Kev's Turbo Fuel Injected Engine Build (Update 14/12/14)

Hi all,

Firstly this is not going to be a full on engine build thread with everything written or photographed as there is lots of those type threads already on the internet if you do a search. It's more a quick overview of the process with photos telling most of the story.

Link here to previous parts that arrived since last year.

Quick list of recent main parts (Supplied by Rod Penrose) :

CB Performance Aluminium Case
Pauter Roller Rockers
Scat Wedge mated Crank, Flywheel and Gland nut
Scat 'H' Beam Rod
Scat Chromoly Head Studs
AA 92mm thick wall cylinders
AA Forged (really) pistons to suit
CB Mini Wedge Port heads
Engle TCS 20 cam and Followers


Most of the fuel injection stuff is from the 'VW Speed Shop' in Great Britian. ECU, wiring, coils and sensors from the USA.

This long process started around November 2013 when I pulled the motor out of my car that I had intended to convert to turbo, injected etc. After pulling the engine down and inspecting, it did not have the internals that I was told it had when I purchased it as a completed running motor. The parts were good for what it was, but not for what I am planning on doing. I then had months to wait for some of my parts to arrive from the good old US of A.

This is just a mock up of the Turbo exhaust to see how it fits and to make sure the Turbo was going to clear my rear valance before I pulled old motor out.




Parts finally arrived and the long preparation process of blueprinting the engine begins.




The engine case havles themselves need modifications. The oil pump pickup hole is misaligned and as were the main journal oil supply holes. The black texta lines are indicating where the actual bearing oil groove lies. Both needed porting to match up.






A modification to the Cam followers allowing more oil to pass through and up to the rocker gear. This aids in lubrication, but also aids in increased cooling of the heads.




The camshaft needs to be clearanced in 8 positions to stop the conrod big ends hitting it due to larger crank stroke.




Camshaft bolts also need clearancing to make sure they dont kiss the oil pump.




Checking the cam lift to make sure it is the same as the supplied information card.





Bolted top half of case on and checked cam shaft and crank shaft end floats. And about to check deck height to see what I have to start with. Obviously way to much, but needed to work out how much material I need to remove to obtain the desired compression (deck height).



Then time for cleanup so as the assembly process can begin.




Although this doesn't show a time line, there is a lot of work involved to getting the engine case and components to this stage. This actually took me weeks to here as only working on it here and there. Beginning of the assembly process. Also as going full flow from the oil pump, need to fit threaded plugs into case and oil pump.








Case halves finally together, oil pump fitted.




Then started fitting a few of the external accessories. Deep sump, oil cooler adaptor, crank angle sensor parts.






Added an extra external oil cooler to the car.




Checking ring clearance and adjusting to suit. Case savers and barrels (no pistons) fitted to engine case as mockup to check head stud bolt lengths.






As you can see here, the head bolts are to long and all need to be shortened.






All rings fitted back onto pistons and pistons fitted into barrels. Then barrels and pistons fitted to engine.




As of today, heads now bolted on for last time with new pushrod tubes and seals.




Just sat rockers on quickly to see how they look and I love it.




As I said, this engine build process has taken me about 2 months working on it when I can. If you ever have anyone build you a half decent motor and ask why it cost so much, I can vouch there is a lot of work involved and more then I had realised.

I will continue to update over time and when new things are added or changed. Hope this hasn't been too much in one post and bored people.

Cheers, Kev

Can you leave the rocker covers off?

Those roller rockers look cool 👍👍👍

🤓

It's like automotive porn 😉

coming along nice

Well done Kev👍
For one horrible moment there,I thought,you're a brave man doing it in the kitchen,but as I scrolled down I can see you have a very well set up Man Cave

Looking good mate, did you set up rocker geometry before you buttoned everything up? Otherwise you run the risk of wiping the cam lube off

👍👍 hope to someday be patient enough to build something like this. Well done Camo

Good job mate, just finished similar project with CB magna fuel and spark. It is a lot of work. What injection? Maybe I missed it.
Good luck with it all.

mandog wrote:What injection? Maybe I missed it.

Photos of my EFI stuff are in the link at the top, but here it is again 😉

http://forums.aussieveedubbers.com/viewtopic.php?tid=103555&page=1#pid973090

Kev

Nice going, Kev.....nothing much more to do - looks like we'll see the car at Wakefield Park on Saturday, then ? 😏

Hey Kev, good to meet you at Vintage yesterday. Engine build looks sweet!

Nice stuff mate.

Thanks Todd, Pete and others.

This was just setting up geomertry for the roller rockers. Half lift and then set adjustable pushrod so as rod is inline with rocker adjusting stud.





Have done a little more, fitted up tinware and carbies for breakin test run on stand. Hopefully by early next week I will fire her up, all depends on family commitments this weekend.



Kev

Awesome 😉

Lookin good Kev

Had all the chromoly pushrod tubes cut (machined) to length. The machine shop rang and offered to fit all the tips for me, but I asked them not to. Look at all the metal shavings that came out of them. Imagine if this went through your engine or blocked the oil supply through the pushrods and you had no oil getting to the rockers.





Now that I finally had my pushrods back I could install them and finally fit up my new lovely roller rockers. Look at this photo, can you see the new problem that arose.



That's right, now there is no way my standard steel vw rocker covers are going to fit with those long cam lock down nuts. They are actually made for bolt on rocker covers. And to add to this, the bigger (thicker) rockers also touch on full lift at pushrod end.

But guess what, I have a spare pair of alloy bolt on covers here and those nuts are still to long. Take the nuts back off again and have them machined down 5.5mm (more delays) so I can finally get some covers to fit on there.



As you can see above, getting very close to start up. Wired up coil, tacho etc. Just need to get a oil pressure switch and some fuel line, add oil and fire her up.

But I feel this has been the easy part getting to here. I think wiring in heaps of wires to the ECU, throttle position sensor, air temp sensor, crank angle sensor, cam angle sensor, oxygen sensor, head temp sensor, map sensor, 4 x coils, 4 x injectors, water pump for intercooler (radiator for this still to be fitted) and whatever else I have forgotten will be the harder part.

But I will get there, eventually 🥲🥲🥲🥲🥲

Kev

P.S. I would like to also say another thank you to Rod Penrose for his assistance. I needed to borrow a couple of things to assist the engine build and more so I could get to this stage (exhaust) and he was more than willing to help 👍👍👍

P.S.S. Also to AUSSIE_MICK for lending me the tacho. If I don't say it, he might have a bit of a whinge 😂 😂😂

Nice work Kev 👍 thanx for posting, takes time and effort to do so, but makes for a much needed "go to read" here.

Neat wiring takes a lot longer than you would think, so be patient.

EFI and electronics is the fun and easy part i reckon 🤓

vlad01 wrote:EFI and electronics is the fun and easy part i reckon 🤓

Well, do you need a holiday in Sydney 😂😂😂😂😂

nah, no way going near that dump! 😂

Top work its rewarding to do the job your self

Hi all,

it's alive - YEAH 👍👍👍👍

As I said, I have the engine set up on a stand and started it up today. Still just using carbies, distirbutor and different exhaust for the break in period.

These videos don't give a true sound at all, it sounds very crisp and I am very happy with it. I think it does sound better in this first clip than the second one.



another one



Kev

Great job, there just something about a tuff aircooled vw ,sounds sweet👍👍

Congrats dude!

I have only one thing to say, scratch😂
Sorry guys, private joke!

Ah that sweet sound of clackity clack..love it..can't wait for turbo time..are u running a muffler off the turbo or dump pipe if that's what they are called?? I personally think they sound better with a muffler...have fun

Fabo...

cnfabo wrote:are u running a muffler off the turbo or dump pipe if that's what they are called?? I personally think they sound better with a muffler...have fun Fabo...

I'm pretty sure I will be running a muffler, as I think it will be to loud for my liking without one. Although I must say, they sound hot without one but that DB level is more for drag strip I think.

Time will tell 😁

Muffler for street.. dump pipe for track 😉😁👍

Awesome job mate, looks and sounds tough as, That cam clearancing looks scary though! Necessary evil I guess

Awesome love it!!

This arrived this morning, so now I can hopefully pull my finger out and start the big wiring process. Oh, forgot it's school holidays so I wont get a thing done this week and then work 😬

I guess Rome wasn't built in a day and all good things come to those that wait. This is what I keep telling myself anyway 🥲

If anyone has a spare rocket out there, I need one up my proverbial to get started 😂








Kev

With school holidays and work, haven't had much time to do anything. Managed to make up a mounting board and mount my ECU, relay/fuse box and knock sensor box. Now just need to make the wiring harness and get it in there.



Kev

Cool..........is the motor back in the car yet ?

Craig Torrens wrote:Cool..........is the motor back in the car yet ?

Yes Craig and sorry for the delay. The motor was back in about 2 weeks ago, but then I didn't touch it for over a week. But have worked on it this week although it doesn't appear to be much, there is about $400 of new (17) 'AN' fittings and fuel lines just in the engine bay although you cant see most of them.

Also did some wiring modifications (re routing) to the wiring that was already in there. eg oil temp sender that is now on the oposite side of engine. Haven't even started the EFI wiring and all the sensors.

Also made brackets up to hold 4 x LS2 coils and mounted them to the firewall. Although not in this photo also mounted my remote oil filter and made up new hoses for that also. Modified bracket for the new efi fuel pressure regulator.

Temperarily fitted the exhaust and turbo as I need to trim the inner tinware just to get turbo in there and just sat the water to air intercooler in place for a photo.





Kev

Started on the wiring yesterday and more today and all this wire is just 4 coils and 4 injectors 🤪🤪🤪

And I still need to wire in air temp sensors, cylinder head temp sensor, 02 sensor, waste gate control valve, throttle position sensor, crank angle sensor, cam angle sensor and these are just engine bay sensors.

Then there is still the oil cooler thermo fan, fuel pump, water pump and another thermo fan for inter cooler.




Kev

Another update, although it may not look a lot since last time. I can't believe how time consuming this modification is. So lucky I am not paying for the majority of the labour.

You can see in the first photo, I removed the original waste gate position off number 2 cylinder pipe and have had one added just after the collector. Note: this is like the CB Performance turbo exhaust but this one is all stainless steel and from the VW Speed Shop.



Obviously the waste gate in place. Still needs the exit pipe made up and added once I have a muffler etc added.



Had inlet plenums and cross pipes (and exhaust mod) made up at a mates business (Definite Dimension Engineering - free plug for Rob) great job 👍 And this is how she looks currently. Although I still have heaps to do 🥲



Kev

Hi Kev,
Thanks for steering me over to this thread.
WOW!!!
You are definitely LIVING the dream.
I'm just clinging to my dreams atm, but your incredible journey here gives me (& I'm sure many others also) so much hope to one day follow suit.
Many thanks, Muz.

Not much room left now.
Just as well you went with the removable valance!

Nice work big Kev, i gotta come past and see this thing in the flesh

Holy crap! That looks awesome.

Hi all,

although I have been quite on this forum, I have been busy working on my car every weekend as time permits. I finally got to the point of turning the engine over in attempts to start it 2 weks ago. Well, it was not as easy as I was hoping and I have been conversing with others on the Megasquirt forums and was finally able to start it for the first time today.

This is near the first start up of my new fuel injected, turbo VW engine. Still running very rich as you will see, but now the tuning process will begin.



Cheers, Kev

sounds tough as

Thanks Steve,

may be a bit quiter and sound more tame when I actually have a muffler on there. Here I come Westi, well maybe soon.

Kev

So Kev
When will the turn key Turbo Injected Motors go to market? 😁

Hahaha that sounds sick Kev..

It's DONE, and who would know what is lurking underneath 😁

Camo wrote:It's DONE, and who would know what is lurking underneath 😁

Wowsers!!!!!!

Very nice ,, but it doesn't look like a sleeper.
People will expect you put a Porsche donk in her. Mitchell

So now you will have nothing to do with all your free time. Whats next?🙂

Great work Kev
👍

Great work Kev, any numbers on it yet

I love the look of this car as well. I think the orange with those wheels and the stance all seem so right.

Well done.

Yogie

Thanks everyone.

Mick - spare time, yet right 🙅

Steve - No numbers, still doing some final tuning and need to fix throttle as only getting 52% TPS due to shit worn system 🙁

I must say though, I love driving it. So much smoother with efi and even with half throttle and only seeing about 2psi of boost it starts pulling like a train 😉

Kev

Good stuff Kev, cant wait to see it

Awesome job mate , how's the tuning going ?

Wicked.

mandog wrote:Awesome job mate , how's the tuning going ?

Really good. The Megasuirt has a self learning mode which is jsut a matter of driving, but I am using a guy in the states whom is tuning it and has helped in leaps and bounds.

I download the tune and some data logging and send it to him via email and he replies with another tune attachement which I just open in my tuning program. Then when I plug the laptop into the car, it just asks if you want to update the ECU which I do.

Again go and do drivng and auto tune at the same time, again down load this new tune and logging and send back. We have done it about 5 times so far and its going great.

Not bad, tuned for $250. Of course a final tune on a dyno will be best which I will do in the future when I am 100% happy with what we are doing.

Kev

yep, dyno is the only way to get a proper ignition table dialed in. Thats where the drivability and power will come from.

I thought your build thread was awesome!! This engine really sets it on fire!! 👍 😏

adlbeetle66 wrote:This engine really sets it on fire!! 👍 😏

No, that was the old engine 😂😂😂😂😂 🥲

Camo wrote:

adlbeetle66 wrote:This engine really sets it on fire!! 👍 😏

No, that was the old engine 😂😂😂😂😂 🥲

lol

Hi Kev, haven't visited your thread for ages. Great to see, & hear it running.

Sensational planning, & execution, to squeeze all that motor under the decklid, & behind the apron.

Any updates??

Cheers, Muz.

Yeah 👍 and any numbers?

Great stuff !!! Maybe one day 👍