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

063bug

0 posts · joined Feb 2005 · 9 Jun 2009, 11:56 am

#717527

The attention to detail on this project is amazing... not to mention the documentary/photos... this thread is a credit to you 👍

2443TT Fahrvergnugen

962 posts · joined Dec 2002 · 19 Jun 2009, 12:08 pm

#719501

At last guys I finaly have a set of heads, and they are truely awesome! The machining is really as good as it looks. Valve seats are blended to the casting so there is no noticable lip to feel if you run your finger over it. Exhaust flanges are huge too, should make for a good sealing area considering the exhaust back pressure on the engine will be approaching 35PSI.

I discovered that the Australian government doesnt have a free trade agreement with the Swiss too. Import duty and GST was another $718 on top of the purchase price of $3275. So Ouch! Just as well Kevin Rudd gave me some money to help buy these! But they look like they will be up to the task of what I have planned for them.

I know what I'll be doing this weekend.... 😀

bajachris88 The international telephone dialing code for Antarctica is 6

6,661 posts · joined Apr 2005 · 19 Jun 2009, 12:30 pm

#719503

HOLY CRAP!
HA theres not even any slight more room for those values to be any big, thats insane!

(ô_!_/ô) (ô_!_/ô)
69' baja: kombi box, thing spindles, irs, disc front, type 3 rear drums, 2 inch lift kit, 31x10 rears. 👍
New engine in process: 94mm p&bs, 74mm C/w chomol Crank, 35.5x39 SP heads, turbo. Wierd combo, hopeful torque monsta!

reub VWRX is gone...

2,054 posts · joined Sep 2002 · 19 Jun 2009, 12:40 pm

#719504

Sensational dude

Reub

Mick058 Custom Title Time!

1,580 posts · joined Jan 2008 · 19 Jun 2009, 12:49 pm

#719506

Alright! Some progress coming up.

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

Romans 10:9

polak Everything is alright with enough Vodka :P

913 posts · joined May 2009 · 19 Jun 2009, 2:05 pm

#719512

those heads are frikken ridiculous!!!🤪🤪 beautiful job on the machining too... i couldnt wait till the weekend, id be taking a sickie today😂😂

VW - helping put oil back into the ground for over 60 years

Flintstones Custom Title Time!

1,077 posts · joined Aug 2002 · 19 Jun 2009, 9:34 pm

#719573

Very nice!!!!😎

STOCK Wolfsburg Wizard

446 posts · joined Apr 2008 · 29 Jun 2009, 4:52 pm

#721313

I THINK SOMETHING JUST MOVED IN MY PANTS😂😂

🤘
STOCK

2443TT Fahrvergnugen

962 posts · joined Dec 2002 · 29 Jun 2009, 4:56 pm

#721316

Sorry for the lack of progress now the heads are here, it was supposed to be all systems go...

Seems the set of raceware head studs I have are 8mm and not 10mm like I thought I had ordered (nearly 2 years ago). So I didnt get very far at all with it last weekend. Ive since decided to use a set of CB 10mm chromoly studs that I have here, and have so far cut 1/2 of them to size so far. I hope to find time to work on the engine in the evenings this week and get it to a rocker cover to rocker cover stage of assembly.

2443TT Fahrvergnugen

962 posts · joined Dec 2002 · 3 Jul 2009, 8:05 pm

#722105

Update at last...

I've made a little progress with the engine this week, although not as much as i'd have liked. I was going to use the CB 10mm chromoly head studs I had spare here but found out some of them were rusty. Ive had them in storage too long. So Ive decided to put the engine together anyway so I can finish the cooling system and start on the header and intake fabrication, and ive ordered some replacement studs.

Here's some pics of the engine. Ive started modifying my 911 style fan shroud too, with a little fiberglass here and there to make it a more snug fit onto the oxy boxer block. Should have more pics over the weekend.

Cheers,

Ian

reub VWRX is gone...

2,054 posts · joined Sep 2002 · 4 Jul 2009, 11:53 am

#722201

Project 'blown' budget now dude?? 😁

Looks the goods, and can't wait to see with shroud etc on.👍

Reub

Flintstones Custom Title Time!

1,077 posts · joined Aug 2002 · 4 Jul 2009, 9:02 pm

#722291

reub-revhead wrote:Project 'blown' budget now dude?? 😁

Looks like Ian's gonna have to sell that skyline of his to finish the Dub😂
Cheers
D

2443TT Fahrvergnugen

962 posts · joined Dec 2002 · 6 Jul 2009, 6:58 pm

#722568

Well here's a few pics of the shroud. Its close to being finished, I just need to spend a little more time wet rubbing it pror to having it 2pac clear coated again.

Ive also made some templates up to have some new flanges water-jet cut. Im going to do something a little diferent here. The flange will mirror the exhaust port shape and is being cut from 25mm mild steel plate. I will then put the flanges in a lathe and turn down the first 15-17mm of the flange, but taper it so the port expands out from 38mm to 40mm inside diameter. Bends will be tig welded internally and externally to the flanges. The flanges will be match ported as well of course.

The fan housing is a porsche 911 11 blade type. I'll be sending that and the fan away to get them ceramic coated to make them look nice. Im sick of polishing already.

And the other side...

Head studs should arrive this week too, so the heads can come off and the top end of the engine be finally assembled.

Cheers,
Ian

2443TT Fahrvergnugen

962 posts · joined Dec 2002 · 6 Jul 2009, 7:03 pm

#722569

Flintstones wrote:
reub-revhead wrote:Project 'blown' budget now dude?? 😁
Looks like Ian's gonna have to sell that skyline of his to finish the Dub😂
Cheers
D

Oh yeah, not going broke but I am tightening the belt. I did some mental sums and I still have a god $5k to spend on new engine management and injectors, wiring, intercooler and all the oil plumbing that still remains.

Im planning to buy a house around october-december and saving for that is the main priority.

Golde60 Fahrvergnugen

858 posts · joined Aug 2002 · 6 Jul 2009, 10:23 pm

#722643

i just thought it was called blown budget because of the forced induction. clearly the priority has not changed from building the best.

keep it up man, it is inspirational to watch

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

2443TT Fahrvergnugen

962 posts · joined Dec 2002 · 9 Jul 2009, 7:27 pm

#723147

A quick update... No new head studs have arrive just yet but no matter i'll be working on the turbo header this weekend instead. Ive had some flanges waterjet cut and machined them up on the lathe so im ready to begin on the merged collectors on the weekend. That means the engine will be bolted to the gearbox for the first time and the rear apron attached so I can work on turbo placement etc.

Something that is often a right pain in the ass with large headers is the inability to weld a decent size pipe to the flange and stil get a nut on it properly due to externally welded pipe. The only solution is internally welded pipe and that can mean slipping the pipe inside a conventional flat flange. This is OK for most NA engine setups, but thicker piping is needed for turbo applications and this then reduces your inside diameter.

So thats why ive done it this way. The head exhaust ports will be match ported to the flanges and taper out to 40mm ID pipe.

Cheers,
Ian

volkdent Learner Dubber

15 posts · joined May 2005 · 10 Jul 2009, 1:12 am

#723227

I've never seen that solution, very inventive and attractive to boot! I can't help but imagine that this will turn out to be one of the best looking GLers in the world.

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

hellbugged 48's and straight cuts

5,080 posts · joined Apr 2003 · 10 Jul 2009, 6:32 am

#723234

2443TT wrote:So thats why ive done it this way. The head exhaust ports will be match ported to the flanges and taper out to 40mm ID pipe.

very nice..........but only 40mm ID exhaust ?

2443TT Fahrvergnugen

962 posts · joined Dec 2002 · 10 Jul 2009, 7:22 am

#723241

hellbugged wrote:
2443TT wrote:So thats why ive done it this way. The head exhaust ports will be match ported to the flanges and taper out to 40mm ID pipe.
very nice..........but only 40mm ID exhaust ?

Only for the primaries. When the collectors happen it changes to 50mm ID.

VWFREAK VWFREAK

2,577 posts · joined May 2004 · 10 Jul 2009, 3:15 pm

#723302

Crazy, whats the estimated completion date now ?

2443TT Fahrvergnugen

962 posts · joined Dec 2002 · 12 Jul 2009, 8:11 pm

#723732

Hi Guys,

I'd rather not guess a completion date at this stage. Im just working on it as much as I can now. The propper head studs should arrive this week so the top end of the engine goes together properly next weekend. The header should be finished this week.

Speaking of... here is the results of this weekends activities.

The header has 39mm ID primaries that merge to the 2" secondaries in the middle under the sump. This then goes back and is split evenly with another 2" merge to go to each turbo.

Turbo's are mounted high to keep them away from dirt etc, and it also guarantees no problem with the oil returns to the rocker covers.

From the inside you can see the compressor outlets. They meet in the middle to feed the water-air intercooler, and then a pipe goes back through to a centrally mounted throttle body. Well thats the plan at least.

The turbo's are Greddy T517Z's 8cm turbo's rated at 350hp each. They should be reasonably responsive even if the plan was to just run the turbo's in parrallel. But Im still planning on setting up a sequential bi-turbo system. Which is why the header allows all gas flow to a single turbo when valving is closed.

Hope to finish the front pipes later this week.

Cheers,
Ian

reub VWRX is gone...

2,054 posts · joined Sep 2002 · 12 Jul 2009, 8:15 pm

#723733

Awesome work as always dude👍

Reub

2443TT Fahrvergnugen

962 posts · joined Dec 2002 · 15 Jul 2009, 9:31 pm

#724254

Update time. The engine is back on the bench as the head studs arrived from LN engineering on monday.

Cutting to length. Had to shorten all studs a 1/4" at the inside and the center two top studs an additional 1/4 at the outside.

Here is the cylinders and pistons with rings finally assembled and in the engine, sealant under the barrels etc ready for heads.

Heads on at last. Inner valve springs are removed at the moment, and I still need to remove an outer and check rocker geometry and measure up the pushrod length.

Sexy head studs! Only tightened to wrist tightness so far. I need to make a tool so I can torque the top center head studs as I cant get a socket on there, and being a double hex nut its going to be an interesting challange.

Cooling tin with the part that goes around the head removed (as it wouldnt fit the MS230 heads).

I started shimming up the rockers too, but need to make up some spacers for the outer rockers on the weekend when I get a chance.

Unfortunatly I cant finish the other side of the engine just yet. As luck goes I have a set of ARP head studs to suit a case that has a deep insert on the number 3 cylinder (longer stud), but thats not any good for my oxy case. Charles at LN engineering has shipped over a replacement stud, so with any luck in another week I can finish the other side of the engine.

Ive decided to alter the turbo placement a little too, so the half finished header is being chopped a little and altered on the weekend.

Cheers,
Ian
Cheers,

polak Everything is alright with enough Vodka :P

913 posts · joined May 2009 · 16 Jul 2009, 1:31 pm

#724319

wow! thats coming together nice, can wait to see/hear it in person.... noticed the modplates on the tinwork in the back... did you have any issues getting it done? are modplates easier/cheaper than getting it engineered, or is it the same thing... sorry for the stupid questions, but i dont know anything about the legal side of doing extensive mods. also dont know if u know, but if i were to not run the back seats in a beetle, are there any legalities i would need to comply with?

VW - helping put oil back into the ground for over 60 years

vassy66T1 Wow ... are U reading this?

2,120 posts · joined Jun 2003 · 16 Jul 2009, 3:39 pm

#724320

Fabtastic and really quite insane!!!
Ingenious solution for the exhaust ports 👍

That car isn't modified is it??🙅

2443TT Fahrvergnugen

962 posts · joined Dec 2002 · 16 Jul 2009, 4:28 pm

#724325

polak wrote:wow! thats coming together nice, can wait to see/hear it in person.... noticed the modplates on the tinwork in the back... did you have any issues getting it done? are modplates easier/cheaper than getting it engineered, or is it the same thing... sorry for the stupid questions, but i dont know anything about the legal side of doing extensive mods. also dont know if u know, but if i were to not run the back seats in a beetle, are there any legalities i would need to comply with?

With the chassis I just did a lot of planning before starting, got all the critical measurements straight and then talked to an engineer and discussed what I was doing before I started work. After he ok'd my design in principal, I started to put it together and had him inspect it before having the finishing welds done.

Provided you do your homework and present a good case, Im fairly certain most engineers will approve anything within reason. Mod plates are a QLD thing, and yes you do need a plate for altered seating capacity too (ie no back seats).

Cheers,
Ian

polak Everything is alright with enough Vodka :P

913 posts · joined May 2009 · 16 Jul 2009, 5:22 pm

#724336

thanks for that Ian, i guess im going to have to look into the nsw regs as i dare say they may be different... cheers adam

VW - helping put oil back into the ground for over 60 years

Flintstones Custom Title Time!

1,077 posts · joined Aug 2002 · 16 Jul 2009, 9:31 pm

#724407

WOW,Really impressive Ian
it's a shame that you'll have to hide so much of it with the cooling tins, shroud etc
Cheers

oval TOFU Bitte, ein Bit!

2,946 posts · joined Jul 2003 · 18 Jul 2009, 10:52 pm

#724724

All I can say is 'wow'.

❗

...and Robert's ya father's brother...

2443TT Fahrvergnugen

962 posts · joined Dec 2002 · 25 Jul 2009, 3:59 pm

#725832

Hi everyone,

That last head stud arrived last week so Ive been working on the engine for most of the last 3 days and have finally go it very close to finished now.

Headstuds torqued, rockers aligned, lash caps and pusrod tubes installed.

Here it is... completed long block.

Distributor drive plug installed, fuel pump block off/spacer plate made.

Carbon fibre fan shroud clear coated in 2pac standox clear

Dry sump pump mound bolted on.

And the RPM 4 stage dry sump pump loose mounted.

I decided to not be a girl and spent a few hours on the polisher today too and re-polished the 911 alternator fan housing and alternator stand. Dry sump pump drive belt is now installed too.

Im getting the remaining tinware sand blasted and will be painting it with flat black 2pak next week.
Cheers,
Ian