 channel CDI unit has arrived. This little box is very similar to the MSD
DIS4 HO (high output version), except that it doenst have a 2 step limitor in it, and the inputs are able to be configured as rising or falling edge.
This allows it to be directly wired to an ECU, instead of having to have a Ignitor module interface stage. The output of this sucker is amazing too.
With the MSD Blaster SS coils, output to the plug will be about 54,000 volts! It also does the multi-strike spark at low RPM like the MSD, which has
really helped the idle of the car. Its still idling at 1200-1250rpm, but sounds a little smoother at the same time.
The intake system for the sequential twin turbo operation is pretty well finished, though I still need air cleaners, a hose for one of the bypass
valves, and some minor welding to replace some of the silicon hoses as pictured, air boxes, and to make the bolt in firewall section. I will not be
letting that stop me when I go for a drive though.
Here are a few more pics.
Hope to have more pics tomorrow... fingers crossed.
Cheers,
Ian
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 matberry
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| posted on May 2nd, 2010 at 09:53 PM |
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Thanks for the updates.
Not long for that well earned Coke. 
Matt Berry Motorsports...air cooled advice, repairs and mods Ph 0408 704 662
OFF-ROAD,CIRCUIT,DRAG,STREET,ENDURANCE
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reub
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| posted on May 2nd, 2010 at 10:03 PM |
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Still not sure any of us can comprehend potential of this build dude....
Looking forward to hearing the WHOOHOO from your first drive, and the following poo stains that emerge from eventual all out power 
Reub
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LIFE IN THE LOW LANE
A.k.a.: Brennden Alder
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| posted on May 3rd, 2010 at 07:13 PM |
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I'm presuming Ian that coke will not be a 600ml bottle after all the work that you have put into this thing!!
[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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2443TT
A.k.a.: Ian
Fahrvergnugen
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| posted on May 3rd, 2010 at 07:31 PM |
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Sadly no test drive today... Only Reub got to do that today...
Its been raining all day here, so instead Ive re-adjusted the suspension, blead the brakes, and mounted the passenger side seat and seat belt.
Perhaps this week some time i'll get the chance to do a couple of blockies at the very least.
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colonel mustard
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| posted on May 3rd, 2010 at 07:35 PM |
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No rain here this weekend.... send it down to brissy mate!
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dangerous
A.k.a.: Dave Butler Muffin Man
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| posted on May 4th, 2010 at 05:16 AM |
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This morning it is pissing down!!
http://www.bom.gov.au/products/IDR663.loop.shtml#skip
| Quote: | Originally
posted by westi
That's mad Alan.
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Flintstones
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| posted on May 4th, 2010 at 11:49 PM |
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Great job on an extensive build
Can hear the "tshh" of the coke being opened!
Need to see some vids from the maiden voyage
Cheers
D
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2443TT
A.k.a.: Ian
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| posted on May 9th, 2010 at 05:16 PM |
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Still no can of coke yet. Ive decided to do the responsible thing and finish making the car "legal" before going for a lap. I dont think I should
push my luck with the boys in blue. They are going to have a heart attack as it is the first time I get pulled over. Having something there that is
wrong that could get me defected is pushing my luck a little.
Its funny the things you can over look when you think your nearing the end of the project, such as side rear vew mirrors, windscreen wiper wiring,
wiring for the power windows, and getting the seat height right so you can see over the dashboard... Ive taken care of these little issues this
weekend.
I want to finsih the bolt in firewall this week too. Coming up with the right design for air filter boxes to mount through the firewall is proving to
be quite a challange. Ive been toying around with a few idea's but havent really come up with something I like yet. Once I finish the firewall the
rest will hopefully fall into place from there.
Cheers,
Ian
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2443TT
A.k.a.: Ian
Fahrvergnugen
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| posted on May 15th, 2010 at 04:03 PM |
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Another update.
I ordered my air filters over 2 weeks ago and the frickin things still arent here. I did manage to finish the bolt in firewall today. Just need to
rub it up with some Jif and a scotch bright to give it that dull burnished look. Holes will be cut each side in the back tray where the intakes go
through, and the air boxes will be. Then hoses from the air boxes to the windows and its all done. So yet again at a stand still due to slow parts
delivery...
Here are the pics:
Thats all for now.
Ian
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56t4
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| posted on May 17th, 2010 at 08:28 PM |
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Hi Ian,great work mate. I just read thru the whole thread very inspirational stuff.Can't what to see a vid of the beast on the road.
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2443TT
A.k.a.: Ian
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| posted on June 11th, 2010 at 03:41 PM |
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Hi All,
Fricken finally another update. I had hit a major hurdle with trying to get all the intake piping, air cleaners and intercooller in under the
firewall. I intentionally put in a bolt in firewall to have plenty of room, but it all seems to disappear pretty quickly. Every step forward I made
with finishing something has required 5 steps backwards to make it all fit and work. Ive had to re-located oil lines, fuel lines wiring, and the
intake pipe setup is now on its 5th version I think.
So, the new setup has a HKS mushroom air filter mounted inside an air box above each turbo. These are pretty cool filters, with a large 3" trumpet
inside the filter assembly. The base of the filter is machined alloy with a pretty chromed wire gril over the filter foam. Ive had to re-weld the
fittings off the turbo's to alter the angles (for about the 4th time). Output from the drivers side turbo goes through a pnumatically operated valve
which will be used to bring the 2nd turbo online above 3500 rpm. There is a smal 25mm bov being used as a bypass/pre-spool valve for this 2nd turbo.
As you can see I decided to change to a turbosmart vport bov for the main intake pipe.
Then with the 2nd hot pipe installed it T's into the main line from the 1st turbo. Granted a T isnt necessarily all that efficent with flow, but 95%
of the time intake air flow is through the first turbo only, and when the 2nd is producing boost the pipes are al pressurised anyway so flow shouldnt
be an issue. I'd have liked to do away with some more of the silicon hoses in favor of more tig welded stainless but I cant get tight enough radisus
bends, so I'd need a 2.5" stainless donut to do it all the right way. Just raw welds... no polishing yet. I just want to drive it and prove it
works!
The insanity contines naca scoops mounted on the firewal with air supply holes cut for the air boxes. The whole lot is held together with pop riveted
in nut-inserts and allen head bolts. The air supply hoses to the windows and the firewall end naca ducts will probably end up being satin black
painted PVC tube, with silicon joins to the ducts at each end. Satin black is my new favourite colour...Cheap too.
Here it is with the rest of the firewall in place.
And from the tailgaiters view.
Tomorrow I have to take off 1/2 the intake manifold so I can change the vacuum connections and connect a fitting for the idle air control
valve(something I overlooked when making it a few months ago...
I hope to finish the car eventually....
Cheers,
Ian
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vlad01
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| posted on June 11th, 2010 at 07:45 PM |
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I just read this whole thread from start to finish.
awesome 
71 notchback,
Past owner of, 70 NB, 73 SB and 72 FB TLE |
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Flintstones
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| posted on June 11th, 2010 at 09:33 PM |
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The joys of modifying
Hang in there Ian, it's almost done.
That Coke is just around the corner
Cheers
D
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vlad01
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| posted on June 17th, 2010 at 12:30 PM |
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| Quote: | Originally
posted by 2443TT
At last guys I finaly have a set of heads, and they are truely awesome! The machining is really as good as it looks. Valve seats are blended to the
casting so there is no noticable lip to feel if you run your finger over it. Exhaust flanges are huge too, should make for a good sealing area
considering the exhaust back pressure on the engine will be approaching 35PSI.
I discovered that the Australian government doesnt have a free trade agreement with the Swiss too. Import duty and GST was another $718 on top of the
purchase price of $3275. So Ouch! Just as well Kevin Rudd gave me some money to help buy these! But they look like they will be up to the task of
what I have planned for them.
I know what I'll be doing this weekend....
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what are these
heads 
omg they have 9! ..... 9!!!!!!!!!!!! cooling fins.
 ultimate daily driven race car heads. who makes them and where
did you get em from.
71 notchback,
Past owner of, 70 NB, 73 SB and 72 FB TLE |
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2443TT
A.k.a.: Ian
Fahrvergnugen
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| posted on July 2nd, 2010 at 07:00 PM |
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| Quote: | Originally
posted by vlad01
what are these
heads
omg they have 9! ..... 9!!!!!!!!!!!! cooling fins.
ultimate daily driven race car heads. who makes them and where
did you get em from.
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The heads are JP Motorsport MS230's. Made in sweedan. Here's a litle more information.
http://www.volksworld.com/news/latest/251741/jp-motorsport-cylinder-heads.html
Now for an update...
I've been a little side tracked with rebuilding a skyline engine and racing the last few weeks, but have finally found the time to make some progress
on the vw again.
I decided to ditch the idea of adding and idle control valve. I will just accept that the engine idles a little slower when its cold.
Speaking of which, with the intake manifolds finished and all the plumbing connected, I've been able to get the engine runnng quite sweetly to the
point that its ready for a basic road tune and test. This means I had to finish the firewall and air intakes, which is now done.
The whole lot is held in with riveted in nut-certs (or thread inserts) and allen head bolts. So here is the assembly.
First the top sheet goes on, and the air boxes bolt to this sheet, and the body of the car.
Next, the front sheet goes in, and the naca scoops with flanges are bolted into place.
Then on go the hoses.
There is still room to put a back seat in the car again, but the car is now mod plated as a 2 seater. The whole lot will be being covered up with a
vinal covered thick padded sheet (held in place with velcro). This will help cut down on engine noise getting into the car as well.
I still need to pull the clutch master cylinder and have it sleeved down to a smaller size, as the clutch is fully dis-engaged with only 2/3 pedal
movement. This probably wont stop me going for a test drive should I get number plates onto the car this weekend.
Thats all for now.
Ian
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grogy
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| posted on July 2nd, 2010 at 11:06 PM |
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the workmanship and problem solving are a credit to you. a real work of vw art. all the best ian, i been eagerly waiting to see your car running,
there are not many bugs like this one. regards greg
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cam070
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| posted on July 3rd, 2010 at 02:20 AM |
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I anticipate this shold be done very soon, at which time I have a few small jobs for you........ You can certainly help build me car any day!
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Golde60
Fahrvergnugen
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| posted on July 4th, 2010 at 06:41 PM |
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all the best with the first shake down drive. i hope it goes well - you deserve that coke.
...................( O \ l / O ).....................
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2443TT
A.k.a.: Ian
Fahrvergnugen
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| posted on July 6th, 2010 at 09:42 AM |
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Still havent been for a drive yet. It had been like melbourne weather all weekend, drizzly rain and cold. I did finally take some HD video of the
car running though and managed to upload it to youtube.
http://www.youtube.com/watch?v=W_P2mtkncNM
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dangerous
A.k.a.: Dave Butler Muffin Man
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| posted on July 6th, 2010 at 10:04 AM |
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That is awesome Ian.
Sounds great!
| Quote: | Originally
posted by westi
That's mad Alan.
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reub
Veteran Volks Folk
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| posted on July 6th, 2010 at 12:35 PM |
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Reub
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silver
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| posted on July 6th, 2010 at 02:31 PM |
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Sounds great!
When should we start a sweep on how much HP this thing will have??
Keeping it real !
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