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

Golde60 Fahrvergnugen

858 posts · joined Aug 2002 · 17 Oct 2008, 5:29 pm

#675291

that thing is gonna look scary in the rear vision mirror

can t wait to see it with the guards on

dont change those wheels, I reckon they contrast the paint really well. great choice of colour by the way. I reckon it will look much better in the flesh, but looks pretty special from here....

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

2443TT Fahrvergnugen

962 posts · joined Dec 2002 · 17 Oct 2008, 10:33 pm

#675332

Hi all, progress update time.

The last of the panel work was completed early this week along with the 2lt of tectol rust proofing that was sprayed inside every gap to prevent any future rust. Inside the new firewall and engine bay is now all flat black, as is in behind the gril under the rear window.

This afternoon I started on the final assembly of the car. Slow progress so far, but the body is now firmly bolted to the chassis. Steering is 1/2 in and the suspension is now back together properly.

Tomorrow is the dash, interior and i'll probably be finishing the floor pan sections but will see how it goes.

Cheers,
Ian

555bug WRX Bug Boy

1,123 posts · joined Aug 2002 · 17 Oct 2008, 10:52 pm

#675336

mental 🙂

VWFREAK VWFREAK

2,577 posts · joined May 2004 · 18 Oct 2008, 2:37 pm

#675385

Crazy, but in a good way. 👍

2443TT Fahrvergnugen

962 posts · joined Dec 2002 · 18 Oct 2008, 10:06 pm

#675428

Hi all,

Didnt make a lot of progress today. I spent most of the day trying to locate the necessary parts to put things back together properly, but after turning my workshop upside down twice im familiar with where most of the parts are again.

So the dashboard is now rewired and installed again. I was a little worried the ultralite gauges wouldnt match the dark colour but they match better to the atlas grey than they did to the arctic silver. Seems i am going to have to move the gear shift back a little at some stage though as 1st gear nearly makes contact with the ash tray knob.

Anyway, here are the pics.

Cheers,
Ian

kroozzn63 Bishop of Volkswagenism

3,005 posts · joined Jan 2004 · 19 Oct 2008, 9:50 am

#675455

fark thats gunna stick on the road like a mozzy ona blood clot, hope you got your engineers cert wow

show us your gates

2443TT Fahrvergnugen

962 posts · joined Dec 2002 · 19 Oct 2008, 10:25 am

#675461

Yep all the engineering certification is done. 3 plates with 12 codes from memory. The car is still registered too which is helpful because most workshops would have a heart attack if i asked them for a RWC for it.

humpty Bishop of Volkswagenism

3,336 posts · joined Sep 2002 · 19 Oct 2008, 1:40 pm

#675471

God I love that shifter... So close Ian, so damn close.... The Shoptalk/German Look gang would getting a little wet over this surely?

FUCH your early!

http://www.noh2o.org/

Flintstones Custom Title Time!

1,077 posts · joined Aug 2002 · 19 Oct 2008, 7:17 pm

#675539

That shifter setup is just so hard core!! love it😎

Cheers
D

2443TT Fahrvergnugen

962 posts · joined Dec 2002 · 19 Oct 2008, 7:47 pm

#675549

Indeed it is a nice shifter but it is a dam pain in the ass to adjust properly. Today I moved it back about 3 inches so its in the correct position now for driving (it was hard to get that close to right when the body was off the pan).

I also had to shorten the reverse lockout spring in the 930 gearbox about 15mm so that I could actually select reverse gear. As the throw of the shifter is reduced so much it was amplifying the lockout effect so much that the universals would slip on the gear selector shaft. Door striker plates and latches are on the car now too as are the templates for the floor pan sections. I'll be making up the last bits of carbon for the floor tomorrow afternoon.

I couldnt go any further with assembly just yet as I want my panel beater to come back and polish the doors and boot lid before I finish the final assembly of them. Im getting very close to needing an engine now, as i'll be needing to mount radiators and all the plumbing next so engine assembly is definatly on for next weekend.

Cheers,
Ian

JVLRacing Custom Title Time!

1,100 posts · joined Mar 2007 · 19 Oct 2008, 8:00 pm

#675553

thank fuk you cleaned your floor before rollin your car back in!😂.....luv the gear selector too.JVL

2443TT Fahrvergnugen

962 posts · joined Dec 2002 · 19 Oct 2008, 8:09 pm

#675557

humpty wrote:God I love that shifter... So close Ian, so damn close.... The Shoptalk/German Look gang would getting a little wet over this surely?

Im not posting pics on shoptalk or german look... Last time I went there it seemed the forums were dead. I might post the engine build on STF though as a few people ive been dealing with in the US have expressed interest in the engine and my plans.

JVLRacing wrote:thank fuk you cleaned your floor before rollin your car back in!😂.....luv the gear selector too.JVL

The floor of the workshop has been very clean since the last of the prep work, followed by the interior spray work being done there when the floor was wet down.

I have to admit that it is cool to be able to lie on my back under the car and tighten an overhead bolt without having crap fall in my eyes. Everything is so spotless.

Ha! And that would be my 700th post! I am now an "Insano Dub head"... yep thats right 🤪

JVLRacing Custom Title Time!

1,100 posts · joined Mar 2007 · 19 Oct 2008, 9:29 pm

#675578

😂goodman! cant handled dirty sheds and congrats

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

2,534 posts · joined Mar 2007 · 19 Oct 2008, 10:18 pm

#675592

Ian looking sensational!!

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

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

humpty Bishop of Volkswagenism

3,336 posts · joined Sep 2002 · 19 Oct 2008, 11:04 pm

#675597

The forced induction forum on STF is getting a little action but GL is well and truly dead... Shame really... But the GL dudes on STF are doing ok.... But you machine is in another league... Kinda like that mid engined Audi V8 powered Bug... But wider!😉

FUCH your early!

http://www.noh2o.org/

063bug

0 posts · joined Feb 2005 · 22 Oct 2008, 7:59 am

#676009

....following this thread like I'm transfixed... amazed by what your doing, how you've done it and how much detail your putting on the forum... love your work.

wibble Freakinbuggied

404 posts · joined Jan 2003 · 22 Oct 2008, 4:24 pm

#676089

Geez dude haven't you finished yet? 😂 Lookin good hey...

http://www.waycoolbuggies.com

2443TT Fahrvergnugen

962 posts · joined Dec 2002 · 23 Oct 2008, 4:16 pm

#676248

HA HA.. no not quite... And so much for the doing the engine build this weekend. Im working instead. Fingers crossed i'll finish mid-day saturday, and if thats the case i'll be starting on the bottom end saturday afternoon/evening.

My panel guy has wet sanded around all the window frames and polished them this week, so that when the glass is installed the rubbers wont be damaged by polishing when the whole car is wet rubbed and polished. Other than that there hasnt been any major progress with the project. Unfortunatly I have to go to work and earn some money sometimes...

Cheers,
Ian

mactaylor Custom Title Time!

1,005 posts · joined Aug 2007 · 23 Oct 2008, 6:11 pm

#676275

great stuff ian looks like you will be on the road soon, i think lenny with the vl up there needs an aircooled lesson!!!

EVERLAST CONCRETE TANKS
1800 552 123

Dasdubber DAS Resto Haus

5,746 posts · joined Aug 2002 · 23 Oct 2008, 8:15 pm

#676295

Its looking absolutely fantastic Ian - a real credit to you. Can't wait to see it completed!

www.dasrestoparts.com.au

2443TT Fahrvergnugen

962 posts · joined Dec 2002 · 29 Oct 2008, 2:04 pm

#677229

Hi Guys,

Time for another update. The car is getting a final block back with 1200+2000 and a polish now. The first step is using a hard aluminium block with 1200 to remove any high spots or debris in the paints surface. Then the 1200 marks are removed with the 2000.

The results are nothing short of amazing and are pretty hard to photograph.

Rubbed with 2000

Polished

Photo with flash

Photo with no flash

Like a mirror that disappears into darkness.

And the polish system being used. PPG.

On the engine front, I am waiting on one final part. A hall effect sensor that will be mounted through the front of the engine block, that will take trigger references from the cam drive gear. The engine will be distirbutorless, using multi-coil ignition.

The last of the modifications to the cylinder heads will be done this weekend too. They are modified CNC ported competition eliminators, 48x40 with a litte extra port work done and modified for water cooling. I'll post some pics as the last of the welding is being done.

Cheers,
Ian

reub VWRX is gone...

2,054 posts · joined Sep 2002 · 29 Oct 2008, 2:14 pm

#677230

SENSATIONAL!!!

Reub

volkdent Learner Dubber

15 posts · joined May 2005 · 29 Oct 2008, 2:34 pm

#677232

Wow, just wow...

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

vassy66T1 Wow ... are U reading this?

2,120 posts · joined Jun 2003 · 29 Oct 2008, 4:31 pm

#677242

Paint job looks hot as!!!!!
Stellar job. 😎

Golde60 Fahrvergnugen

858 posts · joined Aug 2002 · 29 Oct 2008, 5:39 pm

#677256

awesome

looking forward to seeing it done

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

JVLRacing Custom Title Time!

1,100 posts · joined Mar 2007 · 29 Oct 2008, 8:00 pm

#677290

hi allan! m8 how many coates of clear was put on the car?.....really impressed with that job m8..😎

2443TT Fahrvergnugen

962 posts · joined Dec 2002 · 29 Oct 2008, 8:14 pm

#677292

I believe there is two base coats (first to cover and colour, the second as a dusted on coat to make the metalic stand out) and 2 clear coats, but he my painter said he put the clear on pretty heavy too.

The standox clear aparently goes on considerably thicker than most other clear coats. He did tell me how thick it was approximatly in microns but i cant remember exactly. I think its something like 100-120 total (60 microns per coat). Thinner cheap ass clear coats would be more like 30-40 microns per coat. He also said that cheap clears dont polish up as nicely as the standox does too.

JVLRacing Custom Title Time!

1,100 posts · joined Mar 2007 · 29 Oct 2008, 8:20 pm

#677294

2443TT wrote:I believe there is two base coats (first to cover and colour, the second as a dusted on coat to make the metalic stand out) and 2 clear coats, but he my painter said he put the clear on pretty heavy too.

The standox clear aparently goes on considerably thicker than most other clear coats. He did tell me how thick it was approximatly in microns but i cant remember exactly. I think its something like 100-120 total (60 microns per coat). Thinner cheap ass clear coats would be more like 30-40 microns per coat. He also said that cheap clears dont polish up as nicely as the standox does too.

thanks for that...as a detailer and seeing alot of crappy clear coats but that looks yummy after a rub with 1200 then 2000

2443TT Fahrvergnugen

962 posts · joined Dec 2002 · 29 Oct 2008, 8:32 pm

#677296

JVLRacing wrote:
2443TT wrote:I believe there is two base coats (first to cover and colour, the second as a dusted on coat to make the metalic stand out) and 2 clear coats, but he my painter said he put the clear on pretty heavy too.

The standox clear aparently goes on considerably thicker than most other clear coats. He did tell me how thick it was approximatly in microns but i cant remember exactly. I think its something like 100-120 total (60 microns per coat). Thinner cheap ass clear coats would be more like 30-40 microns per coat. He also said that cheap clears dont polish up as nicely as the standox does too.
thanks for that...as a detailer and seeing alot of crappy clear coats but that looks yummy after a rub with 1200 then 2000

Indeed. Though I dont think it would have been possible to do at all if the panels werent first made as flat as they are. It really is all in the preporation as they say. Blocking and polishing a car thats not flat would be dangerous to do I think. Imaging going through the clear and base coats to primer by mistake... no thanks!

I remember getting a phone call from the people that did the previous panel work before they painted it arctic silver saying how proud they were of how flat the car was, and that they really didnt want me to paint it white, like I was considering at the time. They wanted me to choose a dark colour, and I can only imagine how bumpy it would have looked if i'd said atlas grey to them.

The rear 1/4 panel high spots would have looked like little hills magnafied by the clear.

JVLRacing Custom Title Time!

1,100 posts · joined Mar 2007 · 29 Oct 2008, 8:41 pm

#677299

2443TT wrote:
JVLRacing wrote:
2443TT wrote:I believe there is two base coats (first to cover and colour, the second as a dusted on coat to make the metalic stand out) and 2 clear coats, but he my painter said he put the clear on pretty heavy too.

The standox clear aparently goes on considerably thicker than most other clear coats. He did tell me how thick it was approximatly in microns but i cant remember exactly. I think its something like 100-120 total (60 microns per coat). Thinner cheap ass clear coats would be more like 30-40 microns per coat. He also said that cheap clears dont polish up as nicely as the standox does too.
thanks for that...as a detailer and seeing alot of crappy clear coats but that looks yummy after a rub with 1200 then 2000
Indeed. Though I dont think it would have been possible to do at all if the panels werent first made as flat as they are. It really is all in the preporation as they say. Blocking and polishing a car thats not flat would be dangerous to do I think. Imaging going through the clear and base coats to primer by mistake... no thanks!

I remember getting a phone call from the people that did the previous panel work before they painted it arctic silver saying how proud they were of how flat the car was, and that they really didnt want me to paint it white, like I was considering at the time. They wanted me to choose a dark colour, and I can only imagine how bumpy it would have looked if i'd said atlas grey to them.

The rear 1/4 panel high spots would have looked like little hills magnafied by the clear.

yeh touch wood, metal i havnt rubbed that hard😂.....now i dont risk it due to some poor workmanship!😎your prep ..great stuff