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

cram Officially Full-On Dubber

368 posts · joined Jan 2005 · 8 Oct 2008, 6:21 pm

#673745

Awesome work Ian!
Inspirational stuff.

mountainbug LindaLop

183 posts · joined Nov 2002 · 8 Oct 2008, 8:31 pm

#673785

Mate... grand proportions.. You are raising the bar even higher.. Well Done.... A bit like daz on steroids
Cheers
Johno

555bug WRX Bug Boy

1,123 posts · joined Aug 2002 · 8 Oct 2008, 9:25 pm

#673795

it come a bloody long way since I was up North last many years ago 🙂 Its a credit to you

hellbugged 48's and straight cuts

5,080 posts · joined Apr 2003 · 8 Oct 2008, 9:34 pm

#673796

bring on tomorrow!

unbelievable vision and persistance.......kudos

1303Steve Scirocco Rare

8,650 posts · joined Aug 2002 · 8 Oct 2008, 9:48 pm

#673803

Hi

It looks fast standing still. Great work.

Steve

2443TT Fahrvergnugen

962 posts · joined Dec 2002 · 9 Oct 2008, 6:03 pm

#673903

Atlas Grey at last! Today was insane juggling work and getting the car to the booth, off the chassis etc. But its done now.

The finish came up very nice. As i do this post the paint is still wet.

She is sleeping in the booth tonight. The paint will be checked over closely when back home, touched up, interior polished etc before assembly. Then the real work starts!

Enjoy!

Cheers,
Ian

trickysimon 100km/h is only 9 seconds away

1,473 posts · joined Dec 2007 · 9 Oct 2008, 6:07 pm

#673905

Wow talk about shiny 👍
Bet thats gunna look tough when its finished.
Simon

JVLRacing Custom Title Time!

1,100 posts · joined Mar 2007 · 9 Oct 2008, 6:09 pm

#673906

Dont scratch it😎

Dasdubber DAS Resto Haus

5,746 posts · joined Aug 2002 · 9 Oct 2008, 6:20 pm

#673907

Mmmm, I can smell the clear coat from here! Looks great Ian, keep up the awesome work.
Al

www.dasrestoparts.com.au

reub VWRX is gone...

2,054 posts · joined Sep 2002 · 9 Oct 2008, 6:26 pm

#673909

SWEET👍

Reub

555bug WRX Bug Boy

1,123 posts · joined Aug 2002 · 9 Oct 2008, 8:27 pm

#673936

👍

vassy66T1 Wow ... are U reading this?

2,120 posts · joined Jun 2003 · 9 Oct 2008, 8:50 pm

#673940

Looking fantastic!!!

Well done!!

Flintstones Custom Title Time!

1,077 posts · joined Aug 2002 · 9 Oct 2008, 10:44 pm

#673975

Man, that is such a nice colour on the dub!!
Cheers
Dino

humpty Bishop of Volkswagenism

3,336 posts · joined Sep 2002 · 9 Oct 2008, 11:06 pm

#673979

Speechless...

FUCH your early!

http://www.noh2o.org/

StenGuns Veteran Volks Folk

2,147 posts · joined Mar 2004 · 10 Oct 2008, 5:39 am

#673988

Outstanding

dangerous 23 Windows of Awesome

5,901 posts · joined Jan 2005 · 10 Oct 2008, 6:32 am

#673991

Nice work Ian,
now for the engine porn!......

westi wrote:That's mad Alan.

Cam Custom Title Time!

1,535 posts · joined Aug 2002 · 10 Oct 2008, 9:31 am

#674025

dangerous wrote:Nice work Ian,
now for the engine porn!......

What he said 😀

volkdent Learner Dubber

15 posts · joined May 2005 · 10 Oct 2008, 10:14 am

#674029

Gorgeous!!! I need a cigarette....🤪

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 · 10 Oct 2008, 12:37 pm

#674051

Thanks for the feedback guys!

Got it back on the chassis and home again this morning. There is still more to do to the paint yet. Its going to be de-nibbed and have the interior polished before I go instlaling the dashboard and interior again. The body comes off the pan one more time to make doing the final work easier.

Here are a few pictures...

Im exhausted. Its been a long week juggling work and arranging this to happen at the same time. Engine build isnt far away... Just waiting on conrod bearings from Rod, and i need to clean my workshop out too. Everything has a layer of dust on it.

Cheers,
Ian

bond Veteran Volks Folk

2,456 posts · joined Jul 2003 · 10 Oct 2008, 12:51 pm

#674053

ian - any mock up shots with the fenders on as yet?!

can't wait.

nick

2443TT Fahrvergnugen

962 posts · joined Dec 2002 · 10 Oct 2008, 1:44 pm

#674061

Not as yet Nick. I still need to let the paint harden up properly. I'll probably hang the front fenders monday but the rears will stay off as will the rear apron for a while to allow engine fittment, exhaust header fabrication etc. I am geting pretty psyched about getting it running though! Early-mid December is the goal.

STOCK Wolfsburg Wizard

446 posts · joined Apr 2008 · 10 Oct 2008, 2:04 pm

#674066

WOW , WOW , WOW ,
IF MY NEXT PROJECT LOOKS HALF AS GOOD
ID BE STOKED
UNREAL JOB MATE
👍👍👍

🤘
STOCK

063bug

0 posts · joined Feb 2005 · 10 Oct 2008, 3:17 pm

#674084

.... awesome 👍

humpty Bishop of Volkswagenism

3,336 posts · joined Sep 2002 · 10 Oct 2008, 7:38 pm

#674150

Far out that paint looks awesome...
Its amazing how quick your paint shop turn-around was.... It pays to have good prep I guess...
You gonna leave the rims the same colour or paint them?

FUCH your early!

http://www.noh2o.org/

2443TT Fahrvergnugen

962 posts · joined Dec 2002 · 10 Oct 2008, 8:19 pm

#674157

I employed a friend that is a spray painter/panel beater nearly the the past 3 weeks. Then we rented a booth from a local panel shop that my mate new well. We had to supply all our own materials and do all the labour. The shop supplied air, light and the booth for $200. Its a good way of doing it if you can find the time to do all the hard work yourself. The amount of errands ive run this past week is nuts. Ive driven an extra 100km in round town traffic just going out collecting small items. Might not sound like much but I actually live about 5 minutes from evey place I went in the middle of the industrial area.

For the moment the rims will remain factory colour. I have some nice gold crest centercaps in my other set of rims that these will inherit too. I'd really like to send up with a set of 18" 3 piece RS rims on it at some stage. I dont think i'll go messing with the factory rims since they do go pretty good with the colour anyway.

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

2,534 posts · joined Mar 2007 · 10 Oct 2008, 9:29 pm

#674168

Absolutely awesome Ian. starting to see the light at the end of the tunnel yet??

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

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

MickH Hairy Gutted Sloth

3,389 posts · joined Sep 2003 · 11 Oct 2008, 12:24 am

#674185

You need your number plates to be "SUBTLE"...like in as subtle as a brick.....nothing stelth about it!! Awsome job!!!!

tssnq.com.au

reub VWRX is gone...

2,054 posts · joined Sep 2002 · 11 Oct 2008, 10:23 am

#674230

2443TT wrote:I employed a friend that is a spray painter/panel beater nearly the the past 3 weeks. Then we rented a booth from a local panel shop that my mate new well. We had to supply all our own materials and do all the labour. The shop supplied air, light and the booth for $200. Its a good way of doing it if you can find the time to do all the hard work yourself. The amount of errands ive run this past week is nuts. Ive driven an extra 100km in round town traffic just going out collecting small items. Might not sound like much but I actually live about 5 minutes from evey place I went in the middle of the industrial area.

For the moment the rims will remain factory colour. I have some nice gold crest centercaps in my other set of rims that these will inherit too. I'd really like to send up with a set of 18" 3 piece RS rims on it at some stage. I dont think i'll go messing with the factory rims since they do go pretty good with the colour anyway.

😂 that sounds very familiar dude...

Reub

humpty Bishop of Volkswagenism

3,336 posts · joined Sep 2002 · 11 Oct 2008, 11:59 am

#674245

reub-revhead wrote:
2443TT wrote:I employed a friend that is a spray painter/panel beater nearly the the past 3 weeks. Then we rented a booth from a local panel shop that my mate new well. We had to supply all our own materials and do all the labour. The shop supplied air, light and the booth for $200. Its a good way of doing it if you can find the time to do all the hard work yourself. The amount of errands ive run this past week is nuts. Ive driven an extra 100km in round town traffic just going out collecting small items. Might not sound like much but I actually live about 5 minutes from evey place I went in the middle of the industrial area.

For the moment the rims will remain factory colour. I have some nice gold crest centercaps in my other set of rims that these will inherit too. I'd really like to send up with a set of 18" 3 piece RS rims on it at some stage. I dont think i'll go messing with the factory rims since they do go pretty good with the colour anyway.
😂 that sounds very familiar dude...

Oh yeah.... You'd know all about that hey Reub? 😂

FUCH your early!

http://www.noh2o.org/

SLAPPA Learner Dubber

8 posts · joined Oct 2008 · 12 Oct 2008, 4:58 pm

#674419

Looks good Ian.... have to come around & see it when i get back home..