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 hypo-vw
A.k.a.: Wayne Penrose
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Australias 1st 10sec street beetle (Jan 2007) 10.49secs@132mph street tyres
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 posted on September 23rd, 2006 at 02:47 AM |
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pic 1- the bottom end is finished and the porsche alternator mount plate and fan strap has been fitted .
pic 2- one piston and barrel is fitted to check the deck-height . This will assist me in calculating the engines compression ratio .
pic 3- the inlet valve seat area has been rewelded .
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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
Australias 1st 10sec street beetle (Jan 2007) 10.49secs@132mph street tyres
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| posted on September 23rd, 2006 at 02:56 AM |
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pic 1- the flywheel has been dowelled to the crankshaft to reduce the risk of stress on the flywheel bolts . The flywheel is a modified type-1
chromemoly unit that was modified by FAT Performance in USA with a type-4 centre . It takes the 200mm diameter clutch .
pic 2- the new ally/bronze seats have been fitted to the heads , and now I have to matchport the ports to the seats .
pic 3- more welding has been done to the lower section of the heads to enable me to seal in any inlet port leakage .
[ Edited on 22-9-06 by hypo-vw ]
[ Edited on 22-9-06 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
Veteran Volks Folk
Australias 1st 10sec street beetle (Jan 2007) 10.49secs@132mph street tyres
Posts: 2151
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| posted on September 23rd, 2006 at 03:01 AM |
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pic 1- extensive welding performed to the top of the heads around the inlet port area , to ensure a good seal from the inlet ports .
pic 2- entire exhaust system has been wrapped in heat-wrap tape to keep the heat in the pipes and out of the engine bay area .
pic 3- the new turbo bag to insulate the turbo .
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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
Australias 1st 10sec street beetle (Jan 2007) 10.49secs@132mph street tyres
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| posted on September 23rd, 2006 at 03:05 AM |
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pic 1- all of the inlet plumbing has been powdercoated in silver .
pic 2- the inlet plumbing has been fitted back into the oval and connected to the intercooler .
pic 3- the turbo and exhaust plumbing has been fitted back into the oval .
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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
Australias 1st 10sec street beetle (Jan 2007) 10.49secs@132mph street tyres
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| posted on September 23rd, 2006 at 03:10 AM |
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pic 1- a view from under the oval . Looks pretty good with the engine pipes wrapped and the transmission / mountings detail .
pic 2- the heads have now been matchported to the valve seats , so the heads can be sent to Southern Engine Reconditioning to have the valve guides
reamed to suit the chev valves and also machine the valve seats .
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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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dangerous
A.k.a.: Dave Butler Muffin Man
23 Windows of Awesome
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| posted on September 23rd, 2006 at 08:38 AM |
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Looking good Wayne.
| Quote: | Originally
posted by westi
That's mad Alan.
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hypo-vw
A.k.a.: Wayne Penrose
Veteran Volks Folk
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| posted on September 23rd, 2006 at 09:15 AM |
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pic 1- I have decided to replace the conrod bolts with a higher grade bolt that is manufactured by ARP performance products .
pic 2- Dean replaces all the conrod bolts for me and retensions the rod bolts as per the stretch-bolt instructions .
pic 3- I manufacture new header pipes to exit the exhaust ports as the old pipes had dents knocked into them to clear the pushrod tubes . This time
the pushrod tubes will be modified to clear the exhaust tubes as I didn't go to all this effort to have the exhaust restricted as it exits the
cylinder heads . I have measured the diameter of the old pipes at the narrowest point and they are 25% smaller than the new pipes . Should make a huge
difference .
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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
Australias 1st 10sec street beetle (Jan 2007) 10.49secs@132mph street tyres
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| posted on September 23rd, 2006 at 09:26 AM |
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pic 1- the valve seats have been refaced , the guides machined for the 11/32" chev valve stems and the heads are placed on the milling machine for
the last time to reface the chambers . Through the welding process the chambers distorted .012" and had to be machined to a true parallel surface
.
pic 2- Devcon aluminum putty is applied around all of the welding to ensure that there are no air leaks . The small holes inside the inlet ports are
also filled with Devcon and machined back when dried .
pic 3- engine parts are all washed up and ready to assemble .
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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
Veteran Volks Folk
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| posted on September 23rd, 2006 at 10:34 AM |
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That's some serious work you've put in Wayne. Hope it all pays off for you.
Very impressed...and a little excited by it :P
Reub
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nbturbo
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| posted on September 23rd, 2006 at 11:36 AM |
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Totally agree-as they say in the Classics-a picture is worth a thousand words-enough said.
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hypo-vw
A.k.a.: Wayne Penrose
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| posted on September 23rd, 2006 at 04:55 PM |
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| Quote: | Originally
posted by reub-revhead
That's some serious work you've put in Wayne. Hope it all pays off for you.
Very impressed...and a little excited by it :P
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I am pleased to hear that you may be a little excited . I am .
The idea of sharing each and every step with you is not to show off or be a smart-arse . I genuinely would like to share these experiences with AVD
readers . I am entering new territory myself and this may also encourage others to do the same .
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 23rd, 2006 at 05:09 PM |
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pic 1- the cylinder heads are complete and assembled . Chambers are CC'd and measure 63cc . With a 2mm deckheight the engine compression ratio is
calculated at 10:1 . A little higher than I had first planned but I think this will work nice with 14psi boost . The Berg dual valve springs tested at
130lbs @ the seat installed with a 0.060" shim at the base , and 295lbs @ .510" lift .
pic 2- the 50mm intakes and 41mm exhausts only just fit with less than a millimeter between them .
pic 3- due to the design of the piston that I am using , the pistons have to be assembled onto the conrods prior to fitting any of the piston rings .
The rings are machined and fitted to the barrels to ensure correct end gap ( approx. 0.020") and then the rings are fitted to the pistons . The
reason for this is the gudgeon pin is under the oil ring and cant be fitted with the oil ring in place . A ring compressor is then used to clamp the
rings so that they can be fitted into the barrels .
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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
Australias 1st 10sec street beetle (Jan 2007) 10.49secs@132mph street tyres
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| posted on September 24th, 2006 at 12:21 AM |
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pic 1- the barrels are all fitted to the pistons and ready to bolt on the cylinder heads .
pic 2- the cylinder heads are fitted and tensioned .
pic 3- Torco camlube is applied to the scat heavy duty camfollowers prior to assembly . The scat camfollowers have a 0.024" oiling hole in the centre
of the contact face to assist with cam-lobe lubrication .
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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
Australias 1st 10sec street beetle (Jan 2007) 10.49secs@132mph street tyres
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| posted on September 24th, 2006 at 12:30 AM |
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pic 1- this pic shows how the pushrod tubes have been modified to clear the exhaust header pipes .
pic 2- as the oval is a street registed and driven car , I dont need any oil leaks to create rego problems . So I have applied a generous coating of
white sikaflex 252 to all of the areas on the engine case that have been welded on . This should reduce the risk of oil leakage from any pourous areas
.
pic 3- the fan housing now needs to be trimmed around the inlet port areas as it no longer fits .
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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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| posted on September 24th, 2006 at 12:36 AM |
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pic 1- with the engine finished , rocker geometry sorted and tappets adjusted , the engine is sealed by fitting and wiring the rocker covers , then
the fan housing and 911 Porsche cooling fan is fitted .
pic 2- the inlet manifolds are marked and now need to be match-ported to gain maximum efficiency of the induction system .
pic 3- I use new Berg IDA gaskets between the throttle bodies and the inlet manifolds.
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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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| posted on September 24th, 2006 at 12:43 AM |
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pic 1- the inlet manifold gaskets have to be hand-cut to match the modified ports .
pic 2- the inlet manifolds are match-ported and are ready to bolt on .
pic 3- after spending many hours on the engine today , it is finally finished . The engine is so much shorter now with the higher compression ratio
that the crossover pipe between the 2 plenims and the throttle linkage had to be shortened by 10mm .
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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
Australias 1st 10sec street beetle (Jan 2007) 10.49secs@132mph street tyres
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| posted on September 24th, 2006 at 12:46 AM |
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ENGINE FITTED
the engine is fitted back into the oval . All of the hoses and plumbing now need to be connected , and I might fire it up tomorrow night .
It is booked in on the dyno on tuesday morning .
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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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humpty
Bishop of Volkswagenism
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| posted on September 24th, 2006 at 12:59 AM |
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Damn Wayne.... you (and Dean!) been getting busy!.... Are you gonna get to run it before the 'weekender' at Craigs?
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hypo-vw
A.k.a.: Wayne Penrose
Veteran Volks Folk
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| posted on September 24th, 2006 at 01:09 AM |
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| Quote: | Originally
posted by humpty
Damn Wayne.... you (and Dean!) been getting busy!.... Are you gonna get to run it before the 'weekender' at Craigs?
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I will run it on the dyno on tuesday morning and then just a quick squirt around the block ( sensibly ) before taking it to Warrick .
Warrick will be its first real test .... even if it is just 1/8 mile , it will still give me an idea of how it will go .
I managed to cover all of the modifications that I had previously mentioned , except one ! Didn't fit the larger injectors just yet , so the boost
will stay at 14psi for Warrick . I wont run the oval on the 1/4 until they are fitted and the engine retuned with the boost screwed up .
Can't wait !! 7 more sleeps ......... just any sleep will do me !!
[ Edited on 23-9-06 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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reub
Veteran Volks Folk
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| posted on September 24th, 2006 at 10:59 AM |
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Engine porn....Good luck with it all. Was considering flying down for the weekend but unfortunatey the money is better spend on my new engine for the
58.
Do you know if Rod got his fired and on the dyno?
Reub
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hypo-vw
A.k.a.: Wayne Penrose
Veteran Volks Folk
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| posted on September 24th, 2006 at 04:08 PM |
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| Quote: | Originally
posted by reub-revhead
Do you know if Rod got his fired and on the dyno?
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Our father (Allan ) came to my shop and gave me a hand to fit the barrels over the pistons on friday afternoon . When he was there he was telling me
that Rods car would not fire-up and that the computer was not working and may have been spiked .
Rod apparently drove to Sydney on friday to get the computer repaired , but from what dad tells me , he had to purchase other unit . He hasn't made
the dyno yet but I'm sure that he will in the next couple of days .
Hope all goes well with it , as the event wouldn't be the same without him and his car there .
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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fullnoise
Fahrvergnugen
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| posted on September 24th, 2006 at 04:58 PM |
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Jam
Hi Wayne,
I don't know how you managed to jam all that in the back of an oval. Amazing work.
Thanks for sharing the photos. I can't wait to see it fly in Warwick.
CYA CT
esratrams
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Boostn
Wolfsburg Wizard
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| posted on September 24th, 2006 at 06:16 PM |
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3 generations all working on the same VW
how cool Wayne
the oval is looking good!
VOLLKOMMEN ART
nick@vollkommenart.com
Speed and Style
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hypo-vw
A.k.a.: Wayne Penrose
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| posted on September 25th, 2006 at 12:56 AM |
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well I spent another 4 hours on the oval this evening and I still didn't get to fire it up . I have got about an hours work and double checking
things before I fire it tomorrow . Her are some more pics from tonight .
pic 1- the old header pipes are marked where I will cut them off and weld them to the new tubes .
As previously mentioned , the old pipes were quite restrictive as they were dented to clear the pushrod tubes . This is very easy to see in this pic ,
and you can understand why I wanted to change them , especially after going to so much effort on head design and flow .
pic 2- here I am cutting the exhaust tubes .
pic 3- this pic shows the pipes welded back together and attached to the rest of the exhaust system .
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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
Australias 1st 10sec street beetle (Jan 2007) 10.49secs@132mph street tyres
Posts: 2151
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| posted on September 25th, 2006 at 01:01 AM |
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pic 1- the muffler and the rear engine support bar are both bolted to the engine . The muffler is connected to the pipework prior to welding the
header pipes to ensure that all will line up when fitted .
pis 2&3- view of the rear of the oval with entire exhaust system fitted and all plumbing / wiring connected . Nearly ready to fire-up .
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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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pete wood
A.k.a.: figure itout
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Location: Nth Nth StMarys, Sydney
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Mood: upgrades = jackstands
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| posted on September 25th, 2006 at 12:41 PM |
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Dude that is awesome.:thumb
When do you sleep?
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reub
Veteran Volks Folk
VWRX is gone...
Posts: 2054
Threads: 160
Registered: September 2nd, 2002
Member Is Offline
Theme: UltimaBB Pro Blue
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| posted on September 25th, 2006 at 08:30 PM |
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VOLKSPORN! :thumb
Reub
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Dasdubber
A.k.a.: Alan Agyik
23 Windows of Awesome
DAS Resto Haus
Posts: 5746
Threads: 289
Registered: August 26th, 2002
Member Is Offline
Location: Gold Coast
Theme: UltimaBB Pro Blue
Mood: feeling fine...
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| posted on September 25th, 2006 at 09:06 PM |
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Wow - that is certainly a lot of work! Thanks for sharing it with us.....I am gobsmacked! I'd love to have a N/A version of that engine some
day.....would be loads of fun I am sure! (I think I'd soil myself if I drove that sort of combo with the extra power of a turbo) :thumb
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hypo-vw
A.k.a.: Wayne Penrose
Veteran Volks Folk
Australias 1st 10sec street beetle (Jan 2007) 10.49secs@132mph street tyres
Posts: 2151
Threads: 82
Registered: May 9th, 2004
Member Is Offline
Location: unanderra
Theme: UltimaBB Pro Blue
Mood: hypo cruis'n
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| posted on September 25th, 2006 at 10:52 PM |
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IT IS ALIVE !!!
pic 1- the engine pipes are wrapped in the heat wrap after welding them last night . The exhaust system is entirely finished .
The engine has been fired and sounds awsome . Not as noisy as it use to be and for those who will see it run at Warrick , you will be surely surprised
how quiet and quick the oval is .
pics 2&3- here I am refitting the rear apron and guards to the oval .
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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
Australias 1st 10sec street beetle (Jan 2007) 10.49secs@132mph street tyres
Posts: 2151
Threads: 82
Registered: May 9th, 2004
Member Is Offline
Location: unanderra
Theme: UltimaBB Pro Blue
Mood: hypo cruis'n
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| posted on September 25th, 2006 at 11:11 PM |
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pic 1- the oval has no shortage of attention from staff and mates . Here our first year apprentice Ben ( near right front guard ) his brother Kane (
left front guard ) and my good mate Chris ( rear of oval ) , all lend a hand and give the oval a wash and detail .
Shortley after the oval was washed , I took my mate Chris for a test drive in the oval . I drove up and down our street slowly to warm up the
transmission and then gave the oval a few quick squirts on 7 psi boost . It responded extremely well and Chris was impressed .
I then flicked the dual stage boost controller to 14psi and all hell broke loose . I honestly couldn't keep my foot into it as the oval was turning
the tyres easily in 3rd gear and I was useing much more of the road than I should have been and Chris was shocked .
The modifications that I have done have obviously made a huge improvement even without added boost .
I then drove the oval back into the shop and hoist lifted it for an inspection , and found the engine and transmission to be completely free from oil
leaks .
The oval goes to the dyno tomorrow for a last check over before heading off to Warrick .
My mate Chris , still has not stopped smileing and just can't believe that the oval is powered by a 4 cylinder Volkswagen engine . He wants one for
his Formula Vee race car . "I dont think so Chris"
pics 2&3- the oval is finished and looks like a sedate little callooker again .
SEE YA ALL AT WARRICK GUYS !!
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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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