2443 Twin turbo street bug project, back on track again.

2443TT · 2007-11-17T12:39:46+00:00

Hi Everybody, Well my 1966 bug has been off the road for more than a year now. What started out as some mild engine changes and a gearbox upgrade (that never eventuated), has turned into a complete rebuild of the car. I've now got the car stripped of its guards, suspension removed, Porsche brakes are gone etc. All that remains is the shell and its sitting on stands. The reason all this happened is that after a few conversations with Rod Penrose, I discovered I needed to change a lot more things to improve the reliability of my setup if I wanted to extract very serious HP from it for any extended period of time. This meant some serious engine changes... which then got a little out of control. The end result of all the parts chasing, machining and custom made parts will be a 2443cc twin turbo'd, twin intercooled engine, water cooled heads, setup for sub 7:1 compression, flanged crank, 4 stage dry sump system, twin plate clutch, around 8500 rpm and potential for about 400-500rwhp. The engine build is on hold till the last of the machining work is finished and will be posted on another thread when it kicks into full swing. Having that much power meant that using a vw gearbox was going to be pretty pointless. I'd been previously trying to source a custom built box from Rancho. That was for the 2332 engine, but as it turned out I would have probably broken that box inside a year anyway. So the only option was to go porsche. 915 boxes are good for about 300hp, or more if you spend money on them. The g50's are massive, and require an absurd amount of cutting away of the chassis from what I've seen of other people cars. Unless I were to go 1/2 or full tube frame chassis, G50 was off the cards. I did come very close to getting a G50 though, and found a 2wd converted 5 speed for $4300 in sydney. But as it turns out Dave Butler had a 930 box. It didnt take much to persuade him to sell it either. These boxes are used in the Ultima GTO's with 500hp small block V8's on them. In stock form they handle 550hp, and with an oil cooler and remote oil pump they are basically the same box used in the 750hp 935 race cars. At last an indestructable gearbox. THe down side is that the ratio's are very high, but that can be fixed with a ratio change down the track. Now with an engine and gearbox sorted, I needed a way to get the power to the ground. It had been my plan to widen the guards and put some very serious rubber under the car. I've had the car that looks stock that goes like a rocket. Now Im going all out, the outward appearance is going to have to have as much intimidation factor as the engine sound will have. To make all this possible I was going to have to completely re-work the suspension on the existing chassis, or just build a new one and start from scratch. I scored a swing axel chassis to use as a donor pan and went about cutting and clearancing for the gearbox. So for suspension I've sourced all 1988 944 Turbo components. These are the widest rear trailing arms made for the 944's and increase the wheel track by around 100mm with the wheels I will be using. The front suspension is going to be converted to a custom Mcpherson strut arrangement using 944 turbo A-Arms, and spindles etc. All the suspension is going to be fully adjustable, so I can set the car up for motokhana or drags. I want the car to handle, stop and go. Anyway enough background... I've spend a few weekends contemplating how to best attack the new chassis and today I started to get serious with it. 930 Gearbox Clearancing My unique approach to an IRS conversion. Front gearbox mount/crossmember, and front torsion housing re-inforcing (the cardboard template). So thats about all for now. I hope to finish the front gearbox mount tomorrow. Im going to try and make regular posts for this build. The goal is to have it finished in 5 months. Cheers, Ian Swinkels

VWFREAK VWFREAK

2,577 posts · joined May 2004 · 15 Apr 2008, 6:52 pm

#641020

The madness continues. When will you learn Ian and stop doing things by halves. lol

Great stuff, your a man possessed.

2443TT Fahrvergnugen

962 posts · joined Dec 2002 · 15 Apr 2008, 9:09 pm

#641048

kroozzn63 wrote:man that is so cool , you must have time on your hands good luck to you ,cant wait to see its shell on ist it gunna be a sleeper or a show pony?

No show pony. I'll be racing the car at 1/4 and 1/8th mile events as well as motorkarna. This build is about taking it as far as I can, and then driving it on the street.

Actually I rarely have any time on my hands. Self employed, on call, and I frequently work stupidly long hours and all weekend. I work on the car when I can though and when am still awake enough to not accidently amputate fingers. Ive had quite a couple of good injuries while working on this project though... Its been fun.

humpty wrote:Whats so special about the brackets that you need to send them to Whiteline to make?.... I have had loads of things laser or water jet cut locally and its a very quick turn around....

The brackets arent special at all and are all of a 1/2 hrs work. The delay is getting the swabars made. Ive cut up some old sway bars and welded them back together so they fit the porsche suspension and clear the gearbox etc. Then they get sent away to whiteline to be used as templates to be re-made from a single piece of spring steel. I cant finish the final mounts that weld to the rear torsion housing, and to the fron A-arm supports till i have the finished bars back here to mount on the car.

So I got stuck into the car again this afternoon.

Brake lines done - check
3/8th supply and return fuel lines done - check
Gearbox reverse selection problem fixed - check
(it was something to do with the detent spring that locks out reverse. Once i took it apart and put it back together it started working again... go figure?)

Im finishing the hydraulic clutch lines tomorrow. I'll post more pics then.

Cheers,
Ian

LIFE IN THE LOW LANE All people have the right to stupidity but some abuse the pr

2,534 posts · joined Mar 2007 · 16 Apr 2008, 10:46 am

#641119

3 weeks wait for custom stuff from witeline isn't that bad. I have waited 5 weeks for strut braces for current model corolla's and about the same time for sway bars as well. they don't keep much stock on the shelf. they make it as the order comes in.

Great work Ian. I always appreciate someone who is doing something different from the norm. We found this doing my brother's Type 3 as there isn't anyone out there putting a 2332 EFI turbo in a type 3 so a lot of stuff is custom made by us or made by fabricators we know. Not to mention the trial and error factor!!! something we have done have been remade a few times cause we weren't happy with the first and even 2nd outcomes of things like brackets and mounts etc.

This will be a very nice car when it's finished with power to boot!!!!

ACCEPT THAT SOME DAYS YOU ARE THE PIDGEON AND SOME DAYS YOU ARE THE STATUE

Alder Outlaws VW Racing - check it out on fb!!

2443TT Fahrvergnugen

962 posts · joined Dec 2002 · 19 Apr 2008, 9:28 pm

#641745

I think Alex Holtz told me about that type 3 with the 2332 turbo a few years ago, is that the same one?

So today I finished the seat mounts and bolted the eats in place. All in all im pretty happy with how the car is looking now.

I also put the gearbox and shifter back in to make sure I could get reverse gear since having investigated why i couldnt select reverse last time. I dont know why i didnt think of it before, but i think 1/2 the problem is the reduce ratio of the shifter I am using. Less throw means more force at the gear stick is needed to select reverse gear, as the spring tension on the reverse lock out is amplified by the reduces ratio of the short shifter. I think i'll be shortening the reverse lock-out spring in the gearbox a little to make it easier to select reverse.

Anyway, here's the pics. Latest updates really are only the seats, brake lines etc. But its nice to see it all together again. Im going to finish the rear lower shock mounts tomorrow and then all that really remains is the hydraulic clutch lines and the anti sway bar mounts.

Cheers,
Ian

pete wood 23 Windows of Awesome

6,828 posts · joined Jan 2004 · 19 Apr 2008, 11:16 pm

#641758

if I didn't know better, I'd swear someone snuck up and hit you with a bat that had the letters "german-look" engraved on it. 😂

BTW, love the strut front, something I dreamt of at one time. 👍

"stoopid is stronger than axles"
http://drivingnotpolishing.blogspot.com.au/

2443TT Fahrvergnugen

962 posts · joined Dec 2002 · 19 Apr 2008, 11:19 pm

#641759

Yeah had the bright red cal-look bug with the 15" fuch's for a few years. Then the sillver body, but the tyres were really never wide enouugh to call it a real german looker, and the king+link + swing axel just cant cut it for a real GL car.

dangerous 23 Windows of Awesome

5,901 posts · joined Jan 2005 · 20 Apr 2008, 6:37 am

#641770

Awesome work Ian!

Back onto the engine soon I gather?

westi wrote:That's mad Alan.

Flintstones Custom Title Time!

1,077 posts · joined Aug 2002 · 20 Apr 2008, 7:27 am

#641771

That should be a fun car to drive!!👍👍
Looks so purposeful.

Cheers

mactaylor Custom Title Time!

1,005 posts · joined Aug 2007 · 20 Apr 2008, 10:47 am

#641787

looks great ian keep up the good work! are you going to trim the rear top shok mounts down or leave them for bump stops?

EVERLAST CONCRETE TANKS
1800 552 123

LIFE IN THE LOW LANE All people have the right to stupidity but some abuse the pr

2,534 posts · joined Mar 2007 · 20 Apr 2008, 6:09 pm

#641825

Hey Ian yep same car. Been a long and expensive trip to get it to be driveable as you would know. Did have the engine together but influenced by others breakages and new products onto the market and all of a sudden we're back at square one. total rebuild and design but getting close. Cranked it over yesterday to check oil system and pressurize fuel system with new pumps etc. Found a couple of small leaks but apart from that all good.

So next step off to the dyno for the install of ECU and get it running!!

Progress is looking good on your front. Almost ready for the engine to take it's place!!

ACCEPT THAT SOME DAYS YOU ARE THE PIDGEON AND SOME DAYS YOU ARE THE STATUE

Alder Outlaws VW Racing - check it out on fb!!

2443TT Fahrvergnugen

962 posts · joined Dec 2002 · 22 Apr 2008, 10:20 pm

#642178

LIFE IN THE LOW LANE wrote:Progress is looking good on your front. Almost ready for the engine to take it's place!!

dangerous wrote:Awesome work Ian!

Back onto the engine soon I gather?

Yes true the engine wont be far away. Im still waiiting on the Rocky Jennings WBX case, though he has sent me some progress pics for it. Im hoping for an update again from him soon. I believe he is custom making the bearings at the moment to allow the T4 center main T1 flanged crank to fit the WBX case.

For the moment i am having to just imagine what it will be like sitting in the drivers seat with 2.5 lt of heavily cam'd turbo'd fury waiting to shred tyres.

Cheers,
Ian

trickysimon 100km/h is only 9 seconds away

1,473 posts · joined Dec 2007 · 20 May 2008, 9:41 pm

#647039

Surely there has been an update in the last month 😂
Come on where are the pics lol
Simon

2443TT Fahrvergnugen

962 posts · joined Dec 2002 · 20 May 2008, 10:29 pm

#647050

Sadly not much im afraid... I did call Fulcrum yesterday and was told that they sometimes take 4 weeks to manufacture custom sway bars (its been 4 weeks now...), and that they will be here when they are here.... in otherwords we are too busy to go chasing part for you at the moment.

On another note i do have some engine pics to share though. These are the first of many to come when the parts arrive from the US. This is the machining of my Rocky Jennings Oxyboxer case. The case is a 2.1 waterboxer converted to air cooled, sleaved lifter bores, and re-located cylinder head stud mount points. Rocky is modifying the case so it will support the flanged 88mm crankshaft, and has made a custom set of bearing to suit. All the main studs are being replaced with raceware studs for extra strength. I will reveal more about the engine build when it starts in about another month or so, safe to say all the parts are 100% VW porn.

The pics...

Engine case should arrive in 2-3 weeks.

66deluxe Custom Title Time!

1,593 posts · joined Aug 2005 · 21 May 2008, 5:14 pm

#647164

Very nice, this engine is going to be mad, always been a fan of the oxy boxer, the best of both type 1 and type 4. Big fan of Rocky Jennings work too.

This is my Volkswagen, there are many like it, but this one is mine. Without me my Volkswagen is useless, without my Volkswagen, I am useless.

61 Karmann Ghia 2110cc type1 w Los Panchito's
66 Deluxe Beetle 2270 type 4
10 Subaru WRX Impreza

JVLRacing Custom Title Time!

1,100 posts · joined Mar 2007 · 28 May 2008, 11:55 am

#648523

just little of topic! wat happen with the motor you done subie heads on vw block?JVL

2443TT Fahrvergnugen

962 posts · joined Dec 2002 · 28 May 2008, 12:02 pm

#648524

Its in storage. Im finishing my own car first before i get stuck back into working on Warren's engine. It will happen next year probably.

JVLRacing Custom Title Time!

1,100 posts · joined Mar 2007 · 28 May 2008, 1:57 pm

#648550

ok! thanks....it got potential!😎

2443TT Fahrvergnugen

962 posts · joined Dec 2002 · 31 May 2008, 10:27 pm

#649219

Well the sway bars still havent arrived yet. I suspect they must be still designing the machine thats going to bend them for me... so ive given up waiting and moved on.

Today the body met the new chassis for the first time. The fit was reasonable... but there is going to be a fair amount of modifications to the rear parcel shelf area to accomodate the 930 gearboxs fat nose cone and gear set. As you can see it will definatly be needing some custom guards.

More to come... Tomorrow im going to get a full days work in on it for a change.

Cheers,
Ian

bond Veteran Volks Folk

2,456 posts · joined Jul 2003 · 31 May 2008, 10:51 pm

#649225

coming along ian! an extre 3" on each gaurd is going to look phat as!

nick

humpty Bishop of Volkswagenism

3,336 posts · joined Sep 2002 · 1 Jun 2008, 12:48 am

#649240

Eeeekkkk!

FUCH your early!

http://www.noh2o.org/

1303Steve Scirocco Rare

8,650 posts · joined Aug 2002 · 1 Jun 2008, 11:18 am

#649288

Hi

Looking good. How did the front suspension improvements fit around the stock body? What ET are your wheels?

Steve

2443TT Fahrvergnugen

962 posts · joined Dec 2002 · 1 Jun 2008, 11:31 am

#649290

Ill take a better pic of the body clearance to the suspension today. There is about 8mm clearence each side, so i guess i measured it just right. Wheelbase is 2400mm and wheel track is 1735mm, the same as a 1988 1944 porsche. I cant remember the wheel offsets off hand... they are 996 twin turbo rims if that helps.

LIFE IN THE LOW LANE All people have the right to stupidity but some abuse the pr

2,534 posts · joined Mar 2007 · 1 Jun 2008, 6:36 pm

#649346

They gonna be some very phat guards there Ian!!

ACCEPT THAT SOME DAYS YOU ARE THE PIDGEON AND SOME DAYS YOU ARE THE STATUE

Alder Outlaws VW Racing - check it out on fb!!

VWCOOL 23 Windows of Awesome

5,158 posts · joined Jun 2003 · 2 Jun 2008, 12:58 pm

#649483

lol.. I reckon you should slice the body down the centre...!

Pay your debts, CxxT

Cam Custom Title Time!

1,535 posts · joined Aug 2002 · 2 Jun 2008, 7:01 pm

#649561

Looking wicked, dude! Makes a nice change from a narrowed front end on a 6 volt-er 😀

trickysimon 100km/h is only 9 seconds away

1,473 posts · joined Dec 2007 · 2 Jun 2008, 8:59 pm

#649612

Tomorrow im going to get a full days work in on it for a change.

Any interesting pics? 😵

Simon

westi what the

1,610 posts · joined Aug 2005 · 2 Jun 2008, 9:26 pm

#649627

yeh i agree,cut her down the middle.
i love to cut.i 'll give ya hand .cut cut cut.
lol
keep up the good work.

down sharon.

2443TT Fahrvergnugen

962 posts · joined Dec 2002 · 2 Jun 2008, 10:03 pm

#649646

Sorry nothing new to report... Hardly got any work done on sunday despite my plans to spend the whole day on the car. Good news is that im taking 1/2 of tomorrow off so i can finish the trial fit.

At the moment its still sitting about 4cm high in the back as the later model style rear chassis-body mounts sit higher than the earlier model chassis's. The rear shock mount cross bar is fouling on the parcel shelf a little too which is no big deal.

westi wrote:yeh i agree,cut her down the middle.
i love to cut.i 'll give ya hand .cut cut cut.
lol
keep up the good work.

Hmmm... I think that between what ive done with this car now, and what youve done to yours Westi, I am sure there isnt a purist on the forum that we havent pissed off!

I think i prefer the wide fender look though... This is how wide it should look when done. 4" widened all round.

Cheers,
Ian

westi what the

1,610 posts · joined Aug 2005 · 2 Jun 2008, 10:06 pm

#649652

nice one.
if you think we have pissed off a few purists.what till i star my 21 window.you will hear shreeck's of discust the whole world over.i can wait.

down sharon.

trickysimon 100km/h is only 9 seconds away

1,473 posts · joined Dec 2007 · 2 Jun 2008, 10:22 pm

#649658

What would a purist be doing on the drag racing forum? 😂

Simon