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 063bug
A.k.a.: Alan
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| posted on June 9th, 2009 at 11:56 AM |
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The attention to detail on this project is amazing... not to mention the documentary/photos... this thread is a credit to you  |
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2443TT
A.k.a.: Ian
Fahrvergnugen
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| posted on June 19th, 2009 at 12:08 PM |
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At last guys I finaly have a set of heads, and they are truely awesome! The machining is really as good as it looks. Valve seats are blended to the
casting so there is no noticable lip to feel if you run your finger over it. Exhaust flanges are huge too, should make for a good sealing area
considering the exhaust back pressure on the engine will be approaching 35PSI.
I discovered that the Australian government doesnt have a free trade agreement with the Swiss too. Import duty and GST was another $718 on top of the
purchase price of $3275. So Ouch! Just as well Kevin Rudd gave me some money to help buy these! But they look like they will be up to the task of
what I have planned for them.
I know what I'll be doing this weekend.... 
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bajachris88
A.k.a.: Chris Leete
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| posted on June 19th, 2009 at 12:30 PM |
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HOLY CRAP!
HA theres not even any slight more room for those values to be any big, thats insane!
(ô_!_/ô) (ô_!_/ô)
69' baja: kombi box, thing spindles, irs, disc front, type 3 rear drums, 2 inch lift kit, 31x10 rears.
New engine in process: 94mm p&bs, 74mm C/w chomol Crank, 35.5x39 SP heads, turbo. Wierd combo, hopeful torque monsta! |
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reub
Veteran Volks Folk
VWRX is gone...
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| posted on June 19th, 2009 at 12:40 PM |
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Sensational dude
Reub
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Mick058
Custom Title Time!
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| posted on June 19th, 2009 at 12:49 PM |
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Alright! Some progress coming up.
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polak
A.k.a.: Adam Pawlowski
Fahrvergnugen
Everything is alright with enough Vodka :P
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| posted on June 19th, 2009 at 02:05 PM |
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those heads are frikken ridiculous!!! beautiful job on the machining too... i couldnt wait till the
weekend, id be taking a sickie today
VW - helping put oil back into the ground for over 60 years |
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Flintstones
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| posted on June 19th, 2009 at 09:34 PM |
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Very nice!!!!
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STOCK
Wolfsburg Wizard
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| posted on June 29th, 2009 at 04:52 PM |
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I THINK SOMETHING JUST MOVED IN MY PANTS
STOCK |
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2443TT
A.k.a.: Ian
Fahrvergnugen
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| posted on June 29th, 2009 at 04:56 PM |
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Sorry for the lack of progress now the heads are here, it was supposed to be all systems go...
Seems the set of raceware head studs I have are 8mm and not 10mm like I thought I had ordered (nearly 2 years ago). So I didnt get very far at all
with it last weekend. Ive since decided to use a set of CB 10mm chromoly studs that I have here, and have so far cut 1/2 of them to size so far. I
hope to find time to work on the engine in the evenings this week and get it to a rocker cover to rocker cover stage of assembly.
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2443TT
A.k.a.: Ian
Fahrvergnugen
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| posted on July 3rd, 2009 at 08:05 PM |
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Update at last...
I've made a little progress with the engine this week, although not as much as i'd have liked. I was going to use the CB 10mm chromoly head studs I
had spare here but found out some of them were rusty. Ive had them in storage too long. So Ive decided to put the engine together anyway so I can
finish the cooling system and start on the header and intake fabrication, and ive ordered some replacement studs.
Here's some pics of the engine. Ive started modifying my 911 style fan shroud too, with a little fiberglass here and there to make it a more snug
fit onto the oxy boxer block. Should have more pics over the weekend.
Cheers,
Ian
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reub
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| posted on July 4th, 2009 at 11:53 AM |
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Project 'blown' budget now dude?? 
Looks the goods, and can't wait to see with shroud etc on.
Reub
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Flintstones
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| posted on July 4th, 2009 at 09:02 PM |
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| Quote: | Originally
posted by reub-revhead
Project 'blown' budget now dude??
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Looks like Ian's gonna have to sell that skyline of his to finish the Dub
Cheers
D
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2443TT
A.k.a.: Ian
Fahrvergnugen
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| posted on July 6th, 2009 at 06:58 PM |
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Well here's a few pics of the shroud. Its close to being finished, I just need to spend a little more time wet rubbing it pror to having it 2pac
clear coated again.
Ive also made some templates up to have some new flanges water-jet cut. Im going to do something a little diferent here. The flange will mirror the
exhaust port shape and is being cut from 25mm mild steel plate. I will then put the flanges in a lathe and turn down the first 15-17mm of the flange,
but taper it so the port expands out from 38mm to 40mm inside diameter. Bends will be tig welded internally and externally to the flanges. The
flanges will be match ported as well of course.
The fan housing is a porsche 911 11 blade type. I'll be sending that and the fan away to get them ceramic coated to make them look nice. Im sick of
polishing already.
And the other side...
Head studs should arrive this week too, so the heads can come off and the top end of the engine be finally assembled.
Cheers,
Ian
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2443TT
A.k.a.: Ian
Fahrvergnugen
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| posted on July 6th, 2009 at 07:03 PM |
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| Quote: | Originally
posted by Flintstones
| Quote: | Originally
posted by reub-revhead
Project 'blown' budget now dude??
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Looks like Ian's gonna have to sell that skyline of his to finish the Dub
Cheers
D
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Oh yeah, not going broke but I am tightening the belt. I did some mental sums and I still have a god $5k to spend on new engine management and
injectors, wiring, intercooler and all the oil plumbing that still remains.
Im planning to buy a house around october-december and saving for that is the main priority.
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Golde60
Fahrvergnugen
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| posted on July 6th, 2009 at 10:23 PM |
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i just thought it was called blown budget because of the forced induction. clearly the priority has not changed from building the best.
keep it up man, it is inspirational to watch
...................( O \ l / O ).....................
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2443TT
A.k.a.: Ian
Fahrvergnugen
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| posted on July 9th, 2009 at 07:27 PM |
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A quick update... No new head studs have arrive just yet but no matter i'll be working on the turbo header this weekend instead. Ive had some
flanges waterjet cut and machined them up on the lathe so im ready to begin on the merged collectors on the weekend. That means the engine will be
bolted to the gearbox for the first time and the rear apron attached so I can work on turbo placement etc.
Something that is often a right pain in the ass with large headers is the inability to weld a decent size pipe to the flange and stil get a nut on it
properly due to externally welded pipe. The only solution is internally welded pipe and that can mean slipping the pipe inside a conventional flat
flange. This is OK for most NA engine setups, but thicker piping is needed for turbo applications and this then reduces your inside diameter.
So thats why ive done it this way. The head exhaust ports will be match ported to the flanges and taper out to 40mm ID pipe.
Cheers,
Ian
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volkdent
A.k.a.: Jason
Learner Dubber
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| posted on July 10th, 2009 at 01:12 AM |
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I've never seen that solution, very inventive and attractive to boot! I can't help but imagine that this will turn out to be one of the best
looking GLers in the world.
Jason
If I could just get paid for my sleepless nights....
2008 BMW 335i
2001 BMW M3 'Vert
1998 BMW M3 Sedan
1960 VW Bug Bad Dub Racing |
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hellbugged
A.k.a.: Daimo Pell
23 Windows of Awesome
48's and straight cuts
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| posted on July 10th, 2009 at 06:32 AM |
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| Quote: | Originally
posted by 2443TT
So thats why ive done it this way. The head exhaust ports will be match ported to the flanges and taper out to 40mm ID pipe.
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very nice..........but only 40mm ID exhaust ?
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2443TT
A.k.a.: Ian
Fahrvergnugen
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| posted on July 10th, 2009 at 07:22 AM |
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| Quote: | Originally
posted by hellbugged
| Quote: | Originally
posted by 2443TT
So thats why ive done it this way. The head exhaust ports will be match ported to the flanges and taper out to 40mm ID pipe.
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very nice..........but only 40mm ID exhaust ?
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Only for the primaries. When the collectors happen it changes to 50mm ID.
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VWFREAK
A.k.a.: Peter / Bones
Son of Jim - Creator of Good
VWFREAK
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| posted on July 10th, 2009 at 03:15 PM |
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Crazy, whats the estimated completion date now ?
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2443TT
A.k.a.: Ian
Fahrvergnugen
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| posted on July 12th, 2009 at 08:11 PM |
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Hi Guys,
I'd rather not guess a completion date at this stage. Im just working on it as much as I can now. The propper head studs should arrive this week so
the top end of the engine goes together properly next weekend. The header should be finished this week.
Speaking of... here is the results of this weekends activities.
The header has 39mm ID primaries that merge to the 2" secondaries in the middle under the sump. This then goes back and is split evenly with another
2" merge to go to each turbo.
Turbo's are mounted high to keep them away from dirt etc, and it also guarantees no problem with the oil returns to the rocker covers.
From the inside you can see the compressor outlets. They meet in the middle to feed the water-air intercooler, and then a pipe goes back through to a
centrally mounted throttle body. Well thats the plan at least.
The turbo's are Greddy T517Z's 8cm turbo's rated at 350hp each. They should be reasonably responsive even if the plan was to just run the turbo's
in parrallel. But Im still planning on setting up a sequential bi-turbo system. Which is why the header allows all gas flow to a single turbo when
valving is closed.
Hope to finish the front pipes later this week.
Cheers,
Ian
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reub
Veteran Volks Folk
VWRX is gone...
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| posted on July 12th, 2009 at 08:15 PM |
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Awesome work as always dude
Reub
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2443TT
A.k.a.: Ian
Fahrvergnugen
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| posted on July 15th, 2009 at 09:31 PM |
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Update time. The engine is back on the bench as the head studs arrived from LN engineering on monday.
Cutting to length. Had to shorten all studs a 1/4" at the inside and the center two top studs an additional 1/4 at the outside.
Here is the cylinders and pistons with rings finally assembled and in the engine, sealant under the barrels etc ready for heads.
Heads on at last. Inner valve springs are removed at the moment, and I still need to remove an outer and check rocker geometry and measure up the
pushrod length.
Sexy head studs! Only tightened to wrist tightness so far. I need to make a tool so I can torque the top center head studs as I cant get a socket on
there, and being a double hex nut its going to be an interesting challange.
Cooling tin with the part that goes around the head removed (as it wouldnt fit the MS230 heads).
I started shimming up the rockers too, but need to make up some spacers for the outer rockers on the weekend when I get a chance.
Unfortunatly I cant finish the other side of the engine just yet. As luck goes I have a set of ARP head studs to suit a case that has a deep insert on
the number 3 cylinder (longer stud), but thats not any good for my oxy case. Charles at LN engineering has shipped over a replacement stud, so with
any luck in another week I can finish the other side of the engine.
Ive decided to alter the turbo placement a little too, so the half finished header is being chopped a little and altered on the weekend.
Cheers,
Ian
Cheers,
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polak
A.k.a.: Adam Pawlowski
Fahrvergnugen
Everything is alright with enough Vodka :P
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| posted on July 16th, 2009 at 01:31 PM |
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wow! thats coming together nice, can wait to see/hear it in person.... noticed the modplates on the tinwork in the back... did you have any issues
getting it done? are modplates easier/cheaper than getting it engineered, or is it the same thing... sorry for the stupid questions, but i dont know
anything about the legal side of doing extensive mods. also dont know if u know, but if i were to not run the back seats in a beetle, are there any
legalities i would need to comply with?
VW - helping put oil back into the ground for over 60 years
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vassy66T1
A.k.a.: Marcus Vass
Veteran Volks Folk
Wow ... are U reading this?
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| posted on July 16th, 2009 at 03:39 PM |
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Fabtastic and really quite insane!!!
Ingenious solution for the exhaust ports
That car isn't modified is it??
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2443TT
A.k.a.: Ian
Fahrvergnugen
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| posted on July 16th, 2009 at 04:28 PM |
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| Quote: | Originally
posted by polak
wow! thats coming together nice, can wait to see/hear it in person.... noticed the modplates on the tinwork in the back... did you have any issues
getting it done? are modplates easier/cheaper than getting it engineered, or is it the same thing... sorry for the stupid questions, but i dont know
anything about the legal side of doing extensive mods. also dont know if u know, but if i were to not run the back seats in a beetle, are there any
legalities i would need to comply with?
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With the chassis I just did a lot of planning before starting, got all the critical measurements straight and then talked to an engineer and discussed
what I was doing before I started work. After he ok'd my design in principal, I started to put it together and had him inspect it before having the
finishing welds done.
Provided you do your homework and present a good case, Im fairly certain most engineers will approve anything within reason. Mod plates are a QLD
thing, and yes you do need a plate for altered seating capacity too (ie no back seats).
Cheers,
Ian
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polak
A.k.a.: Adam Pawlowski
Fahrvergnugen
Everything is alright with enough Vodka :P
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| posted on July 16th, 2009 at 05:22 PM |
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thanks for that Ian, i guess im going to have to look into the nsw regs as i dare say they may be different... cheers adam
VW - helping put oil back into the ground for over 60 years
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Flintstones
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| posted on July 16th, 2009 at 09:31 PM |
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WOW,Really impressive Ian
it's a shame that you'll have to hide so much of it with the cooling tins, shroud etc
Cheers
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oval TOFU
Son of Jim - Creator of Good
Bitte, ein Bit!
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| posted on July 18th, 2009 at 10:52 PM |
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All I can say is 'wow'.
...and Robert's ya father's brother...
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2443TT
A.k.a.: Ian
Fahrvergnugen
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| posted on July 25th, 2009 at 03:59 PM |
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Hi everyone,
That last head stud arrived last week so Ive been working on the engine for most of the last 3 days and have finally go it very close to finished
now.
Headstuds torqued, rockers aligned, lash caps and pusrod tubes installed.
Here it is... completed long block.
Distributor drive plug installed, fuel pump block off/spacer plate made.
Carbon fibre fan shroud clear coated in 2pac standox clear
Dry sump pump mound bolted on.
And the RPM 4 stage dry sump pump loose mounted.
I decided to not be a girl and spent a few hours on the polisher today too and re-polished the 911 alternator fan housing and alternator stand. Dry
sump pump drive belt is now installed too.
Im getting the remaining tinware sand blasted and will be painting it with flat black 2pak next week.
Cheers,
Ian
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