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 2443TT
A.k.a.: Ian
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| posted on July 7th, 2005 at 10:12 PM |
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2332 Turbo progress update
Hey all, I'm having de-ja-vu... having posted this already before the forum got rebuilt.. but anyway...
Here it is again, my new 2332 turbo engine.... These pics show the progress of the construction of the new header.
I am only learning to tig weld, and fortunatly I'm only tacking it and i'm having a professional weld it all up properly.
Well here's the pics....
Cya,nn[ Edited on 7-7-2005 by iswinkels ]nn[ Edited on 7-7-2005 by iswinkels ]
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2443TT
A.k.a.: Ian
Fahrvergnugen
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| posted on July 7th, 2005 at 10:13 PM |
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Another picnn[ Edited on 7-7-2005 by iswinkels ]
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2443TT
A.k.a.: Ian
Fahrvergnugen
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| posted on July 7th, 2005 at 10:15 PM |
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Another picnn[ Edited on 7-7-2005 by iswinkels ]
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reub
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| posted on July 7th, 2005 at 10:16 PM |
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Sweet DUDE! :thumb
Reub
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VWCOOL
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| posted on July 7th, 2005 at 10:17 PM |
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Ohhhh yeah...!:thumb
Pay your debts, CxxT
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2443TT
A.k.a.: Ian
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| posted on July 7th, 2005 at 10:17 PM |
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Another picnn[ Edited on 7-7-2005 by iswinkels ]
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2443TT
A.k.a.: Ian
Fahrvergnugen
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| posted on July 7th, 2005 at 10:20 PM |
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Another picnn[ Edited on 7-7-2005 by iswinkels ]
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2443TT
A.k.a.: Ian
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| posted on July 7th, 2005 at 10:24 PM |
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Last one... for till I buy some more stainless!
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dangerous
A.k.a.: Dave Butler Muffin Man
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| posted on July 8th, 2005 at 06:22 AM |
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What have you decided to do with the tranny Mr Iswinkles?
| Quote: | Originally
posted by westi
That's mad Alan.
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2443TT
A.k.a.: Ian
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| posted on July 8th, 2005 at 09:35 AM |
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I'm going to be using a MD4E Mendeola in swing axel configuration.
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Turbo54
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| posted on July 8th, 2005 at 09:46 AM |
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Hi Ian,
I deceided to go the same path, GT2871RS w/ .86 exhaust housing. The smaller housing apparently has over boosting problems.
Should look like this!
T54nn[ Edited on 7-7-2005 by Turbo54 ]
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C'mon kids gather round,
there's a new sensation hitting town,
It's moving straight, low to the ground,
it'll pick you up when your feeling down.
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Doug Sweetman
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| posted on July 8th, 2005 at 10:28 AM |
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nice work - where did you come up with the design ?
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Turbo54
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| posted on July 8th, 2005 at 12:00 PM |
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The header design is similar to one being worked on by someone on another website that Ian and myself are on a fare bit. I am doing the same setup
with mine. Its great beacuse it hides all the junk pipe behind the engine leaving a good amount of room to use a decent sized turbo and exhaust. The
original design by Purple69 looks like a bit of a bitch to get off the motor once on so I and Ian will be putting a few more flanges in for easier
fitment. Ian, I would of made the shortest pipe (No.3?) go under the other pipes and a bit of a bigger radius on the bends so its not so sharp. (heat
on the bend and back into head). Just a thought, Turbo54
C'mon kids gather round,
there's a new sensation hitting town,
It's moving straight, low to the ground,
it'll pick you up when your feeling down.
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2443TT
A.k.a.: Ian
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| posted on July 8th, 2005 at 12:12 PM |
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Turbo54, the bend does look sharp, but its not realy. There is about a 1/4 inch of straight pipe inside the flange on the number 3 cylinder and its a
full 90 degree bend from there. Its just the angle from which the photo was taken that makes it appear to be sharper.
The only big diference I made compared to purple67's header design was the system uses a merged collector instead of a 4 into 1. This makes my
collector shorter and smaller so its not as close to the cylinders. The header is all stainless as well.
About the GT2871 overboosting when its got the '64 housing, that becuase the turbo still has the GT25 size wastegate hole size, so it can't vent
enough exhaust gas to keep boost constant. Particularly a problem when boosts get up high on 2lt engines, or on engine larger than 2lt when exhaust
flow is increased a lot. There are two options to solve this. The easiest is to port the gate a little with a die grinder but that will only work so
far... The best option is to run an external wastegate, and if you can afford it, invest in an electronic boost controller like a eBoost or an AVCR
Apexi.
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2443TT
A.k.a.: Ian
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| posted on July 8th, 2005 at 08:06 PM |
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Another few pics of the header.... nearly finished. Just need one more bend (which I forgot to buy today). I might get lucky tomorrow and the place
I get my stainless from at wholesale price might be open still.
Anyways... the pics...
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2443TT
A.k.a.: Ian
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| posted on July 8th, 2005 at 08:07 PM |
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Last one for today...
nn[ Edited on 8-7-2005 by iswinkels ]
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Turbo54
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| posted on July 9th, 2005 at 08:37 PM |
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Ian, can you please post a picture from the other side.
I want to see how the merged 4-1 looks. Also what diameter is the pipe to the turbo going to be?
T54
C'mon kids gather round,
there's a new sensation hitting town,
It's moving straight, low to the ground,
it'll pick you up when your feeling down.
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pete wood
A.k.a.: figure itout
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| posted on July 9th, 2005 at 09:29 PM |
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Man, I have to say I'm impressed. I'm not sure what blows my mind the most. The cash, the components or the detail going into this. Can't wait to
see it altogether, especially with the mendeola tranny. BTW, how much mods are needed to fit the mendeola into your chassis? Is it a 4 or 5 speed?
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Adolph
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| posted on July 10th, 2005 at 04:55 PM |
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Where did you get the SS bends and flanges from?
Who is a supplyer of weld on flanges, or did you get it from a mufler shop?
Thanx Hermann
2000cc turbo type 4, dragster (325Kw)
2714cc no turbo, no gas, street bug (140Kw)
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2443TT
A.k.a.: Ian
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| posted on July 13th, 2005 at 10:25 AM |
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Well its back to the drawing board with part of the header design. I took the header to a mate to have the tig welds done properly and he told me the
way i'd put it together made it impossible to finish the welds off. I have since attacked the header with a drop saw and have begun making it
slightly diferently.
The merged collector is now being replaced with a normal 4 into 1 section, simply because it can be welded on more easily. I know its a cop-out but
after talking with my tig welding mate, he says I should have started at the merge and worked backwards from there, as well as made the collector come
together in sections... hard to explain, but I know its beyond my capabilities...
The up pipe to the turbine T25 flange will be 2", and blended into the rectangle input pipe.
As for the flanges, the head flanges cut locally here at a machine shop that does water jet cutting from autocad drawings, so they are very accurate.
The 2.5" flanges are laser cut and I got them from Ebay in australia (they were cheaper than the water jet cut ones). Last of all I got the T25
flanges from ebay in the us.
I'll post some more pictures after I've got the new collector sorted out.
As for the mendola transaxel, I can get it built to the same specs as my current gearbox. Axel tubes and axels etc will be the same length so my
porsche brakes will bolt right on. The M4D trans will more or less bolt straight in as well when built as a swing axel box. I believe its a lot
harder when you start converting to 930 cv's etc, as your then into custom length axel territory... talk to Reub (VWrx) about how much fun they are
to work with!
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64vwmark
A.k.a.: Mark Shepherd
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| posted on July 13th, 2005 at 10:34 AM |
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How much power are you expecting to get out of it?
What compression ratio are you running?
Beach Buggy
74 L Beetle
Mk4 Golf |
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2443TT
A.k.a.: Ian
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| posted on July 13th, 2005 at 01:18 PM |
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I'm hoping for about 280-300hp at the wheels, so i think thats around 350 crank HP.
The specs of the engine are:
rimco modified vw crankcase, modified with turbo oil return in the left side of the factory sump secton
84mm CB 4340 billet crank, nitrided, etc
Scat 4340 12lb flywheel, 8mm dowels, wedgemated
Scat 5.325" rods with 3/8" arp bolts (43ft-lb torque)
Clevite 77 bearings
Mahle pistons weight matched with total seal 2nd ring and chromoly top rings
Engal TCS-10 cam, Magnum 8640 straight cut steel gears
Scat light weight lifters
CB competition eliminator heads with 44x38 valves, ported and polished, 52cc combustion chambers, titanium retainers, etc.
Bugpack 32mm pump, avid remote oil pressure reguator with return to extended sump.
Electric oil pump with remote oil cooler (controlled by the engine management)
Empi wide profile sump, modified with 4 fittings for senders and oil returns etc.
Scat pro comp 1.25:1 rocker gear (from my current engine), and aircooled.net alloy pushrods
660cc injectors (good for 100kw per cylinder).
Same intercooler/induction system as on my current engine, new stainless header.
The engine is setup with 7.8:1 compression, and I intend to run a max of 15lb boost once its run in. In street tune it will be a conservative 6lb
which should still make 200hp.
The two modes on the boost controller will be labeled race WRX, and race GTR.  Actually i'll probably get an apexi boost controller so i can preset boost levels in each gear, and
also ramp the boost on slowly, otherwise it will just have too much traction problems.
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dangerous
A.k.a.: Dave Butler Muffin Man
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| posted on July 13th, 2005 at 07:19 PM |
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Thanks for responding to our questions, Ian, there's some good info there.
| Quote: | Originally
posted by westi
That's mad Alan.
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2443TT
A.k.a.: Ian
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| posted on August 5th, 2005 at 11:57 PM |
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Well the header is finished, and came up pretty good too. I've polished 1/2 of the down pipe and the wastegate.
The rest of the header is being wrapped in 3mm x 2" header wrap.
I wimped out with the construction of the 4 into 1 merged collector, and instead had all 4 pipes go to a flat 90x90mm stainless plate. I then got a
4" to 2" reducer and flattened the 4" end out to be square, and tigged that onto the 90x90 plate. It turned out way better than I had imagined.
Also, after removing the 1641cc turbo engine i've measured up and it is possible to fit a pair of small r33 GTR turbo's under the rear apron of a VW
AND hide them. That would make the exhaust extremely easy to setup. If I ever end up considering a turbo upgrade beyond the GT28-71, it will be to a
pair of GTR V-spec turbo's. They high-flow those suckers and make 400KW out of them!
The 2332 turbo engine is now installed in the car at last!
It would have been running this weekend but my supplier of earls fittings didn't get the order through in time, so the oiling system is incomplete.
It should be nice though cause its all -10 AN stainless braided hose and anodised fittings.
So far the cooling shroud is mounted and modifed to clear the competition eliminator heads, and everything is pretty much finished. All that remains
now is cleaning and assembly of the induction side of things.
I'll post more pics tomorrow.nn[ Edited on 5-8-2005 by iswinkels ]
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2443TT
A.k.a.: Ian
Fahrvergnugen
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| posted on August 7th, 2005 at 12:36 AM |
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Well i've finally fitted up the turbo header today after thermo wrapping the entire header.
The garrett GT28-320 turbo internal wastegate is now properly blocked off with a bolt down link to bolts on the t25 flange. It works very well and
doesn't interfere with any of the other turbo fittings or adjustments which is a nice change from how I had it setup last time.
Tomorrow the cooling shroud goes on, as does the manifolds, and throttle bodies, distributor, ignition leads etc. At which point the engine could be
fired up if I had oil lines that is.... I'll just have to spend the next two days polishing my intake pipes and intercooler...
Can't wait to head the beast running. I've already got a race tee'd up with a 450rwhp GTS-T skyline. Will be great fun having one of the fastest
cars in Cairns!
Well enough crap, here's some more pictures...
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2443TT
A.k.a.: Ian
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| posted on August 7th, 2005 at 12:37 AM |
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Another pic
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2443TT
A.k.a.: Ian
Fahrvergnugen
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| posted on August 7th, 2005 at 12:38 AM |
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Last pic for today...
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reub
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| posted on August 7th, 2005 at 01:58 PM |
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Looking good DUDE. Can't wait to hear how it goes.... :thumb
Reub
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pete wood
A.k.a.: figure itout
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| posted on August 7th, 2005 at 02:44 PM |
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Out of interest, how are you doing the whole rego thing? Is it considered a 1600 coz of the block? or is it all fine to be 2332cc and turbo with QLD
rego rules?
What are you doing with ya old tranny?
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2443TT
A.k.a.: Ian
Fahrvergnugen
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| posted on August 7th, 2005 at 09:08 PM |
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I've got mod plates to cover all the mods to the car. Technically its a 1600 still, and what department of transport don't know won't hurt them.
I will be telling them its a 2lt though with the new engine number.
I'm using my hellbug tranny to run the engine in, and will be later replacing the tranny with a built unit i'll be importing. I'm also installing
a 5 link kaffar brace to eliminate wheel hop and keep the rear end rigid. 9/10 tranny breakages are caused by wheel hop from what I understand. As
my engine won't start to realy make power till about 3500 rpm, i'm hoping this delayed transission to power will help reduce driveline stress as
well.
Last of all, my digital camera crapped itself today! So i'll have to borrow wibbles till I can get a new one... I'll have more pics tomorrow.
Cheers,
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