| [ Total Views: 214399 | Total Replies: 905 | Thread Id: 36521 ] |
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 Turbo54
Veteran Volks Folk
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| posted on July 31st, 2006 at 11:39 AM |
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Wayne, I am after a muffler the same as yours. Can you supply? How Much and postage to Adelaide.
Do you know how many DB you car has?
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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malcolm
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| posted on July 31st, 2006 at 12:54 PM |
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after stripping the motor and finding the wear on the engine parts would that motor be to stressed for a daily driver.also can you fit oil squirters
in a type 4 case .
cheers malcolm.
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seagull
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| posted on August 1st, 2006 at 01:26 AM |
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I have my grinder ready
Looking for that special lady : PM me for coffee & cake
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555bug
Custom Title Time!
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| posted on August 1st, 2006 at 07:06 PM |
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yes please Wayne, I need to know before the W deck lid goes on. Pictures  |
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seagull
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| posted on August 2nd, 2006 at 01:14 AM |
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Please W
Looking for that special lady : PM me for coffee & cake
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dangerous
A.k.a.: Dave Butler Muffin Man
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| posted on August 2nd, 2006 at 07:45 AM |
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| Quote: | Originally
posted by malcolm
after stripping the motor and finding the wear on the engine parts would that motor be to stressed for a daily driver.also can you fit oil squirters
in a type 4 case .
cheers malcolm.
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Remember that this bottom end served Wayne for many years of circuit and hillclimb action,
only barrel spacers were added for the turbo.
I would immagine that a slightly different counterweight could improve the CM bearing life.
I am not Type 4 fluent, but feel that sqiirters could be fitted with out much trouble.
Some use Weber Idle jets.
Wayne you have a U2U.
| Quote: | Originally
posted by westi
That's mad Alan.
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hypo-vw
A.k.a.: Wayne Penrose
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 posted on August 2nd, 2006 at 08:28 AM |
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rear end cut
a couple of pics of the rear of the oval , where I cut the complete rear apron assembly off the car and made it detachable . Hope these pics help ....
I welded a 40mm x 3mm plate down the inside of the body section . Then welded 4 tabs onto the body ( 2 at the top of the cut and 2 at the bottom )
Place the rear section into position and clamp securely . Then drill holes through the body and through the plates and tabs ( 8mm through the side
plates and 6mm through the tabs ) Bolt the rear assembly on and check alignment . All plates and tabs have welded nuts for ease of assembly and
disassembly .
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Team 
FASTEST ET @ WARWICK 2010 & 2011
FASTEST SPEED @ WARWICK 2011
FASTEST ET & SPEED WSID 2012
PB - 6.33@113.07(1/8) & 9.88@135(1/4)
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hypo-vw
A.k.a.: Wayne Penrose
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| posted on August 2nd, 2006 at 08:33 AM |
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| Quote: | Originally
posted by malcolm
after stripping the motor and finding the wear on the engine parts would that motor be to stressed for a daily driver.also can you fit oil squirters
in a type 4 case .
cheers malcolm.
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The motor is not too stressed for a daily driver , but it is going to be repaired ( improved ) and reused in the oval with the goal in mind of running
10.5 @ 130mph . I have no doubt that we will do this .
The oval will also be running at the VWMA Warrick weekender .
Team
FASTEST ET @ WARWICK 2010 & 2011
FASTEST SPEED @ WARWICK 2011
FASTEST ET & SPEED WSID 2012
PB - 6.33@113.07(1/8) & 9.88@135(1/4)
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hypo-vw
A.k.a.: Wayne Penrose
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| posted on August 2nd, 2006 at 08:40 AM |
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| Quote: | Originally
posted by Turbo54
Wayne, I am after a muffler the same as yours. Can you supply? How Much and postage to Adelaide.
Do you know how many DB you car has?
T54
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The mufflers are custom made for each application . Just send me your design and dimensions and I will make it for you . cost approx. $350 . my
muffler is 3" diameter , fibreglassed packed and quitened the oval from 108db to 97db approx . very quiet and can drive on the street without any
noise issues . My muffler is also clearanced at the front for the oil filler tube . See my article in the VWMA on the type-3 to check out other
designs .
Team
FASTEST ET @ WARWICK 2010 & 2011
FASTEST SPEED @ WARWICK 2011
FASTEST ET & SPEED WSID 2012
PB - 6.33@113.07(1/8) & 9.88@135(1/4)
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hypo-vw
A.k.a.: Wayne Penrose
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| posted on August 26th, 2006 at 11:55 PM |
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preparation progress
the engine has been totally stripped down and everything has now been checked . The crank has been crack tested and looks OK .
I have chosen a new set of Manley 105.5mm pistons for the rebuild and have had a set of 105mm barrels bored out .5mm / .020" to suit them . The
pistons are for a V8 chevrolet engine and the conrods need to have new gudgeon bushes made to suit the smaller Chev size pins .
The pistons that I have chosen are 12.5:1 lumpy tops and I am machining the tops down to suit the compression ratio that I would like to set the
engine at .
There is lots of thickness in the piston crowns and machining them is not a problem .
Total seal piston rings have already arrived .
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Team
FASTEST ET @ WARWICK 2010 & 2011
FASTEST SPEED @ WARWICK 2011
FASTEST ET & SPEED WSID 2012
PB - 6.33@113.07(1/8) & 9.88@135(1/4)
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hypo-vw
A.k.a.: Wayne Penrose
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| posted on August 27th, 2006 at 12:00 AM |
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I have had the inlet ports welded up to enable me to machine the ports out for a much larger inlet port and better gas flow .
Prior to porting the heads , I place the heads on my milling machine to reface the inlet port surfaces .
[ Edited on 26-8-2006 by hypo-vw ]
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Team
FASTEST ET @ WARWICK 2010 & 2011
FASTEST SPEED @ WARWICK 2011
FASTEST ET & SPEED WSID 2012
PB - 6.33@113.07(1/8) & 9.88@135(1/4)
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hypo-vw
A.k.a.: Wayne Penrose
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| posted on August 27th, 2006 at 12:09 AM |
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now I sit down for approximately 5 hours and painstakenly port out the inlet ports . You can see by the amount of aluminum filings all over the
workbench , just how much material has been removed .
The second pic shows the inlet port on the left has been ported and the gasket that is used for the template is fitted to the right side port which
shows the extent of the porting required .
The third pic shows the template gasket fitted to the old heads . The old heads produced 210bhp .
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Team
FASTEST ET @ WARWICK 2010 & 2011
FASTEST SPEED @ WARWICK 2011
FASTEST ET & SPEED WSID 2012
PB - 6.33@113.07(1/8) & 9.88@135(1/4)
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hypo-vw
A.k.a.: Wayne Penrose
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| posted on August 27th, 2006 at 12:14 AM |
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after the heads are ported the inlet manifolds are fitted to show just how large the new ports are . The manifolds have now been sent to be welded up
, to enable me to match-port the manifolds to the heads .
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Team
FASTEST ET @ WARWICK 2010 & 2011
FASTEST SPEED @ WARWICK 2011
FASTEST ET & SPEED WSID 2012
PB - 6.33@113.07(1/8) & 9.88@135(1/4)
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hypo-vw
A.k.a.: Wayne Penrose
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| posted on August 27th, 2006 at 12:19 AM |
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next is to mark the engine case and cylinder heads where I want the engineer to build up areas with aluminum weld as I have decided to fit an extra
5th headstud to each cylinder to improve the seal on the type-4 heads .
The barrels that I will be using are drilled for the extra headstud , so they are fitted to the engine case and the case and heads are marked as shown
.
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Team
FASTEST ET @ WARWICK 2010 & 2011
FASTEST SPEED @ WARWICK 2011
FASTEST ET & SPEED WSID 2012
PB - 6.33@113.07(1/8) & 9.88@135(1/4)
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hypo-vw
A.k.a.: Wayne Penrose
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| posted on August 27th, 2006 at 12:26 AM |
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while the engine parts are away being welded , I have removed the turbo and all plumbing and also removed the transmission so that I can strip it down
and check all parts .
All of the inlet turbo plumbing has been sent to be powdercoated whilst all of the exhaust plumbing will be totally wrapped with heat-wrap . A turbo
bag will also be fitted to the turbo to keep the heat in the turbo for added performance .
[ Edited on 26-8-2006 by hypo-vw ]
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Team
FASTEST ET @ WARWICK 2010 & 2011
FASTEST SPEED @ WARWICK 2011
FASTEST ET & SPEED WSID 2012
PB - 6.33@113.07(1/8) & 9.88@135(1/4)
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reub
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| posted on August 27th, 2006 at 12:39 AM |
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Nuts....but extremely cool to see Wayne
Reub
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Dasdubber
A.k.a.: Alan Agyik
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| posted on August 27th, 2006 at 08:32 PM |
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Nice update pics - I'm loving seeing the progress especially being a type IV buff as well! 
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Flintstones
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| posted on August 27th, 2006 at 09:02 PM |
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What kind of horsepower are you expecting from the new manifold/head arrangement?
Cheers
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hypo-vw
A.k.a.: Wayne Penrose
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| posted on August 27th, 2006 at 10:44 PM |
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| Quote: | Originally
posted by Flintstones
What kind of horsepower are you expecting from the new manifold/head arrangement?
Cheers
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Its very hard to estimate the horsepower of the head and manifold modifications as there are other things that I am doing to the engine at the same
time . My aim is to improve on the current horsepower figures of 210bhp @ the rear wheels .
Other items are as follows , fitting of custom grind turbo cam , raising of compression ratio from 6.1 to 9.0 , chromemoly large diameter main bearing
bolts to reduce case flexing , extra 5th head stud for each cylinder to improve head to barrel sealing , new 105.5mm Manley pistons with total seal
piston rings , increase of exhaust valve size from 38mm to 40mm , replacement of stainless steel valves with titanium valves , replacement of
injectors from 550cc to 800cc , fit turbo bag to turbo , fit heat wrap to entire exhaust system , change of fuel from premium unleaded to C16 race
fuel , and most importantly ... screw the boost up to ...........?
I will not be happy with the results if I don't see figures in the range of 320bhp @ the rear wheels
To add to this the transmission is being rebuilt into a new rhino case with heavy duty billet side covers , so that I can give it a much harder time
!!
Also the front beam is being narrowed 4" and the BRM's are finally going on the front also . Have been waiting for a Vintage front disc kit since
May 05 and still hasn't arrived . Cant wait any longer so the beam will be narrowed .
:jesus
[ Edited on 27-8-06 by hypo-vw ]
[ Edited on 27-8-06 by hypo-vw ]
Team
FASTEST ET @ WARWICK 2010 & 2011
FASTEST SPEED @ WARWICK 2011
FASTEST ET & SPEED WSID 2012
PB - 6.33@113.07(1/8) & 9.88@135(1/4)
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Flintstones
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| posted on August 27th, 2006 at 11:39 PM |
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Cool, looking forward to the results.
Cheers
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dragvw2180
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| posted on August 27th, 2006 at 11:46 PM |
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Hey Wayne,
Are you going to shuffle pin the case or is that not needed with your combo,also what improvements are you going to do to the exhaust ports?
What you have done so far looks great,
Mike
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hypo-vw
A.k.a.: Wayne Penrose
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| posted on September 1st, 2006 at 12:12 AM |
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| Quote: | Originally
posted by dragvw2180
Hey Wayne,
Are you going to shuffle pin the case or is that not needed with your combo,also what improvements are you going to do to the exhaust ports?
What you have done so far looks great,
Mike
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Hi Mike , I'm not going to pin the case as I have had great success in the past with my hillclimb engines , using custom made 12mm chromemoly main
bearing bolts . The case halves have to be machined for them to fit through and they keep the case very solid ( no shuffle with revs up to 8900rpm
).
Back in 2003 I lifted the top off a piston at Mt Panorama Hillclimb , Bathurst . It did quite a lot of damage to the engine and destroyed the engine
case . When rebuilding the engine I didn't fit the chromemoly main bearing bolts as I was going to use them in another engine that I was preparing at
the time . This is why I now have had shuffle in this engine and destroyed the centre main bearing .
Team
FASTEST ET @ WARWICK 2010 & 2011
FASTEST SPEED @ WARWICK 2011
FASTEST ET & SPEED WSID 2012
PB - 6.33@113.07(1/8) & 9.88@135(1/4)
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hypo-vw
A.k.a.: Wayne Penrose
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| posted on September 1st, 2006 at 12:22 AM |
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inlet ports have had more material added for better strenght and the lower 2 cooling fins have been welded together to make a mounting surface for the
cylinder head nuts on the 5th head studs .
Close-up of the welded area on the cylinder heads , for the 5th head stud . This area still has to be refaced .
A view of the cylinder head from the combustion chamber side .
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Team
FASTEST ET @ WARWICK 2010 & 2011
FASTEST SPEED @ WARWICK 2011
FASTEST ET & SPEED WSID 2012
PB - 6.33@113.07(1/8) & 9.88@135(1/4)
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hypo-vw
A.k.a.: Wayne Penrose
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| posted on September 1st, 2006 at 12:30 AM |
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exhaust ports have been welded also , so that they can be ported also . First I must mount the heads on my milling machine and reface the exhaust
flange faces .
inlet manifolds have been welded up so that they can be match-ported to the heads . The engineer added 15mm of aluminium weld to the manifold runners
.
You can now see how the manifolds and cylinder heads will match together .
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Team
FASTEST ET @ WARWICK 2010 & 2011
FASTEST SPEED @ WARWICK 2011
FASTEST ET & SPEED WSID 2012
PB - 6.33@113.07(1/8) & 9.88@135(1/4)
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Euro_67
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| posted on September 1st, 2006 at 09:15 AM |
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Wayne, any chance of an update on the Type IV into the notch ?
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hypo-vw
A.k.a.: Wayne Penrose
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| posted on September 2nd, 2006 at 06:24 PM |
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| Quote: | Originally
posted by 1964_Notch
Wayne, any chance of an update on the Type IV into the notch ?
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All updates are posted in the VWMA magazine . Since the last issue nearly 6 weeks ago I haven't had the time to even look at it due to customer
projects , photo shoots for VWMA , Nambucca preparation and Warrick preparation . Craig wont be pleased , but he caused most of the delays by
organising such good events !!
Team
FASTEST ET @ WARWICK 2010 & 2011
FASTEST SPEED @ WARWICK 2011
FASTEST ET & SPEED WSID 2012
PB - 6.33@113.07(1/8) & 9.88@135(1/4)
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66deluxe
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| posted on September 2nd, 2006 at 08:13 PM |
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Wayne, that is lookin good, being a type 4 man, i am very happy to see the progress. Are those intake manifolds been shortened and if they have can
you modify them too fit in a type 3? Cheers Damien.
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
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70Turbobug
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| posted on September 3rd, 2006 at 04:18 AM |
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Great Thread! Great job on the whole project! Do you have any more pics of the cracks in your case? Or where you welded after the cracks? I´d
appreciate it!
I´m in the process of building a 103 x 88 T4 turbo.The case work has just been finished.I´ll be sending it back for a couple of other mods to it -
so that would give me an idea of where I need to stiffen the case at.
This is great info! This is the 1st 2.9+ Liter T4 Turbo I´ve seen in detail that has actually been down the strip:thumb
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hypo-vw
A.k.a.: Wayne Penrose
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| posted on September 16th, 2006 at 01:05 AM |
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WPVW Warrick preparation update.
well after spending the past couple of weeks working the midnight shifts on the oval , I thought it time for a quick update .
pic 1- inlet manifolds have been refaced after extensive welding .
pic 2- a template is made for the combustion chambers so that the chambers can be reshaped and releived around the valve area .
pic 3- a comparison between the original chambers and the modified chambers .
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Team
FASTEST ET @ WARWICK 2010 & 2011
FASTEST SPEED @ WARWICK 2011
FASTEST ET & SPEED WSID 2012
PB - 6.33@113.07(1/8) & 9.88@135(1/4)
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hypo-vw
A.k.a.: Wayne Penrose
Veteran Volks Folk
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Mood: hypo cruis'n
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| posted on September 16th, 2006 at 01:14 AM |
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pic 1- hard at work , porting and polishing the heads . So far I have spent 90 hours on the heads and they are still not finished .
pic 2- the chambers are finished and polished .
pic 3- the exhaust ports are ported to match-port a 1 5/8" exhaust tube that has been pressed into an oval shape . They are then polished . The
exhaust seats are to be replaced , so these ports will have to be cleaned up again after the new seats are fitted .
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Team
FASTEST ET @ WARWICK 2010 & 2011
FASTEST SPEED @ WARWICK 2011
FASTEST ET & SPEED WSID 2012
PB - 6.33@113.07(1/8) & 9.88@135(1/4)
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