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

reub VWRX is gone...

2,054 posts · joined Sep 2002 · 21 Sep 2008, 6:47 pm

#670550

Looking good dude...
Bring on the updates...and the painted car!

Reub

trickysimon 100km/h is only 9 seconds away

1,473 posts · joined Dec 2007 · 21 Sep 2008, 7:28 pm

#670562

You sure wern't joking when you named it Project No Budget 😂
Simon

bond Veteran Volks Folk

2,456 posts · joined Jul 2003 · 21 Sep 2008, 9:25 pm

#670590

an iron cross ian?

gaurds look awesome!

nick

2443TT Fahrvergnugen

962 posts · joined Dec 2002 · 21 Sep 2008, 10:13 pm

#670600

bond wrote:an iron cross ian?

gaurds look awesome!

nick

Yep, its a Blitzkrieg racing iron cross badge. They are billet alloy polished and look pretty cool. Goes to show how dusty the car was that you can still see the iron cross with the badge removed...

2443TT Fahrvergnugen

962 posts · joined Dec 2002 · 23 Sep 2008, 6:27 pm

#670963

Hey all,

Another progress update. Only one guard left to sort out now and they will be ready for a coat of high build polyester primer. Then the whole car will be wet rubbed, primed wet rubbed again etc...

My panel beater has been worked the edge of the body where it meets the guards flat again so there is a no gap between the guards. The idea is to have a perfect fit finish and no need to instal the fender beading for a super clean fit. New tail lights arrived from Vintage Vee Dub today too just in time to be fitted. (Free plug, please give me a discount next time I call).

Ive decided on a colour too. Atlas Grey. Its a very dark nearly black grey metalic used on the porsche carrera gt's.

So here are the pics...

Had a couple of boxes arrive from Carillo and CSP today too, containing the last of the engine parts.

Thats all for now...

Ian

1303Steve Scirocco Rare

8,650 posts · joined Aug 2002 · 23 Sep 2008, 7:33 pm

#670984

Hi

Looking good, I liked the colour your car was. Some silvers look very flat when photographed, yours didn't.

Steve

2443TT Fahrvergnugen

962 posts · joined Dec 2002 · 23 Sep 2008, 7:43 pm

#670991

My panel guy says its all to do with how its applied. When the arctic silver was sprayed on first it looked great. But the touch ups that were done stuffed the whole finish of the car.

Aparently to lay a metalic properly a thin black base goes on first. Then the first base colour coat. Then a second base colour coat goes on as a thin and dry (dusted) layer. This causes the metalic flake to really stand up. Then the clear coats. The best paint in the world will look like crap if applied by a monkey and it was all PPG last time. Its going to be standox this time, which is as good if not better than ppg.

I really liked the arctic silver it was too, but that whole drama I went through with getting the respray done to fix the flaws (and there was quite a few), having them re-spray the whole car again, intruduce more flaws than it had the first time around, manage to get dust through the clear coat from the back to 1/2 way to the front of the car, strip bolts and bend panels... I am just over it. Sure it did look good to anyone that looked at it last time but I knew where the flaws where. I'd hand assembled the whole car from scratch.

Should the panel beaters that sprayed the car last time see it again, they will know for sure that its not their work thats winning a trophy. Plus the whole look of the car is changing this time too. Fenderless, no chrome, satin black headlight trim, indicator trim and door handles and running boards, and tinted tail lights. Last time it was a sleeper, this time its going to look menacing.

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

2,534 posts · joined Mar 2007 · 23 Sep 2008, 7:55 pm

#670998

Looking good Ian. Can't wait to see it with some colour on it!!

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

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

reub VWRX is gone...

2,054 posts · joined Sep 2002 · 23 Sep 2008, 9:44 pm

#671037

Running bumpers?? 👍

Reub

2443TT Fahrvergnugen

962 posts · joined Dec 2002 · 23 Sep 2008, 9:49 pm

#671039

No way dude, bumperless! Just going to have a bracket coming out one of the bumper mount slot that will have a number plate attached to it.

reub VWRX is gone...

2,054 posts · joined Sep 2002 · 23 Sep 2008, 9:50 pm

#671040

2443TT wrote:No way dude, bumperless! Just going to have a bracket coming out one of the bumper mount slot that will have a number plate attached to it.

Sweet 😎

Reub

2443TT Fahrvergnugen

962 posts · joined Dec 2002 · 26 Sep 2008, 8:29 pm

#671590

Hi everyone,

Update time... The bodywork is now for the most part sorted out. The fitment of the guards is now perfect. They are going to be hit with a coat of polyester spray putty to sort them out 100% next week though as there are still a few minor bumps that need to be sorted.

The car had a few low and high spots on panels and the doors that needed to be rubbed back wiith a propper flat sanding block. The more work that has been done to the car this week, the more flaws we found that needed to be repaired. I was hoping for the car to be in primer by friday evening but id rather have less flaws in the body than be further along toward having it painted than I presently am.

The luggage compartment lid handle is now shaved, and the old holes for the previous mirrors have been welded up and smoothed over too.

So here are the pics as it is now.

Cheers,
Ian

Golde60 Fahrvergnugen

858 posts · joined Aug 2002 · 27 Sep 2008, 10:05 pm

#671753

looking good

...................( O \ l / O ).....................

trickysimon 100km/h is only 9 seconds away

1,473 posts · joined Dec 2007 · 28 Sep 2008, 2:38 am

#671775

You def need to grab that rice spoiler off the car in front!
Simon

2443TT Fahrvergnugen

962 posts · joined Dec 2002 · 28 Sep 2008, 8:39 am

#671794

trickysimon wrote:You def need to grab that rice spoiler off the car in front!
Simon

You mean my GTR? Thats not a rice spoiler... its a factory N1 R33 bumper and lip spoiler.

trickysimon 100km/h is only 9 seconds away

1,473 posts · joined Dec 2007 · 28 Sep 2008, 9:51 am

#671799

Oops 🤪
I actually like skylines, the tailights threw me off. Thought it was a Lancer or Honda.
Isnt your skyline white?
Simon

2443TT Fahrvergnugen

962 posts · joined Dec 2002 · 28 Sep 2008, 7:09 pm

#671862

LOL your right! I forgot all about the lancer in the driveway and didnt even realise it was in the photo's. And yes the rice wing is huge on it. Its my panel beaters girlfriends car. Not my style either, and to the dusgust of many of the local import croud it continues to win top jap trophies at the car shows because of the custom paint too. Yes my skyline is still white as per my signature pic...

Made a little progress on the car today, but spent most of the time making my garage water ready for when the wet rubbing starts. Ive glued a rubber strip to the floor the length of the garage to divert water, and have moved most of the stuff that cant get wet so nothing exciting to report as yet. At the current rate it will be in colour by thursday or friday. Im going to see about renting a booth tomorrow.

Cheers,
Ian

2443TT Fahrvergnugen

962 posts · joined Dec 2002 · 29 Sep 2008, 7:08 pm

#672055

Hey alll,

The bug is in primer at last. Just the body for starters. My wimpy air compressor wasnt up to the task of blowing the polyester spray putty through a spray gun, which is the high fill coat thats going on the guards before they are given a coat of standox primer. The body is now ready for a wet rub inside and out which will happen tomorrow.

I arranged a spray booth for thursday and friday, so all going well and weather permitting, the inside will have a coat of base colour on it wednesday afternoon, then the body onto the chassis and over to a booth where everything will be given its final colour and clear coats.

Here are the pics.

Cheers,
Ian

2443TT Fahrvergnugen

962 posts · joined Dec 2002 · 1 Oct 2008, 6:21 pm

#672507

Hi all,

Some colour at last! The interior of the car is now painted and cleared. Its a hard to photograph colour because in my garage with the bad light it looks black without a flash, and with it changes colour completely. Basicly looks like dark gun metal in bright light and under lights you see a blue pearl with gold metalic.

Here are the pics...

Tomorrow is a day of wet rubbing and then its back on the chassis and off to the booth for painting friday.

I am so stoned from breathing paint fumes...😂

Cheers,
Ian

Turbo54 Veteran Volks Folk

2,220 posts · joined Jul 2004 · 1 Oct 2008, 6:58 pm

#672513

Looks killer mate, Needs STELTH number plates. I had a feeling it would go dark. It's going to be a mean car when your done.
T54

C'mon kids gather round,
there's a new sensation hitting town,
It's moving straight, low to the ground,
it'll pick you up when your feeling down.

Flintstones Custom Title Time!

1,077 posts · joined Aug 2002 · 1 Oct 2008, 8:38 pm

#672540

Looking good Ian,
Can't wait to see it finished!!

Cheers
Dino

trickysimon 100km/h is only 9 seconds away

1,473 posts · joined Dec 2007 · 1 Oct 2008, 8:46 pm

#672543

Looks good. So I'm guessing it will be ready for warwick this weekend? 😂
Simon

reub VWRX is gone...

2,054 posts · joined Sep 2002 · 1 Oct 2008, 8:49 pm

#672545

DUUUUUUUUUUUUDE.... going to be sex when finished. That is an awesome colour👍

Reub

JVLRacing Custom Title Time!

1,100 posts · joined Mar 2007 · 1 Oct 2008, 8:57 pm

#672547

my popcorn taste nice😎NICE

volkdent Learner Dubber

15 posts · joined May 2005 · 2 Oct 2008, 4:29 am

#672609

Really looking great, jealous of your straight body!!! Keep up the amazing work.

Jason

If I could just get paid for my sleepless nights....
2008 BMW 335i
2001 BMW M3 'Vert
1998 BMW M3 Sedan
1960 VW Bug Bad Dub Racing

2443TT Fahrvergnugen

962 posts · joined Dec 2002 · 2 Oct 2008, 5:58 pm

#672700

Thanks for the comments guys. The STEALTH and STELTH QLD plates are already taken... Im not sure how appropriate a plate it would be for it too considering the complete engine recipe can rev safely to 9000 rpm now, and will probably be running a 3" exhaust out each side of the car. Not terribly stealthy at all.

Today saw the completion of the rubbing back of the polyester spray putty on the guards, and the car is now had its first rub down with 400 wet on all the primered surfaces. It wont be in the booth tomorrow though. I was a little over ambitious thinking that was going to be possible. I think taking it slow now will produce a far better result later. So 600 and then 800 wet rubbing tomorrow, and the guards will get a coat of standox primer and a final rub as well. I think it will be in the booth tuesday or wednesday next week realisticly.

Today's pics...

Cheers,
Ian

2443TT Fahrvergnugen

962 posts · joined Dec 2002 · 7 Oct 2008, 7:07 pm

#673568

The spray booth is scheduled for thursday, so tomorrow is going to be just a final check over for the whole car. Its all 100% prepped. I put the shell on the chassis this afternoon and bolted it on with 4 bolts for the trip to the paint shop on the back of a flat bed truck come thursday.

Ive had my first oh crap moment with the chassis too. The last thing I welded onto the chassis was the front body mounts that support the body just under the fuel tank. While i double checked it before I welded the mount into place, I forgot to account for the 10mm rubber cushons that go between the mount and the body. So its not so bad though. Nothing a cut off wheel wont fix and I can easily sort that out after its painted.

The body comes off the pan for the paint job, then goes back on for transport to my home again. Then off again to have the finishing work done, that being 1200 sand and buff (allowing me to fix the front body mount on the chassis too). Then finally back on again.

Here are the latest pics.

Cheers,

Ian

humpty Bishop of Volkswagenism

3,336 posts · joined Sep 2002 · 7 Oct 2008, 7:16 pm

#673569

Your a bloody nutter Ian...
Not to my taste, but bloody awesome work....
I can not comprehend the level of work you have put into this machine...
I'm sure it will be an awesome no compromise street car!!
Bring on the track videos!

FUCH your early!

http://www.noh2o.org/

2443TT Fahrvergnugen

962 posts · joined Dec 2002 · 8 Oct 2008, 5:52 pm

#673736

And the irony is that I do work on cars to keep me sane. I find this sort of thing relaxing...

Today the car was wheeled into the back yard to give it a final clean and check over before it sees the booth tomorrow. Here's a few more pics.

The next pics will be of the car in full colour! Woo Hoo!

Cheers,
Ian

reub VWRX is gone...

2,054 posts · joined Sep 2002 · 8 Oct 2008, 5:56 pm

#673737

DUDE!!!
Hanging out to see more pics tomorrow!!!...looking sweet

Reub