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

Marko Learner Dubber

13 posts · joined Jun 2008 · 27 Dec 2008, 8:00 pm

#686101

Yes, mine Oxy's jets are from Porche.

2443TT Fahrvergnugen

962 posts · joined Dec 2002 · 28 Dec 2008, 12:23 am

#686135

I considered piston squirters but went with the coatings option instead. Ceramic crowns for heat, and had the skirts done in teflon. Im using oil squirters in the rocker covers though for valve spring cooling and aiding rocker arm lubrication.

Piston squirters in the nissan engines dont come into play until oil pressure exceeds a certain pressure as they have a check valve in them. When people do the 3lt conversions into GTR's some fit RB26 piston squrters, but most opt for coatings as its easier and we a well proven technology now. Ive seen non squirted/coated 3lt bottom ends hold 625rwhp on pump fuel no problems.

Oil squirters while cooling pistons beter will actualy raise the overall oil temps as the hot spots on the pistons are eliminated (or reduced at least), and more heat is conducted away into the rest of the oil system. This means the oil coolers need to be able to cope with the additional heat. Coatings mean the component never absorbs as much combustion heat in the first place, so no need for the squirters.

Thanks for the idea though.

Ive made a little more progress with the build and havent had a chance to post pics due to christmas/new years functions etc. The carbon fibre floor sheets are now screwed to the chassis. Ive plated the outer edge with 12x3mm flat bar for a little extra support/strength, and will be gluing them in with sikaflex when i am 100% happy with the result. Still have to fit the pedal assembly and dril a few more holes. Ive also finished the mount for the external 4 stage dry sump oil pump on the engine, though are waiting on drive belt so I can sort out weather it will need a tensioner/idler or not.

Thats all for now.
Cheers,
Ian

1303Steve Scirocco Rare

8,650 posts · joined Aug 2002 · 28 Dec 2008, 9:16 am

#686152

Hi

This project is one of favourite post in this forum, cant wait to see it finished.

I used to work at VW tuning shop that fitted a lot of SPG roller cranks into VW motors, they developed a squirter to lubricate the con rod bearings instead of relying on the usual cut-outs in the main bearings that SPG recommended.

The squirters were fed from the cam follower gallery and used 40mm DCN Webber main jets as the actual squirter, as well as lubricating the big ends the squirted the pistons as well.

Steve

Marko Learner Dubber

13 posts · joined Jun 2008 · 28 Dec 2008, 12:56 pm

#686164

Ok, good job Ian. Did you see that

Wasser case and 850hp and 1100nm

2443TT Fahrvergnugen

962 posts · joined Dec 2002 · 28 Dec 2008, 2:18 pm

#686173

Indeed. Its inspirational. I like how he babies it off the line and then it powers into a wheelstand. Thats serious torque. Do you have a build thread on the go here Marko, or was that an old pic from your engine during the assembly phase?

Marko Learner Dubber

13 posts · joined Jun 2008 · 28 Dec 2008, 4:24 pm

#686186

Ian, i open own thread later. Engine is long block now and i have to find some car for that 🙂

Mine is atmo 86x101,6 and i need some throttle bodies, motec and lot's of jobs.

You way it's too hard for me. I'm not understand anything for Turbos's maybe later ia have to study that.

Good and hard job's you car.

063bug

0 posts · joined Feb 2005 · 30 Dec 2008, 8:33 am

#686409

.... I'm patiently waiting to see the new CFfloor panels and those huge wings installed..... no rush, just waiting for my AVD xmas present from 2443TT 🙂

2443TT Fahrvergnugen

962 posts · joined Dec 2002 · 30 Dec 2008, 6:18 pm

#686494

Well since you asked... Truthfully ive been busy with friends and family the past week, and while it seems that 3/4 of Cairns is closed for the new years week just enough of my clients are trading that I cant spend all day playing with vw's.

Here is the floor pan panels. They are 5 layer carbon/fiberglass sheets (3 carbon, 2 glass). The thickness is about 2.5mm but they are light and strong as hell. The front sections supported my weight as I lay on top of them drilling the mounting holes near the firewall end. The panels are yet to be sikaflexed into place but for the moment are held in with 12x3mm flat bar alloy and stainless bolts with nylocks.

I had a sticker arrive in the mail today too...

Im holding off showing pics of the dry sump pump mount/setup till I get a bit more of the engine together. Basiclly i need a set of heads which dont arrive for another month or two.

Cheers,
Ian

reub VWRX is gone...

2,054 posts · joined Sep 2002 · 30 Dec 2008, 9:21 pm

#686530

Very cool dude... nice work👍

Reub

2443TT Fahrvergnugen

962 posts · joined Dec 2002 · 31 Dec 2008, 9:01 pm

#686693

Thanks dude. Here's one more of the interior with the door linings back on.

Flintstones Custom Title Time!

1,077 posts · joined Aug 2002 · 31 Dec 2008, 11:24 pm

#686712

that's such a hard core interior Ian!!!

Cheers
Dino

063bug

0 posts · joined Feb 2005 · 2 Jan 2009, 7:36 am

#686875

That looks so awesome..... love it and really looking forward to seeing some video of it in the future. Thanks for the update 👍

Smiley Veteran Volks Folk

2,125 posts · joined Oct 2008 · 24 Jan 2009, 6:54 pm

#691328

Hi Ian

I found this thread at around lunchtime and have spent all afternoon reading it. The quality of your work and the way the car is turning out is a credit to your workmanship and abilities. It's so great to see someone doing instead of just talking about what they want to do. Looking forward to future updates.

Daniel

If you said I was a Volkswagen man, you'd be right.

2443TT Fahrvergnugen

962 posts · joined Dec 2002 · 24 Jan 2009, 10:11 pm

#691356

Thanks Daniel. I should have some more updates soon. There is a lot of things happening all at once at the moment.

Im working on the mounts for all the engine support gear. Radiators, coolant resivour, dry sump oil tank, fuel system, finalising the engines dry sump drive system. Nothing is finished enough to show just yet though. DRD should have my new heads over to me by the end of Feburary too.

Cheers,
Ian

Smiley Veteran Volks Folk

2,125 posts · joined Oct 2008 · 25 Jan 2009, 10:32 am

#691393

Are you still cramming all that gear up in the front? I suppose you'll need it there to be able to steer because of the monster that's going to be in the back.

If you said I was a Volkswagen man, you'd be right.

Camo Custom Title Time!

1,936 posts · joined Oct 2007 · 25 Jan 2009, 4:52 pm

#691422

I had a sticker arrive in the mail today too...

Cheers,
Ian

How the hell do you get a rego sticker for a car that cant even be driven on the road yet. You Queenslander's are bloody lucky, unlike NSW where every little thing is a fight to get passed.

Again, Love ya work. Kev

.

I thought rebuilding a VW would be cheap - Shit I was wrong, just don't let the wife know !!!!

Click here for my (slowy) modded 1961 Beetle build.

2443TT Fahrvergnugen

962 posts · joined Dec 2002 · 25 Jan 2009, 9:01 pm

#691470

I never de-registered the car back 2+ years ago, when the project was just supposed to be a gearbox change. When things got out of control with the project I figured it would just be easier to keep the car registered than to go through the grief of explaining to a mechanic that the modifications Ive done are legal. So the car is still registered, and so long as its road worthy with the mod plates fitted its still legal. Yes we do have it a lot easier than in NSW and VIC for sure.

66deluxe Custom Title Time!

1,593 posts · joined Aug 2005 · 26 Jan 2009, 7:41 am

#691521

I've kept my bug registered through my build too, and was wondering about all the mods, now i know, thanks Ian.

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

Smiley Veteran Volks Folk

2,125 posts · joined Oct 2008 · 12 Feb 2009, 7:54 pm

#694909

Hey Ian

Just thought I drop a post in and ask how the car is coming along?

If you said I was a Volkswagen man, you'd be right.

SLAPPA Learner Dubber

8 posts · joined Oct 2008 · 12 Feb 2009, 7:56 pm

#694910

yeah come on Bug-man put some new pic's up.......

2443TT Fahrvergnugen

962 posts · joined Dec 2002 · 13 Feb 2009, 12:06 am

#694952

Yeah not much to report. Ive got 1/2 a fuel tank mount done and 1/2 an oil tank mount done, and then i got sidetracked by having 9" of water go through my workshop 3 times in the last month because of the flooding going on up here. So the focus has been making new benches that are well above the flood line.

No damage from the flooding, though my bathroom still has a welder in it, and my entire house upstairs is still 1/2 full of boxes, tools and car parts. Bummer that Ive been too busy with work in between the flooding to really get stuck into the car. I did hear from DRD racing heads though, and my heads will be ready soon.

2443TT Fahrvergnugen

962 posts · joined Dec 2002 · 8 Mar 2009, 8:13 pm

#699310

Hi Everyone,

Long time no progress update. Over the past 2 months ive not acomplished a gread deal on the car. I have however been flooded 3 times, sold my R33 and bought a new R34 gtr, had too much work on all at once, and have been ill latelyl too. Finding time to work on the bug had been impossible, but for the past two weekends in a row now I have been able to get to tinker a little with it again.

So here is a progress update. The fuel system is more or less finished. Im using a Bosch 910 pump to start with, which from experience will max out around 500rwhp. Ive used re-usable billet filters and braided line everywhere for that bling factor, but its also good quality stuff and the size is needed to keep the flow up. Supply lines are 10mm ID and the pressure lines through the car are 3/8". The fuel tank sits a little higher (45mm) than normal because I didnt factor in teh hose fitting on the bottom of the tank not being right on top of the hydraulic clutch master cylinder, but never mind, it all worked out as it gave me a place to mount the pump and get the fuel lines through to the bottom of the tank without making holes in the body.

The fuel tank is a standard tank that has had bungs for -10 size fittings welded on, and a perferated can welded in around the pickup to serve as a built in surge tank. That combined with the sump design of the 66 tank should stop fuel surge. Its being painted metalic silver this week.

Ive been working on the fuel system and making mounts for the dry sump tank, and contemplating where the radiators are going to go. There is going to be twin PWR radiators each side at the front of the car, both for water coolant. I am still a little torn between using a water-oil heat exchanger or a conventional radiator for oil cooling. I'll be seeing how it all fits in good time though and will trial fit both.

Here are the pics:

Other news... DRD racing heads are manufacturing my heads right now. I havent been given an ETA but I think inside a month.

Cheers,
Ian

trickysimon 100km/h is only 9 seconds away

1,473 posts · joined Dec 2007 · 8 Mar 2009, 9:01 pm

#699333

Bout time! 😀
This thing is going to be an animal!

reub VWRX is gone...

2,054 posts · joined Sep 2002 · 8 Mar 2009, 9:06 pm

#699335

One word dude... SENSATIONAL!

Reub

Flintstones Custom Title Time!

1,077 posts · joined Aug 2002 · 8 Mar 2009, 10:48 pm

#699376

Man that thing is W I D E ! ! ! 👍

colonel mustard Son of Jim - Creator of Good

2,829 posts · joined Feb 2009 · 8 Mar 2009, 10:58 pm

#699381

looks hot. estimate at what it is going to weigh?

Mick058 Custom Title Time!

1,580 posts · joined Jan 2008 · 9 Mar 2009, 6:05 am

#699407

freaken awesome

http://forums.aussieveedubbers.com/viewtopic.php?tid=67295 (myride)

Romans 10:9

vassy66T1 Wow ... are U reading this?

2,120 posts · joined Jun 2003 · 9 Mar 2009, 7:27 am

#699428

My favourite custom beetle by a long shot!!!
That is looking fab!
Looking forward to seeing the heads.

2443TT Fahrvergnugen

962 posts · joined Dec 2002 · 9 Mar 2009, 9:20 am

#699453

Thanks for the feedback guys!

colonel mustard wrote:looks hot. estimate at what it is going to weigh?

Despite the steel added for the front suspension it should still be pretty light. Before the body was put on the chassis, and only the front suspension and brakes were fitted (not the wheels) I was still able to lift the front end of the chassis, so at that stage I figured the front weight was about 80kg. If the wheels were fitted though I couldnt lift it as they being 18's arent exactly light.

I am pretty sure the standard torsion bar front end of a stock 1968 beetle assembled drum to drum would be heavier. The back end is where its put on some weight. The 930 gearbox weighs as much as 2 vw transaxels I am pretty sure. Though the rest of the rear end should be lighter than stock. The side rear windows are 6mm plastic, and the rear window is 3mm plastic, so that will help a little.

Im trying to mount as much as possible in the front end of the car to try and get better weight distribution. Though the battery will be going inside the car. I just dont like the idea of putting the battery next to a fuel tank.

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

2,534 posts · joined Mar 2007 · 9 Mar 2009, 4:07 pm

#699529

Looking good Ian. Are you going to run an auxillary type pump set up with swirl pot?

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

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