2443TT Fahrvergnugen
962 posts · joined Dec 2002 ·
last pic...
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She\'s coming together at last!
nbturbo Veteran Volks Folk
2,171 posts · joined Dec 2002 ·
Did you take any pics of your throttle bodies and injectors mounted?Would be keen to see some if you did.
2443TT Fahrvergnugen
962 posts · joined Dec 2002 ·
Here's a pic of the throttle bodies. I thought the method that CB performance used to hold the injectors in kind of sucked, so I cam up with this idea.
The fuel rails have a threaded hole between the injectors. There is an allen head bolt that is locktighted into the rail that pulls the injector rail down to an aluminium block.
The aluminium block is about 6mm thick and has a hole in each end. One end for the allen head bolt to pull the fuel rail downwards, holding in the injectors. The other end bolts onto the bottom of the throttle body to manifold bolt for the number 3 cylinder.
The hardest part (not realy difficult at all), was to shave a little off the bottom of the manifold flange next to the bolt so as to get the correct height for holding the injectors in place.
It works perfectly, and is much more stable than CB's method that used the same aluminium block to hold the fuel rail in from the top.
I hope this helps.
Cheers,
The fuel rails have a threaded hole between the injectors. There is an allen head bolt that is locktighted into the rail that pulls the injector rail down to an aluminium block.
The aluminium block is about 6mm thick and has a hole in each end. One end for the allen head bolt to pull the fuel rail downwards, holding in the injectors. The other end bolts onto the bottom of the throttle body to manifold bolt for the number 3 cylinder.
The hardest part (not realy difficult at all), was to shave a little off the bottom of the manifold flange next to the bolt so as to get the correct height for holding the injectors in place.
It works perfectly, and is much more stable than CB's method that used the same aluminium block to hold the fuel rail in from the top.
I hope this helps.
Cheers,
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2443TT Fahrvergnugen
962 posts · joined Dec 2002 ·
Well here's the latest pics. The car is drivable at last! I've driven it to work for the past two days, which is a good thing becasue I was getting sick of the push bike...
The car still needs a rear bumper, and some more custom work to get the carbon fiber engine lid to fit.
These photo's were taken late in the afternoon, not realy an ideal time of the day to take pictures as it gave the silver a kind of yellow tinge from some angles.
Well enough talk... here's the pictures.
Cheers,
The car still needs a rear bumper, and some more custom work to get the carbon fiber engine lid to fit.
These photo's were taken late in the afternoon, not realy an ideal time of the day to take pictures as it gave the silver a kind of yellow tinge from some angles.
Well enough talk... here's the pictures.
Cheers,
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2443TT Fahrvergnugen
962 posts · joined Dec 2002 ·
Another pic.
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2443TT Fahrvergnugen
962 posts · joined Dec 2002 ·
Last one for the moment...
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nbturbo Veteran Volks Folk
2,171 posts · joined Dec 2002 ·
Thanks-I can't quite work out whats going on there from the pic.A very close up shot.It all looks like it is very compact and neat though.Do you have any from different angles?
Midlife crisis Nartispuddlejumper, Bureau of Toxicity
2,282 posts · joined May 2003 ·
very sweet drive
If you can't laugh at yourself you can't laugh at anyone else! Because life is to short not to LAUGH
pyr0 flame-on
4,457 posts · joined Mar 2003 ·
damn thats smooth turned out great 😎
Founding member of the C'town Rat-Pack
2443TT Fahrvergnugen
962 posts · joined Dec 2002 ·
Here's another attempt for an explanation of the injector rail system I'm using... excuse my lack of artistic tallent....
Thanks for the feedback everyone. I'll hopefully have some of the rear end of the car with the CF engine lid by monday. I am SO looking forward to having it finished...
Cheers,
[Edited on 12-8-2004 by iswinkels]
Thanks for the feedback everyone. I'll hopefully have some of the rear end of the car with the CF engine lid by monday. I am SO looking forward to having it finished...
Cheers,
[Edited on 12-8-2004 by iswinkels]
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nbturbo Veteran Volks Folk
2,171 posts · joined Dec 2002 ·
Thanks-I think I'm onto it now.It's a good looking set up.I havn't seen any aftermarket systems with the injectors in the manifold-they are normally in the base of the throttle bodies.Are the throttle bodies from CB as well.What size are they and how many $$.Do they have provision for a TPS.
2443TT Fahrvergnugen
962 posts · joined Dec 2002 ·
Yep the injectors are normally in the manifolds on the CB manifolds as well as the original port injected vw's. There are kits such as one that Turbo City released that is throttle body injection, but i'd guess that was done more out of cost saving rather than from a performance angle. It allowed them to cheaply adapt hardware from other cars.
The throttle bodies do have bosses that can be drilled to allow fitment of another 4 injectors, to allow 8 injectors to be run. I "might" go this way myself and run another set of 4 370cc injectors, instead of upgrading to 550 cc injectors, as my EFI computer supports injector staging. This allows me the benefit of small injectors for low end economy, as well as the necessary flow for big HP.
The throttle bodies i'm using from CB are 48mm, which is pretty massive, but now i've got my linkage setup properly the throttle control is light and not overly sensative (controlable at low speed).
I hope this all makes sense.
Cheers,
The throttle bodies do have bosses that can be drilled to allow fitment of another 4 injectors, to allow 8 injectors to be run. I "might" go this way myself and run another set of 4 370cc injectors, instead of upgrading to 550 cc injectors, as my EFI computer supports injector staging. This allows me the benefit of small injectors for low end economy, as well as the necessary flow for big HP.
The throttle bodies i'm using from CB are 48mm, which is pretty massive, but now i've got my linkage setup properly the throttle control is light and not overly sensative (controlable at low speed).
I hope this all makes sense.
Cheers,
gayanne Officially Full-On Dubber
307 posts · joined May 2004 ·
Looks good Iswinkels,whos doing the carbon fibre work for you?and do you have a picture of the decklid. JVLRacing
2443TT Fahrvergnugen
962 posts · joined Dec 2002 ·
I got one from Luke... can't remember his last name. Its very good quality but sits low in the middle. Fortunatly I have an original W steel decklid that I am making up some carbon fiber ribs in. These will then be removed from the steelie, and glued into the CF lid. That will pull it in to shape.
I'll post some pictures of that process too shortly.
Cheers,
I'll post some pictures of that process too shortly.
Cheers,
BiX Veteran Volks Folk
2,499 posts · joined Sep 2002 ·
that looks very sweet, love all the wiring being exposed and stuff. I want that car, so where do you live again?
I have no sympathy for my car, only the wallet that pays for it!
Go hard or go home!!!!
Go hard or go home!!!!
gayanne Officially Full-On Dubber
307 posts · joined May 2004 ·
iswinkels wrote:I got one from Luke... can't remember his last name. Its very good quality but sits low in the middle. Fortunatly I have an original W steel decklid that I am making up some carbon fiber ribs in. These will then be removed from the steelie, and glued into the CF lid. That will pull it in to shape.
I'll post some pictures of that process too shortly.
thanks for that, they are my carbon fibre bootlids that i had made from my mould which i supplied to luke its the same on my racecar.Looking forward to seeing it on .JVLRacing
[Edited on 13-8-2004 by gayanne]
2443TT Fahrvergnugen
962 posts · joined Dec 2002 ·
And here goes a little carbon fiber...
As I mentioned earlier I have a carbon fiber W engine lid, but it doesn't quite fit. The curve of the lid doesn't accurately follow the contour of the car.
My solution has been to make a rib out of carbon fiber/fiberglass to pull the engine lid back into shape. I am fortunate to have an original steel W decklid to make up the rib in. Then all that will remain is shaping the rib and glueing it into the CF engine lid... In theory...
Here's a pic of the cf rib being glued together. I've used a sheet of thin 0.3mm resin impreginated 100% carbon fibre cut into strips to make the rib. The strips were then glued togeter in a laminated fashon with gaps in between.
[Edited on 21-8-2004 by iswinkels]
As I mentioned earlier I have a carbon fiber W engine lid, but it doesn't quite fit. The curve of the lid doesn't accurately follow the contour of the car.
My solution has been to make a rib out of carbon fiber/fiberglass to pull the engine lid back into shape. I am fortunate to have an original steel W decklid to make up the rib in. Then all that will remain is shaping the rib and glueing it into the CF engine lid... In theory...
Here's a pic of the cf rib being glued together. I've used a sheet of thin 0.3mm resin impreginated 100% carbon fibre cut into strips to make the rib. The strips were then glued togeter in a laminated fashon with gaps in between.
[Edited on 21-8-2004 by iswinkels]
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2443TT Fahrvergnugen
962 posts · joined Dec 2002 ·
Next i reinforced the rib with fiberglass, and created a wide base to allow it to be glued into the CF decklid. After a little glassing and shaping, the end result is a rib that is very rigid , yet has a low profile and will not foul on the engine.
After lining up the rib I glued one side, then the other using reinforced fiberglass body filler as the glue. in both cases I used a clamp to hold the rib in place.
After lining up the rib I glued one side, then the other using reinforced fiberglass body filler as the glue. in both cases I used a clamp to hold the rib in place.
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2443TT Fahrvergnugen
962 posts · joined Dec 2002 ·
One side glued...
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2443TT Fahrvergnugen
962 posts · joined Dec 2002 ·
And then the other....
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2443TT Fahrvergnugen
962 posts · joined Dec 2002 ·
Next is the hard part... hinges....
I cut a pair of good hinges out of a steel engine lid and went about making up mounts for them out of carbon fiber sheet. With the basic shape correct, I drilled holes and mounted the hinges.
I then back filled the entire mount with reinforced filler. Yes its a little on the overkill side, but I need the surface to have it glue properly to the CF lid. 0.3mm carbon fiber glued at a 90 degree angle to the lid would otherwise not hold.
I didn't take pictures of this stage... as I wasn't sure it was actually going to work out. Fortunently it did.... and here's the pics...
I cut a pair of good hinges out of a steel engine lid and went about making up mounts for them out of carbon fiber sheet. With the basic shape correct, I drilled holes and mounted the hinges.
I then back filled the entire mount with reinforced filler. Yes its a little on the overkill side, but I need the surface to have it glue properly to the CF lid. 0.3mm carbon fiber glued at a 90 degree angle to the lid would otherwise not hold.
I didn't take pictures of this stage... as I wasn't sure it was actually going to work out. Fortunently it did.... and here's the pics...
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2443TT Fahrvergnugen
962 posts · joined Dec 2002 ·
After some careful measurements and a trial fitment usng thin double sided tape to hold it all in place I then glued the hinges to the decklid.
With both hinges glued on, i then trial fitted the lid and it is dam near perfect. Here's a pic of the hinge gluing...
With both hinges glued on, i then trial fitted the lid and it is dam near perfect. Here's a pic of the hinge gluing...
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2443TT Fahrvergnugen
962 posts · joined Dec 2002 ·
Next and again after measuring everthing 5 times I carefully drilled the hole for the engine lid T handle. I drilled the hole smaller than it needed to be, and then used a fine grinding bit to machine out the oval hole.
This was done because anyone that has ever tried to drill carbon fiber will know that the drill bit has a tendancy to want to follow the grain of the CF. This results in the hole moving from where you want it to be, and if your realy un-lucky you can tear the carbon and rip a massive hole in it.
After making an oval hole for the T handle sleve I then wrapped the sleve (chrome bit that goes aroung the T handle) in thin tape and pushed it into the hole. Fiberglass resin does not stick to this plastic tape.
To support the t handle it is necessary to re-inforce that section to be about 5-6mm thick. To do this is built the area up with fiberglass. When it sets I can then remove the chrome bit, remove the tape and then have a perfect fit. I've also re-inforced around the rib a little, just to be in the safe side.
And here's a picture...
This was done because anyone that has ever tried to drill carbon fiber will know that the drill bit has a tendancy to want to follow the grain of the CF. This results in the hole moving from where you want it to be, and if your realy un-lucky you can tear the carbon and rip a massive hole in it.
After making an oval hole for the T handle sleve I then wrapped the sleve (chrome bit that goes aroung the T handle) in thin tape and pushed it into the hole. Fiberglass resin does not stick to this plastic tape.
To support the t handle it is necessary to re-inforce that section to be about 5-6mm thick. To do this is built the area up with fiberglass. When it sets I can then remove the chrome bit, remove the tape and then have a perfect fit. I've also re-inforced around the rib a little, just to be in the safe side.
And here's a picture...
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Cam Custom Title Time!
1,535 posts · joined Aug 2002 ·
dude that engine lid looks mad! Are you going to keep it bare or paint it?
Dave_Bugz Commited Dubber
51 posts · joined Aug 2004 ·
how much have you spent dare I ask?
why dont chicks did bugs? dam ricers have no class 🙂
2443TT Fahrvergnugen
962 posts · joined Dec 2002 ·
And here's the finished result! Sweeeet I'm pretty happy with how the car's looking now. Just need to put on the passenger side mirror and the bonnet VW badge and the exterior trim will be nearly finished.
Filled up at a servo last week and after paying came out and there was a group of 6 people around the car. It is certinly getting some attention.
Still got tons to do with the interior. Soundproofing, headliner and tidying up the wiring.
[Edited on 22-8-2004 by iswinkels]
Filled up at a servo last week and after paying came out and there was a group of 6 people around the car. It is certinly getting some attention.
Still got tons to do with the interior. Soundproofing, headliner and tidying up the wiring.
[Edited on 22-8-2004 by iswinkels]
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2443TT Fahrvergnugen
962 posts · joined Dec 2002 ·
And here's another...
Oh, and about what the car has cost... I prefer to say that real VW enthuesiests don't keep recepts. If I had to guess I'd say around 30-35K. Something around that....
[Edited on 22-8-2004 by iswinkels]
Oh, and about what the car has cost... I prefer to say that real VW enthuesiests don't keep recepts. If I had to guess I'd say around 30-35K. Something around that....
[Edited on 22-8-2004 by iswinkels]
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AdrianH Officially Full-On Dubber
257 posts · joined Mar 2004 ·
Ian,
Have you got the new engine in there ? - I cant belive how quickly you got it all together, awesome job !!
Adrian
Have you got the new engine in there ? - I cant belive how quickly you got it all together, awesome job !!
Adrian
Gibbo Custom Title Time!
1,685 posts · joined Jun 2004 ·
That is a seriously smooth ride my man, a huge pat on the back for you.
Its a credit to all your hard work.
Its a credit to all your hard work.
reub VWRX is gone...
2,054 posts · joined Sep 2002 ·
Looks great mate.....good idea getting the lid and how you ended up mounting it hey.....😀
Reub