Kev's Turbo Fuel Injected Engine Build (Update 14/12/14)

Camo · 2014-05-15T09:24:25+00:00

Hi all, Firstly this is not going to be a full on engine build thread with everything written or photographed as there is lots of those type threads already on the internet if you do a search. It's more a quick overview of the process with photos telling most of the story. Link here to previous parts that arrived since last year. Quick list of recent main parts (Supplied by Rod Penrose) : CB Performance Aluminium Case Pauter Roller Rockers Scat Wedge mated Crank, Flywheel and Gland nut Scat 'H' Beam Rod Scat Chromoly Head Studs AA 92mm thick wall cylinders AA Forged (really) pistons to suit CB Mini Wedge Port heads Engle TCS 20 cam and Followers Most of the fuel injection stuff is from the 'VW Speed Shop' in Great Britian. ECU, wiring, coils and sensors from the USA. This long process started around November 2013 when I pulled the motor out of my car that I had intended to convert to turbo, injected etc. After pulling the engine down and inspecting, it did not have the internals that I was told it had when I purchased it as a completed running motor. The parts were good for what it was, but not for what I am planning on doing. I then had months to wait for some of my parts to arrive from the good old US of A. This is just a mock up of the Turbo exhaust to see how it fits and to make sure the Turbo was going to clear my rear valance before I pulled old motor out. Parts finally arrived and the long preparation process of blueprinting the engine begins. The engine case havles themselves need modifications. The oil pump pickup hole is misaligned and as were the main journal oil supply holes. The black texta lines are indicating where the actual bearing oil groove lies. Both needed porting to match up. A modification to the Cam followers allowing more oil to pass through and up to the rocker gear. This aids in lubrication, but also aids in increased cooling of the heads. The camshaft needs to be clearanced in 8 positions to stop the conrod big ends hitting it due to larger crank stroke. Camshaft bolts also need clearancing to make sure they dont kiss the oil pump. Checking the cam lift to make sure it is the same as the supplied information card. Bolted top half of case on and checked cam shaft and crank shaft end floats. And about to check deck height to see what I have to start with. Obviously way to much, but needed to work out how much material I need to remove to obtain the desired compression (deck height). Then time for cleanup so as the assembly process can begin. Although this doesn't show a time line, there is a lot of work involved to getting the engine case and components to this stage. This actually took me weeks to here as only working on it here and there. Beginning of the assembly process. Also as going full flow from the oil pump, need to fit threaded plugs into case and oil pump. Case halves finally together, oil pump fitted. Then started fitting a few of the external accessories. Deep sump, oil cooler adaptor, crank angle sensor parts. Added an extra external oil cooler to the car. Checking ring clearance and adjusting to suit. Case savers and barrels (no pistons) fitted to engine case as mockup to check head stud bolt lengths. As you can see here, the head bolts are to long and all need to be shortened. All rings fitted back onto pistons and pistons fitted into barrels. Then barrels and pistons fitted to engine. As of today, heads now bolted on for last time with new pushrod tubes and seals. Just sat rockers on quickly to see how they look and I love it. As I said, this engine build process has taken me about 2 months working on it when I can. If you ever have anyone build you a half decent motor and ask why it cost so much, I can vouch there is a lot of work involved and more then I had realised. I will continue to update over time and when new things are added or changed. Hope this hasn't been too much in one post and bored people. Cheers, Kev

vduboy Insano Dub Head

702 posts · joined Oct 2012 · 19 Jun 2014, 12:30 pm

#993645

Awesome job mate, looks and sounds tough as, That cam clearancing looks scary though! Necessary evil I guess

It will all be OK in the end, if it's not OK it's not the end!

joesbuell Seriously Crusin Dubber

190 posts · joined Sep 2011 · 24 Jun 2014, 9:22 pm

#994169

Awesome love it!!

Camo Custom Title Time!

1,936 posts · joined Oct 2007 · 8 Jul 2014, 11:45 am

#995082

This arrived this morning, so now I can hopefully pull my finger out and start the big wiring process. Oh, forgot it's school holidays so I wont get a thing done this week and then work 😬

I guess Rome wasn't built in a day and all good things come to those that wait. This is what I keep telling myself anyway 🥲

If anyone has a spare rocket out there, I need one up my proverbial to get started 😂

Kev

I thought rebuilding a VW would be cheap - Shit I was wrong, just don't let the wife know !!!!

Click here for my (slowy) modded 1961 Beetle build.

Camo Custom Title Time!

1,936 posts · joined Oct 2007 · 19 Jul 2014, 7:37 pm

#996090

With school holidays and work, haven't had much time to do anything. Managed to make up a mounting board and mount my ECU, relay/fuse box and knock sensor box. Now just need to make the wiring harness and get it in there.

Kev

I thought rebuilding a VW would be cheap - Shit I was wrong, just don't let the wife know !!!!

Click here for my (slowy) modded 1961 Beetle build.

Craig Torrens 6 times Australian, 7 times State Hillclimb Class Champion

8,040 posts · joined Jan 2003 · 19 Jul 2014, 8:23 pm

#996093

Cool..........is the motor back in the car yet ?

Camo Custom Title Time!

1,936 posts · joined Oct 2007 · 14 Aug 2014, 9:04 pm

#997878

Craig Torrens wrote:Cool..........is the motor back in the car yet ?

Yes Craig and sorry for the delay. The motor was back in about 2 weeks ago, but then I didn't touch it for over a week. But have worked on it this week although it doesn't appear to be much, there is about $400 of new (17) 'AN' fittings and fuel lines just in the engine bay although you cant see most of them.

Also did some wiring modifications (re routing) to the wiring that was already in there. eg oil temp sender that is now on the oposite side of engine. Haven't even started the EFI wiring and all the sensors.

Also made brackets up to hold 4 x LS2 coils and mounted them to the firewall. Although not in this photo also mounted my remote oil filter and made up new hoses for that also. Modified bracket for the new efi fuel pressure regulator.

Temperarily fitted the exhaust and turbo as I need to trim the inner tinware just to get turbo in there and just sat the water to air intercooler in place for a photo.

Kev

I thought rebuilding a VW would be cheap - Shit I was wrong, just don't let the wife know !!!!

Click here for my (slowy) modded 1961 Beetle build.

Camo Custom Title Time!

1,936 posts · joined Oct 2007 · 16 Aug 2014, 9:52 pm

#998064

Started on the wiring yesterday and more today and all this wire is just 4 coils and 4 injectors 🤪🤪🤪

And I still need to wire in air temp sensors, cylinder head temp sensor, 02 sensor, waste gate control valve, throttle position sensor, crank angle sensor, cam angle sensor and these are just engine bay sensors.

Then there is still the oil cooler thermo fan, fuel pump, water pump and another thermo fan for inter cooler.

Kev

I thought rebuilding a VW would be cheap - Shit I was wrong, just don't let the wife know !!!!

Click here for my (slowy) modded 1961 Beetle build.

Camo Custom Title Time!

1,936 posts · joined Oct 2007 · 8 Sep 2014, 9:29 pm

#999828

Another update, although it may not look a lot since last time. I can't believe how time consuming this modification is. So lucky I am not paying for the majority of the labour.

You can see in the first photo, I removed the original waste gate position off number 2 cylinder pipe and have had one added just after the collector. Note: this is like the CB Performance turbo exhaust but this one is all stainless steel and from the VW Speed Shop.

Obviously the waste gate in place. Still needs the exit pipe made up and added once I have a muffler etc added.

Had inlet plenums and cross pipes (and exhaust mod) made up at a mates business (Definite Dimension Engineering - free plug for Rob) great job 👍 And this is how she looks currently. Although I still have heaps to do 🥲

Kev

I thought rebuilding a VW would be cheap - Shit I was wrong, just don't let the wife know !!!!

Click here for my (slowy) modded 1961 Beetle build.

volksfan Learner Dubber

8 posts · joined Sep 2014 · 8 Sep 2014, 9:30 pm

#999829

Hi Kev,
Thanks for steering me over to this thread.
WOW!!!
You are definitely LIVING the dream.
I'm just clinging to my dreams atm, but your incredible journey here gives me (& I'm sure many others also) so much hope to one day follow suit.
Many thanks, Muz.

volksfan Learner Dubber

8 posts · joined Sep 2014 · 8 Sep 2014, 9:36 pm

#999830

Not much room left now.
Just as well you went with the removable valance!

fish26 Fahrvergnugen

903 posts · joined Jul 2007 · 9 Sep 2014, 12:59 am

#999842

Nice work big Kev, i gotta come past and see this thing in the flesh

bitten by the bug..........several times

rickp Officially Full-On Dubber

200 posts · joined Apr 2010 · 9 Sep 2014, 5:14 pm

#999878

Holy crap! That looks awesome.

Camo Custom Title Time!

1,936 posts · joined Oct 2007 · 14 Dec 2014, 8:26 pm

#1005272

Hi all,

although I have been quite on this forum, I have been busy working on my car every weekend as time permits. I finally got to the point of turning the engine over in attempts to start it 2 weks ago. Well, it was not as easy as I was hoping and I have been conversing with others on the Megasquirt forums and was finally able to start it for the first time today.

This is near the first start up of my new fuel injected, turbo VW engine. Still running very rich as you will see, but now the tuning process will begin.

Cheers, Kev

I thought rebuilding a VW would be cheap - Shit I was wrong, just don't let the wife know !!!!

Click here for my (slowy) modded 1961 Beetle build.

1303Steve Scirocco Rare

8,650 posts · joined Aug 2002 · 14 Dec 2014, 8:51 pm

#1005274

sounds tough as

Camo Custom Title Time!

1,936 posts · joined Oct 2007 · 16 Dec 2014, 2:50 pm

#1005398

Thanks Steve,

may be a bit quiter and sound more tame when I actually have a muffler on there. Here I come Westi, well maybe soon.

Kev

I thought rebuilding a VW would be cheap - Shit I was wrong, just don't let the wife know !!!!

Click here for my (slowy) modded 1961 Beetle build.

AUSSIE_MICK Officially Full-On Dubber

205 posts · joined Jan 2009 · 16 Dec 2014, 2:52 pm

#1005399

So Kev
When will the turn key Turbo Injected Motors go to market? 😁

cnfabo Custom Title Time!

1,353 posts · joined Apr 2008 · 16 Dec 2014, 8:57 pm

#1005415

Hahaha that sounds sick Kev..

Camo Custom Title Time!

1,936 posts · joined Oct 2007 · 16 Feb 2015, 9:27 pm

#1008530

It's DONE, and who would know what is lurking underneath 😁

I thought rebuilding a VW would be cheap - Shit I was wrong, just don't let the wife know !!!!

Click here for my (slowy) modded 1961 Beetle build.

cnfabo Custom Title Time!

1,353 posts · joined Apr 2008 · 16 Feb 2015, 10:06 pm

#1008533

Camo wrote:It's DONE, and who would know what is lurking underneath 😁

Wowsers!!!!!!

waltermitty Legend when my beer goggles are on

1,993 posts · joined Aug 2002 · 16 Feb 2015, 11:33 pm

#1008538

Very nice ,, but it doesn't look like a sleeper.
People will expect you put a Porsche donk in her. Mitchell

23 windows ...8 too many!

AUSSIE_MICK Officially Full-On Dubber

205 posts · joined Jan 2009 · 17 Feb 2015, 5:09 am

#1008539

So now you will have nothing to do with all your free time. Whats next?🙂

Bizarre Moderator The artist formerly known as blue74l

12,789 posts · joined Aug 2002 · 17 Feb 2015, 6:57 am

#1008542

Great work Kev
👍

Futue te ipsum!!!

1303Steve Scirocco Rare

8,650 posts · joined Aug 2002 · 17 Feb 2015, 7:44 am

#1008543

Great work Kev, any numbers on it yet

Yogie Moderator Custom Title Time!

1,608 posts · joined Jun 2003 · 17 Feb 2015, 4:57 pm

#1008561

I love the look of this car as well. I think the orange with those wheels and the stance all seem so right.

Well done.

Yogie

Camo Custom Title Time!

1,936 posts · joined Oct 2007 · 18 Feb 2015, 3:11 pm

#1008594

Thanks everyone.

Mick - spare time, yet right 🙅

Steve - No numbers, still doing some final tuning and need to fix throttle as only getting 52% TPS due to shit worn system 🙁

I must say though, I love driving it. So much smoother with efi and even with half throttle and only seeing about 2psi of boost it starts pulling like a train 😉

Kev

I thought rebuilding a VW would be cheap - Shit I was wrong, just don't let the wife know !!!!

Click here for my (slowy) modded 1961 Beetle build.

1303Steve Scirocco Rare

8,650 posts · joined Aug 2002 · 18 Feb 2015, 4:08 pm

#1008601

Good stuff Kev, cant wait to see it

mandog Learner Dubber

8 posts · joined Dec 2010 · 14 Mar 2015, 9:30 pm

#1009808

Awesome job mate , how's the tuning going ?

Doug Sweetman Nil Bastardo Carborundum

2,128 posts · joined Sep 2002 · 14 Mar 2015, 10:44 pm

#1009814

Wicked.

Camo Custom Title Time!

1,936 posts · joined Oct 2007 · 15 Mar 2015, 10:08 am

#1009824

mandog wrote:Awesome job mate , how's the tuning going ?

Really good. The Megasuirt has a self learning mode which is jsut a matter of driving, but I am using a guy in the states whom is tuning it and has helped in leaps and bounds.

I download the tune and some data logging and send it to him via email and he replies with another tune attachement which I just open in my tuning program. Then when I plug the laptop into the car, it just asks if you want to update the ECU which I do.

Again go and do drivng and auto tune at the same time, again down load this new tune and logging and send back. We have done it about 5 times so far and its going great.

Not bad, tuned for $250. Of course a final tune on a dyno will be best which I will do in the future when I am 100% happy with what we are doing.

Kev

I thought rebuilding a VW would be cheap - Shit I was wrong, just don't let the wife know !!!!

Click here for my (slowy) modded 1961 Beetle build.

vlad01 Compulsive Aussie Vee Dubber

4,270 posts · joined Jun 2010 · 16 Mar 2015, 11:25 pm

#1009941

yep, dyno is the only way to get a proper ignition table dialed in. Thats where the drivability and power will come from.

71 notchback,
Past owner of, 70 NB, 73 SB and 72 FB TLE