well at WPVW , we are at it again !! this time we are building up a 1916cc quad throttle-body , turbo-charged , intercooled VW manx buggy for a very insane customer . The buggy is currently registered and will be street driven with the occasional trip to the strip . I will post regular updates so that you can see this monster develope and keep you informed of updates . I'm sure this project will attract some critisim as the turbo oval project did , but for all those who are genuinely interested , THIS IS FOR YOU !!! this is not just an engine build , but a full resto and performance set-up .
front view of manx buggy
hypo-vw ·
rear view of manx buggy
hypo-vw ·
the heavy duty aluminium engine case . not yet machined for 94mm barrels
hypo-vw ·
BERG straight-cut steel on steel gear setnn[ Edited on 26-7-2005 by hypo-vw ]
hypo-vw ·
PAUTER pro-series alloy conrods with chromemoly bearing caps . VW journal . THESE ARE REALLY TOUGH !!
hypo-vw ·
SUPERFLO pro-series heads with valve covers . have not yet been ported and polished by WPVW
manifolds for the quad throttle bodies to suit the SUPERFLO heads
hypo-vw ·
RHINO transmission housing and chrome axle tubes
hypo-vw ·
BUGPACK heavy duty side covers
hypo-vw ·
BERG side plate strengtheners
hypo-vw ·
BERG heavy duty pinion bearing retainer
hypo-vw ·
ALBINS heavy duty close-ratio gear sets
hypo-vw ·
chromemoly heavy duty axles
hypo-vw ·
BERG 2600lb kennedy pressure plate
hypo-vw ·
BERG 3-puk race disc
hypo-vw ·
GARRETT TO4-E oil cooled turbo , thanks to FRED @ TURBOLOGIC nn[ Edited on 27-7-2005 by hypo-vw ]
hypo-vw ·
GARRETT intercooler core . We will have to manufacture both air and water tanks to complete this intercooler
hypo-vw ·
INJECTION PERFECTION quad throttle bodies
hypo-vw ·
MICROTEC LT-8S injection computer and wiring loom
hypo-vw ·
TIAL 45mm billet wastegate
hypo-vw ·
TURBOSMART supersonic blow-off valve
hypo-vw ·
TURBOSMART dual stage boost controller
hypo-vw ·
MALPASSI rising rate fuel pressure regulator
hypo-vw ·
WPVW engine room
hypo-vw ·
WPVW engine room
hypo-vw ·
WPVW engine room
hypo-vw ·
WPVW engine room
VWENVY ·
Holy Crap Batman!!:thumb
Whats the estimated power to weight on this thing?
warb ·
haha.. one page full of parts posts... crazy,
thats one sweet puzzle..
Doug Sweetman ·
That is some serious hardcore internals there...... those rods look indestructible !
This will be scary fast !
HAve you worked out what injectors you will need for it yet ?
Are you using a deep sump / extension ?
What / who's crank are you using ?
Look forward to further updates....... Hope the oval is still going strong.
Turbo54 ·
Did someone say $$$$$!!
Thats some hardware, how much are the pauter rods, I looked at them but thought they were mega bucks as well as the injection perfection TB's. Can't wait to see it come together. Do you think a little overkill for 1915? With the heads, case rods and transmission etc, why not stick a bigger crank and run less boost, im sure the internals can take loads of boost but the heads are going to out-flow anything a 1915 pumps out?
Turbo54
GL1972 ·
I wonder how it will perform in the sand?
BiX ·
Keep the updates coming, that will be an awesome ride.
pete wood ·
Out of curiosity, why are you using a rising rate regulator if it's gonna be fully programable EFI?
Mannnn thats fully sikkkk. I want one. Cant wait for the regular updates like your previous project.
sean68 ·
that would have to be my dream shopping list:duh
just have to keep dreaming a little while longer
soon soon
that will be one insane ride when finished
i've seen peter from canberra vw centre in his manx with a n/a 2276.....that thing goes like the clappers
fastnuf ·
I wouldnt mind that in the back of my manx. I could see the wind flowing over my bald patch and parting my beard as I pulled a wheel stand whilst driving down the main road.
Allthough I would be too scared to have a power plant like that in the back. It could give an old bastard like me a heart attack.
Can't wait to read the up dates on this awesome machine.......
Dasdubber ·
Holy moly - great stuff. Lets hope people can sit back and enjoy the rebuild rather than criticising someone else's ideas/work. Thanks for sharing it with us all as not too many would be able to build/own an engine like that!
hypo-vw ·
VWENVY wrote:Holy Crap Batman!!:thumb
Whats the estimated power to weight on this thing?
conservative estimated BHP @ the rear wheels should be around 240-260 . depends how it behaves itself as to how much boost will be run , but we are thinking around 22-24psi .
hypo-vw ·
Doug Sweetman wrote:That is some serious hardcore internals there...... those rods look indestructible !
This will be scary fast !
HAve you worked out what injectors you will need for it yet ?
Are you using a deep sump / extension ?
What / who's crank are you using ?
Look forward to further updates....... Hope the oval is still going strong.
they are pretty tough rods , rated at 1200hp I believe . The injectors have been calculated at 800cc . A deep 1 1/2 litre deep sump will be used . The crank is a Bernie Bergmann 69mm full-circle counterweight . ( couldn't post pics of crank and rods assembled yet as they are in the engine for a dummy fit-up , will post pics soon ). and thanks for asking about the oval , it has just had a new 24" long x 7" diameter muffler custom made and fitted . It is so quiet that you cant hear it running from 30 feet . I have taken several customers for test flights , and not one of them could believe that it was powered by a VW engine . will update the oval posts soon .
hypo-vw ·
Turbo54 wrote:Did someone say $$$$$!!
how much are the pauter rods, as well as the injection perfection TB's, why not stick a bigger crank
Turbo54
I purchased the pauter rods in 1997 for one of my 1600 speedway engines , but never got to use them . Back then they cost me AUD$1850 for the set . I'm not sure what they cost today . the 48IDF throttle bodies cost $680 each . When I had purchased the rods , I also purchased the crank to match . The rods are so large that the case has to be clearanced even with a 69mm crank . This is one of the reasons we decided to stay with 1916.nn[ Edited on 13-8-2005 by hypo-vw ]
hypo-vw ·
GL1972 wrote:I wonder how it will perform in the sand?
hope we never find out ! if you are near the sand at a drag strip , then you had better rethink the brakes . ha ha
hypo-vw ·
pete wood wrote:Out of curiosity, why are you using a rising rate regulator if it's gonna be fully programable EFI?
even though the efi system is fully programmable , it is still necessary to run the fuel pressure higher as the pressure in the intake manifold becomes higher . Thinking of the extremes , imagine what would happen if manifold pressure became higher than fuel pressure . High pressure air would blow back up the fuel rails when the injector pulses .
as for the cabrio - it is not water injected , however I have thought of fitting it . boost runs at 7 psi . the crank is a 2 litre counterweighted . the SU carburettor is a 2" off a 4.2 6cyl jaguar .
2443TT ·
Hey Hypo-vw, isn't it fun assenbling engines when all your parts arrive in shrink wrap!
Are you sure your injectors are large enough? I mean 4 x 800cc will only flow enough fuel for 580HP! If your aiming for 260-280 a more modest 550-660cc injectors would provide a more tunable (for low end drivability) than the 800's. (even with sequential efi)
Also, your clutch is a little on the extreme side too, especially for a 450-500kg buggy. A 3 puck and a stage 3 clutch would hold back 400+hp in a full bodied car, and you'd better have a hydraulic actuator conversion or you'll get really good at replacing clutch cables. I would have suggested a 4 puck and a 1700 lb clutch to hold back 300rwhp easy in a buggy, and not stress the drive line as much.
What rod length did you go for? What kind of pistons? Have you considered using an autocraft a dry sump pump with external oil pressure regulation, cause when this car hooks up you know your wheels will be in the air for 1st, 2nd and a little in 3rd, and your deep sump will be drained of oil rapidly at RPM with the oil strugling to get down to the deep sump again...
Sorry, I don't mean to rag on your project but after all forums are about sharing of knowledge after all. It looks like its going to be awesome once its finished.nn[ Edited on 27-7-2005 by iswinkels ]
hypo-vw ·
iswinkels wrote:Hey Hypo-vw, isn't it fun assenbling engines when all your parts arrive in shrink wrap!
Are you sure your injectors are large enough? I mean 4 x 800cc will only flow enough fuel for 580HP! If your aiming for 260-280 a more modest 550-660cc injectors would provide a more tunable (for low end drivability) than the 800's. (even with sequential efi)
Also, your clutch is a little on the extreme side too, especially for a 450-500kg buggy. A 3 puck and a stage 3 clutch would hold back 400+hp in a full bodied car, and you'd better have a hydraulic actuator conversion or you'll get really good at replacing clutch cables. I would have suggested a 4 puck and a 1700 lb clutch to hold back 300rwhp easy in a buggy, and not stress the drive line as much.
What rod length did you go for? What kind of pistons? Have you considered using an autocraft a dry sump pump with external oil pressure regulation, cause when this car hooks up you know your wheels will be in the air for 1st, 2nd and a little in 3rd, and your deep sump will be drained of oil rapidly at RPM with the oil strugling to get down to the deep sump again...
Sorry, I don't mean to rag on your project but after all forums are about sharing of knowledge after all. It looks like its going to be awesome once its finished.nn[ Edited on 27-7-2005 by iswinkels ]
We chose 800cc injectors as we are currently using 550cc 13b turbo injectors in the oval , and it runs out of fuel at 15lbs ( this is why i could only run 14lbs @ the VW drags ) the engine in the buggy is much smaller but we plan to run a lot more boost than I am currently using . If we have trouble tuning the bottom end , I may have to run 8 smaller injectors in a progressive pattern .
The buggy currently weighed 510kg with a stock 1600 . I suspect that the tare weight will rise about 50-60kg to around 560kg once all the plumbing is completed , pumps ,radiator for the intercooler, oil cooler, larger ignition coil etc . If all clutch components are fitted correctly the clutch cable should not suffer . I have run a 3000lb stage 4 pressure plate in my sports sedan now for 5 years , participated at 32 race meetings which means a lot of gear changes , the clutch pedal feels like stock and have never replaced the cable yet . The 3 puk disc is a little harsh , but very usable on the street . One of my employees has run a 3 puk in his 2165 63' bug on the street now for 4 years without any problems .
rods are stock length , pistons are 94mm mahle 'b' type and wheelie bars will keep the front down to a respectable height .nn[ Edited on 27-7-2005 by hypo-vw ]
Brad ·
that is awesome .. I look fwd to hearing it run .....
wibble ·
Watching intently... my manx will be getting reborn over the next six months with a tough webber fed stroker (thanks to Iswinkles) cant wait to see this build up though!
pete wood ·
hypo-vw wrote:rods are stock length , pistons are 94mm mahle 'b' type and wheelie bars will keep the front down to a respectable height.
Are you planning to add eletric steering to them? coz from what I see the main steering wheel will just be for decoration.
:P
jakjones ·
High powered VW Buggy,
Yum🙅
bajaben ·
just wondering where you got the turbo and injector kits from. am looking at doing the same to my 1776cc 65 baja and running about say 4-7 psi as a daily driver, should scare the pants off some people in town who think they are all that
Adolph ·
That thing is going to be fast!!!!
What cam?
How much boost?
2 bar in that engine should make over 400Hp!!:thumb
dubbill ·
an updates???
hypo-vw ·
the engine case has been stripped of all its studs and is ready to bore for the 94mm barrels . I have taken my time and done a lot of homework over the past 2 weeks on the engine case alone as there are a lot of bad reports out there about them . I have even emailed Gene Berg Enterprises and discussed this with their technical support department . I have heard rumours of engine oil system problems due to the oil pressure relief valves not seating correctly and I have had 2 customers of my own have oil leakage from the crank pulley area . After investigating these problems extensively , I have found that the new heavy duty alloy cases have not been fitted with an oil restricter to the front snout bearing ( as the origional cases had ) so excessive amounts of oil in this area cannot escape back through the oil drain and is forced out the rear pulley area . This will be rectified on this case , and the case will be machined at the front spigot with a seal fitted also .
hypo-vw ·
transmission housing has had all of the ribs fully polished
hypo-vw ·
a closer shot of the polished ribs . when the transmission is completed , the ribs will be masked and the trans will be painted gloss black .
hypo-vw ·
fully polished heavy duty side covers
hypo-vw ·
side plate fitted to housing to give you an idea what the trans should look like
hypo-vw ·
the turbo plenims that bolt onto the top of the injection throttle bodies has arrived
hypo-vw ·
the 911 Porsche 11-blade fan assembly has arrived for the 1916cc engine . I wasn't able to find anything available here in OZ , so I had it shipped from the US . will also have a couple of spares in stock soon .
hypo-vw ·
the 94mm piston & barrel assembly has arrived and I am now ready to machine the case to suit them
hypo-vw ·
to ensure that all the compression stays in the cylinders and doesn't end up inside the crankcase , a set of PERFECT SEAL gapless rings will be used
hypo-vw ·
the next step for this project now is to machine the engine case to suit the 94mm barrels , machine the front spigot to take a pulley seal , refit all case studs , then do a dummy assembly of the engine including calculating compression ratio so that the engine can be fitted to the buggy with its correct width and fan housing / manifolds / injection throttle bodies / plenims / exhaust / turbo all fitted . Then the intercooler can be fitted and the necessary modifications can be made to the body for the plumbing prior to removing the body from the pan to have it painted .:jesus
hypo-vw ·
bajaben wrote:just wondering where you got the turbo and injector kits from. am looking at doing the same to my 1776cc 65 baja and running about say 4-7 psi as a daily driver, should scare the pants off some people in town who think they are all that
I dont buy turbo or injector kits . I just purchase all the individual components and then custom make each turbo assembly to suit each individual application .
We are working on developing our own bolt-on turbo kit at the moment so that a customer can come in off the street and purchase a kit off the shelf to fit to their stock / healthy 1600 dual-port engine .
bajaben ·
well good luck with that kit because i will definately be in line for one. in the proccess of saving alot of money so i can get a kit, fuel injection is gonna be the way to go. hope to see some proccess of the kit, also it looks like the manx is gonna be a very tidy buggy indeed
2443TT ·
I'd agree there. Turbo kits are a great way to get a handle and understanding on how a turbo system should go together, but once you've got that sorted there are so many ways you can improve on the standard kit. Cb's kit for example is one of the most complete bolt on kit around and without parts of their system I wouldn't have the grasp on turbo's and efi that I do today.
Basically great to learn with and great fun for most vw entheusiests, but if your looking for some crazy power, you've got to engineer the entire system from scratch.
I've read through the entire thread again, and can't find what cam your going to use? I used a CB2242 (298 intake, 0.430") cam in my 1641 and it could barely pull a vacuum with the quad throttles to -10hg. The new stroker engine thanks to its larger displacement and the TCS-10 cam puls -35-40 stable.
Should make it a LOT easier to tune for low end economy, cause after all thats what we are all after when we build $15-20K engines right 🙂
Did you mention engine management? Which kind and what components... injectors etc...?
Just a thought, but I don't know if you've heard of the "issue" that can happen with the superflo heads... Capsoval (Kirk ?) off the shoptalk forums ran superflo 1 heads on his 2332 turbo for about 6 weeks and the valve guides came loose in the head. They weren't pressed into the head properly from factory and were too loose a fit. That was the only reason I figured it was safer to go with the CB competition eliminator instead. Known product history and reliability. It might pay to check that out...
Cheers,
Adolph ·
Are your customer going to race the buggy, or is it going to be for show?
If he is going to drag race it, in what class do you expect it to run, and are you going to show the build of the chassis and cage as well?
Thanx I really like the build posts.
Hermann
Doug Sweetman ·
Then you will enjoy this one Hermann - when Mr Penrose builds a car, he really builds a very nice car !
hypo-vw ·
Adolph wrote:Are your customer going to race the buggy, or is it going to be for show?
If he is going to drag race it, in what class do you expect it to run, and are you going to show the build of the chassis and cage as well?
Thanx I really like the build posts.
Hermann
The buggy is primarily being built for street use , with the occasional trip to the strip . Will probably run just as a street registed car , he really hasn't looked into classes to the best of my knowledge . If anyone can assist or advise on this issue , please let me know .
I will show the entire build of the buggy , not just the engine and transmission .
hypo-vw ·
after 3 very busy weeks in the engine room with 2 engines and 3 transmissions built for other customers , I now have the time to get back onto the buggy !! Today I finished boring the new aluminium engine case for the 94mm barrels .
hypo-vw ·
after the engine case is bored , then the 2 case halves are refaced where the barrels seat , to ensure that the barrels sit square and that the deck-heights are the same on both sides of the engine . This will make sure that the compression ratio will be the same on both sides .
hypo-vw ·
The superflo heads are then fitted with the inlet manifolds and injection throttle bodies to prepare the engine to be pre-assembled and fitted to the buggy to start manufacturing the turbo plumbing .
hypo-vw ·
a view from the top of the injection throttle bodies when fitted to the head
hypo-vw ·
the turbo plenims are then fitted to the throttle bodies .
hypo-vw ·
bare long motor assembled with no internals , just the 94mm barrels , the berg headstuds , and the superflo heads .
hypo-vw ·
the buggy engine is to be fitted with a 911 cooling fan and fibreglass shroud . The shroud requires some modifications to get it to fit with the superflo heads .
hypo-vw ·
the fan shroud was modified later this afternoon and now fits very nicely around the superflo intake ports .
hypo-vw ·
the engine pre-assembly is now complete and the engine will be fitted to the buggy tomorrow . Will show next stages with engine fitted and turbo plumbing soon !!
hypo-vw ·
another view of the pre-assembled engine with 911 cooling fan assembly , injection throttle bodies and plenims fitted .
56astro ·
Mmmmmmm
2 injector bosses per TB .......
fuel and ..........
NO2 ?
methanol ?
fuel ?
The porsche cooling system gives alot of room around the engine compared with a T1 cooling system eh?
Nice work.
inthebuckethenry ·
I love this shit!!!! 😵💫
thanks for sharing :thumb
hypo-vw ·
yesterday the buggy was placed up on 4 stands in the main workshop area ready to start the pre-assembly and manufacture the turbo plumbing . first step is to remove all the rear lights , wiring , hoses , clips etc . basically anything at all that may get in our way when trying to fit-up the engine and transmission assembly . Number 1 priority is to fit the engine / transmission / turbo & plumbing / intercooler / oil cooler / radiator . everything else can be altered or modified to fit later .
hypo-vw ·
rear view of the buggy , stripped out .
hypo-vw ·
inside the rear of the buggy was an oil cooler , oil filter , breather box and the ignition coil .
hypo-vw ·
engine bay area stripped out
hypo-vw ·
transmission housings assembled and fitted with nolathane engine mountings , ready for fitment .
hypo-vw ·
engine and transmission assembly bolted together to check crossmember clearances .
hypo-vw ·
transmission assembly strapped into chassis .
hypo-vw ·
oil cooler , oil filter , breather box , igition coil and aluminium firewall removed to expose a very poor condition origional fibreglass firewall .
hypo-vw ·
fibreglass firewall cut-out and removed . at a later date , a new removable firewall will be manufactured and refitted .
hypo-vw ·
view from the rear of the buggy with the firewall removed .
hypo-vw ·
engine fitted to buggy for the first time .
hypo-vw ·
rear view with the engine fitted .
hypo-vw ·
stainless steel extractor fitted . will be modified for the turbo .
hypo-vw ·
turbo mounted .
hypo-vw ·
turbo fitted and stainless steel muffler mounted to enable me to manufacture exhaust plumbing ( with the help of LINCOLN @ TEDS MUFFLERS DAPTO )
hypo-vw ·
close up of the turbo fitted to the extractor .
hypo-vw ·
exhaust plumbing being manufactured and the wastegate has also been fitted .
hypo-vw ·
another view of the turbo and the 45mm TIAL wastegate .
reub ·
You're crazy Wayne....I love it!
inthebuckethenry ·
:jesus
Doug Sweetman ·
Is that a T4 or variant ? Bloody hell, that is gonna be a weapon for sure !
Very nice !
hypo-vw ·
Doug Sweetman wrote:Is that a T4 or variant ? Bloody hell, that is gonna be a weapon for sure !
Very nice !
no its not a type-4 engine . its a 1916cc type-1 engine with a porsche style fan cooling assembly . however I do expect that this engine will produce more horsepower than my 2.9 type-4 engine that I am running in the oval .
Doug Sweetman ·
oops, sorry Wayne I meant to say T4 turbo.... just that the exhaust housing looks huge !!!
All work is looking up to your always high standards as per usual Wayne, good worknn[ Edited on 6-9-2005 by Doug Sweetman ]
ruckus ·
Damn you work quickly!
Very inspiring.
dangerous ·
That's Wayne dude.....
darwin_ladybug ·
sick................where did u get all the parts???
hypo-vw ·
Doug Sweetman wrote:oops, sorry Rod I meant to say T4 turbo.... just that the exhaust housing looks huge !!!
All work is looking up to your always high standards as per usual Rod, good work
If you are going to comment on my posts Mr Sweetman don't call me Rod . I have spent over half my life working on VW's to get the good name that I have . Too many times in the past other family members have taken credit for the outstanding work that I do at WPVW . In case you are confused , I am Wayne . please edit you post ASAP and change the names .
Regarding the turbo , it is a TO4-E with a .70 inlet and a .84 exhaust . It is an oil-cooled unit .
hypo-vw ·
darwin_ladybug wrote:sick................where did u get all the parts???
I carry most of the parts shown in stock at most times . Items like turbos , EFI computers have to be ordered to suit each individual application . Items like plumbing arrives at my shop in the form of a large box of various size mandrel bends , and the exhaust and inlet system has to be designed and manufactured for each application . just give me a call on 02-4272 5844 if you want to discuss a particular project that you have in mind. HAPPY TO HELP!!
hypo-vw ·
here are a few shots of the completed exhaust system and wastegate plumbing , including muffler .
hypo-vw ·
another view of the completed exhaust system .
hypo-vw ·
close-up shot of the wastegate and plumbing .
hypo-vw ·
a view from the front of the buggy showing the rear of the engine and the manufactured cross-over pipe between the 2 plenims . also fitted with the blow-off valve .
hypo-vw ·
close-up shot showing the GARRETT TO4-E turbo , TIAL 45mm wastegate , Porsche 911 cooling fan assembly , IDF injection throttle-body , cross-over tube with SUPERSONIC blow-off valve , and the approximate location of the intercooler core .
BiX ·
That is a very sweet piece of work. Are there any issues with the turbo being so close to the inlet for the cooling fan? or will this be sheilded so as not to draw in hot air?nn[ Edited on 5-9-2005 by BiX ]
hypo-vw ·
the exhaust housing of the turbo will we fitted with a stainless steel heat shield to avoid large amounts of hot air being drawn into the fan .
71superbug ·
dont you think that the t04E might be a bit large for a 1916cc?.
Anthony🥷
Doug Sweetman ·
Sorry Wayne, understand that was an honest mistake, so no need to get upset.
I get everybody's name wrong here, theres no malice in it.
t2 ·
looks awsome ...........now if only i understood what i was looking at........
Turbo54 ·
I wouldv'e thought it would be better to run the turbo and otherbits on the otherside of the engine over the wheels to prevent mono city! Also drawinghot air off the turbo in to the fan might be a problem even with a sheild of sorts.
No question it should go like stink, if the body hold together!
T54
hypo-vw ·
71superbug wrote:dont you think that the t04E might be a bit large for a 1916cc?.
Anthony🥷
I dont think so , as we are planning to run the engine to 8500rpm and will need the larger housings to get the flow required .
hypo-vw ·
Turbo54 wrote:I wouldv'e thought it would be better to run the turbo and otherbits on the otherside of the engine over the wheels to prevent mono city! Also drawinghot air off the turbo in to the fan might be a problem even with a sheild of sorts.
No question it should go like stink, if the body hold together!
T54
the awsome amount of heat produced by the turbo would create problems with the limited amount of available space in the back of the buggy . You have to remember that in the back of the buggy will be an intercooler ( air-to -water ) , ignition coil , breather tank , microtec EFI computer , wiring looms , battery , speakers , subwoofer , amplifier , dual-stage boost controller and other items . Putting the turbo in there is just not an option on this buggy . I am not at all concerned by the small amount of heat that will be drawn into the cooling fan as there is massive amounts of air turbulance at the rear of the buggy to disperse 95% of the turbo heat . Also my cabrio runs the turbo in the engine bay just behind the cooling fan and the high volume of air pumped by these units does compensate for the additional heat . I am extremely confident that no overheating problems will be evident . as for the weight hanging out the back of the buggy , the only additional weight is the turbo and wastegate which weighs approximately 6 kilos . All the other exhaust plumbing is there on a buggy any how . To try to compensate for the additional weight of the turbo , we have decided to manufacture a new rear engine cage from aluminium rather than steel . thanks for your comments , much appreciated .
hypo-vw ·
Doug Sweetman wrote:Sorry Wayne, understand that was an honest mistake, so no need to get upset.
I get everybody's name wrong here, theres no malice in it.
thanks Doug , no problem . just a little touchy on the subject . I go to sleep at night knowing that I have done the right thing by all of my customers .
71superbug ·
ahh ok...fair call WAYNE :P.
was just curious about the turbo sizing thats all.
how is it in comparison to the to4b. as i know these turbos are good for 300rwhp on a rotary...what made you decide to go the t04 over a newer garrett GT ball bearing unit?
Anthony🥷
hypo-vw ·
71superbug wrote:ahh ok...fair call WAYNE :P.
was just curious about the turbo sizing thats all.
how is it in comparison to the to4b. as i know these turbos are good for 300rwhp on a rotary...what made you decide to go the t04 over a newer garrett GT ball bearing unit?
Anthony🥷
all ball bearing type turbos are water cooled units . I know that we are going to run a small radiator for the intercooler , but I did not want to heat the water up by passing it through the turbo . It is critical that we keep the intercooler as cool as possible . I chose to stay with a wet bearing ( oil-cooled ) turbo for this reason .
2443TT ·
Oil cooled is less complicated alright. I run two seperate liquid cooling systems. The one for the intercooler that uses a 3/4" davies craig pump, and the other for the turbine bearing housing uses a swiftec 3/8th pump. The amount of hoses under the back of my car makes it look like spaghetti!
GT's provide faster spoolup, but thats not a factor if your going to be reving it to 8500 RPM so not only is it simpler to install, its a little overkill. I did notice a drop in overall oil temps when I hooked up the water cooling on my GT turbo though, which is important when your dealing with a performance engine that you want to survive.
I'm curious to know your plans for rear tyre sizes, gear ratio's and diff ratio.
dangerous ·
What cam are you planning to use Wayne?
Perhaps you might like to call "Sure Cam" up here in Brisbane (Stafford).
He is very clued up on Turbo cams and has a lot more up to date technology than most US companies.
A little expensive but worth every cent.
Don't have his number on me but will let you know if you are interested.
hypo-vw ·
iswinkels wrote:I'm curious to know your plans for rear tyre sizes, gear ratio's and diff ratio.
The buggy is currently running 31" rear tyres on 8" wide rims . gear ratios chosen are 4.11 / 2.31 / 1.70 / 1.40 and a 3.875 ring & pinion . Probably run on 28" slicks at the strip ( but not confirmed as yet )
hypo-vw ·
dangerous wrote:What cam are you planning to use Wayne?
Perhaps you might like to call "Sure Cam" up here in Brisbane (Stafford).
He is very clued up on Turbo cams and has a lot more up to date technology than most US companies.
A little expensive but worth every cent.
Don't have his number on me but will let you know if you are interested.
Thanks Dave , can you send me u2u with those details .
13BVW ·
Good stuff. cant wait to give ya a run on the track. By the way, my manx puts out 216 at the wheels on 10psi.Have run 11.98@114 taking it easy cuz the box the stuffed.
Who did your gearbox? Mine is shot and I need some help.
hypo-vw ·
13BVW wrote:Good stuff. cant wait to give ya a run on the track. By the way, my manx puts out 216 at the wheels on 10psi.Have run 11.98@114 taking it easy cuz the box the stuffed.
Who did your gearbox? Mine is shot and I need some help.
At WPVW we do our own transmission building / reconditioning / modification / race-prep . call me on 02-42725844.bus hrs .
bajachris88 ·
Could u plz u2u me an estimated budget for this total engine/transmission proj? Be wondering, would be worth saving for in the future if i decide to go that way, cause thats gonna be wild.
kroozzn63 ·
man you should make a kit like that with a basic price ,as a bolt on , everyone on here would then have a basic guide to build a motor for, and therefore have a more realistic idea on price because its allways the question on threads with pics of an awesome setup like this..
MickH ·
Get back up there matey.....
MickH ·
bump...Any more progress??
kyro ·
Man thats one fully sick Buggy
hypo-vw ·
the rear panel of the buggy has been cut / modified to allow us to manufacture a much smoother looking rear panel without the bumps and rises in it .
hypo-vw ·
another view of the rear panel modification
hypo-vw ·
seats and carpets removed
hypo-vw ·
a view of the dash and instrument panel prior to stripping . You will be able to compare the new look dash with this image at a later date
hypo-vw ·
the rear floor section has now been cut out much larger and the entire firewall and floor section removed will be replaced with perspex or lexen , so that the engine and transmission detail will be visible
hypo-vw ·
rollcage removed from body
hypo-vw ·
another view of the buggy with the rollcage removed
hypo-vw ·
the engineer ( Cris Dowde Engineering , Dapto ) does a dummy fit-up with the intercooler to make sure everything fits prior to welding the unit together
hypo-vw ·
front screen removed from the buggy
hypo-vw ·
all lights are removed
hypo-vw ·
the bonnet is removed from the buggy to find a huge mess !!
hypo-vw ·
the wiring at the back of the dash assembly is a mess !!
hypo-vw ·
looks a lot cleaner under the dash now with all of the wiring removed
hypo-vw ·
the guages and switches are removed from the dash assembly
hypo-vw ·
THE WIRING IS NOW WHERE IT BELONGS !!
hypo-vw ·
more surprises as the aluminium panel is removed from the dash assembly to reveal a very butchered dash . This will have to be repaired before fitting any of the new guages
hypo-vw ·
dash removed from the buggy . Note how the steering column was attached to the main dash support . HOSE CLAMPS !! very clever................
[ Edited on 25-10-2005 by hypo-vw ]
hypo-vw ·
the pedals are then removed from the floorpan
hypo-vw ·
the clutch pedal hook is found to be extremely worn . If these pedals had not been removed , the hook would have broken off in the very near future
hypo-vw ·
I managed to locate the moulds for the Manx genuine side-pods and we are manufacturing new side-pods for the buggy . We will then mould these side-pods into the existing body to give the buggy that 'modular' look . The side pods will then be modified and used as air-ducts as I will fit a small radiator at the rear of the right side ( to cool the water for the intercooler ) and fit an oil cooler at the the rear of the left side
hypo-vw ·
the new 'flamed' headlamps for the buggy
hypo-vw ·
after trying several different types of seats in the buggy , we have decided to stay with the original seats and have them retrimmed in leather @ Karens Auto Trimming
hypo-vw ·
a new lockable fuel filler has been purchased and will be fitted to the tank . The old one is pictured on the left
hypo-vw ·
the new 'flamed' taillamp assemblies that will be fitted to the buggy
hypo-vw ·
the flamed taillamp cover positioned at the rear of the body
MickH ·
Sweet...:blush
NigeType3 ·
This 'ROCKS'
Craig Torrens ·
Mx 5 seats fit well.........would look good in leather.
humpty ·
Now there's a good tip...Cheers for that Craig!
this buggy is sure coming along Wayne...Good job.
Noticed you are running a swingaxle transaxle... Sticking with it for strength? Those plenums look interesting also...Where'd you find them? Good to know you have genuine MANX side pod molds...now all I need is a MANX (style) to ft them too! My dream buggy..the only one I will ever own!
Great work, keep it up..
Craig Torrens ·
That's what I've used in my J&S......................They also have speakers in the head rests as standard !!
BiX ·
Also concerning the MX-5 seats, there is one style of race seat that will fit an MX-5 so therefore it should fit the manx. For the life of me i can't remember, total mental blank. I think it was the GP-90 or that brand anyway.
wibble ·
OBX also make seats the right demensions to suit
Brad ·
cool, any info on those caps ?
hypo-vw ·
the dash assembly under repair . I also decided to widen the face of the dash to accomodate the new guages
hypo-vw ·
view of the modified / widened dash face
hypo-vw ·
the dash face is prepared for primer .
hypo-vw ·
I have decided to make further modifications to the dash assembly to fit the 5" speedo and tacho , also a mounting area for the dvd unit
hypo-vw ·
Michael removing the engine from the buggy so that fibreglass repairs to the body can commence
hypo-vw ·
the turbo engine removed
hypo-vw ·
the completed modified dash assembly
hypo-vw ·
another view of the dash
hypo-vw ·
the firewall behind the front seats is removed and will be replaced
hypo-vw ·
all body holes are being repaired and filled with fibreglass resin
hypo-vw ·
fuel tank now removed from body . body now looks very bare
hypo-vw ·
a section of the fibreglass on each side is cleaned and prepared so that we can fit speaker bowls . this will allow us to fit speakers to the inside panel at a later date , without the rear of the speakers getting damaged from the weather . this bowl also helps the speaker to perform better
hypo-vw ·
the speaker bowls need to be fitted prior to fitting the side pods
hypo-vw ·
additional tubes are fibreglassed into the body prior to fitting the side pods . these tubes will hold items such as fuel hoses
hypo-vw ·
right side pod trimmed and fitted into place
hypo-vw ·
left side pod fibreglassed into place after being trimmed
Dasdubber ·
Thanks for the update pics - looking really good.
Turbo54 ·
Looking Great Wayne, especially because I have never seen one of these go together before. Keep it coming.
Turbo54