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 2443TT
A.k.a.: Ian
Fahrvergnugen
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| posted on August 30th, 2009 at 06:40 PM |
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Quick update...
Made a little progress today. Match ported the intake manifolds to the intake runners, so they are now match the ID of the 2.5" piping i used on the
intake. I need a much bigger air compressor.
I also polished the intake manifolds a little but didnt get too caried away because I need to get the flanges faced off tomorrow so they are dead flat
and seal to the manifolds properly. Still, it looks pretty on the engine. The hole for the throttle body has been cut with a nibbler. The throttle
body itself is from a nissan RB30 and is 65mm ID.
Next week im sourcing some sort of intercooler setup, and some new injector o-rings. Then I can finally start on the plumbing for fuel, oil etc.
Cheers,
Ian
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reub
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| posted on August 30th, 2009 at 07:50 PM |
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Hardcore dude
Reub
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waltermitty
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| posted on September 26th, 2009 at 04:36 PM |
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Ian Im just about on the gravy stroke and you've slipped off the radar!
Update PLEASE!! Mitchell
23 windows ...8 too many!
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2443TT
A.k.a.: Ian
Fahrvergnugen
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| posted on September 26th, 2009 at 09:12 PM |
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Ok... Update time.
Ive been flat out with work lately, and had worked the last 2 weekends. Put in some rediculas hours. Cant wait for the invoices to get paid for that.
One job that pretty much pays for the completion of the rest of the project no problems.
As far as VW project progress goes, ive had the flanges on the intake manifolds milled dead flat, as the heat distortion they sufferred when being
welded meant that the seal to the manifolds was less than perfect. Its all great now though. The manifolds were also professionally polished (Way
better than what I was able to do), and look pretty amazing.
It took some time to finalise what I was actually going to do with plumbing the intake, intercoolers and setting up the air intakes for the turbo's
but I have a good plan all sorted out now. The current hold up is parts, but its all ordered and paid for now. I 600hp rated PWR barrel water/air
intercooler will arrive next week some time. Then I can finish off the last of the intake piping, air boxes etc.
Here are a few pics. The camera doesnt do them justice, but the polish is pretty dam extreme... although it seems there is a layer of dust on it all
at the moment too.
Cheers,
Ian
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LIFE IN THE LOW LANE
A.k.a.: Brennden Alder
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| posted on September 26th, 2009 at 10:47 PM |
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Nice work as always Ian!! Are you making the trek down for Warwick next weekend by any chance??
[size=4] ACCEPT THAT SOME DAYS YOU ARE THE PIDGEON AND SOME DAYS YOU ARE THE STATUE[/size]
Alder Outlaws VW Racing - check it out on fb!!
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2443TT
A.k.a.: Ian
Fahrvergnugen
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| posted on October 5th, 2009 at 07:54 PM |
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Afraid I didnt make Warwick, though I want to next year. With luck i'll even be there with a car.
I finally finished of the left side dump pipe on the weekend. A lot of hammering, welding, grinding and die grinding later im pretty happy with the
results. Infact it turned out way better and had much better clearance than the drivers side did, so I had to re-do that again too.
And the re-done drivers side.
Fuel system 95% finished, just need a gauge to screw into the regulator. Oil hoses started, filter mounted...
I should make some huge inroads with the project in the next week or so. There is a lot of parts due to arrive soon. Intercooler, oil cooler, exhaust
valve, hose fittings and a lot of hose. Im finally seeing light at the end of the tunnel.
Cheers,
Ian
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Turbo54
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| posted on October 5th, 2009 at 08:14 PM |
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Looking great Ian, keep it up.
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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Flintstones
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| posted on October 5th, 2009 at 08:31 PM |
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Looking great Ian.
Your definitely going to need volume to fill that intake
How long do you think it'll be before she gets fired up?
Cheers
D
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Dasdubber
A.k.a.: Alan Agyik
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| posted on October 5th, 2009 at 08:37 PM |
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Fantastic work Ian, keep those updates coming!
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2443TT
A.k.a.: Ian
Fahrvergnugen
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| posted on October 5th, 2009 at 09:06 PM |
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| Quote: | Originally
posted by Flintstones
Looking great Ian.
Your definitely going to need volume to fill that intake
How long do you think it'll be before she gets fired up?
Cheers
D
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Thanks guys, it had been a few weeks since ive been able to give the VW the attention it needed, between work and the other engine project ive been
working on for the GTR. The other project.... http://www.odengines.com
Realisticly I think it will probably be another 3 months. Im not planng for any more holdups but having said that now something else is sure to go
wrong.
The only challange left is the induction side of the engine, and I have a pretty nice picture in my head for how its going to go... Just need to form
that into reality now.
I'll keep you all posted.
Cheers,
Ian
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JVLRacing
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| posted on October 5th, 2009 at 09:22 PM |
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 popcorn is becomin alot nicer everytime i tune into this
thread.....
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LIFE IN THE LOW LANE
A.k.a.: Brennden Alder
Son of Jim - Creator of Good
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| posted on October 5th, 2009 at 10:03 PM |
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Would love to see your car make the trek down for Warwick next year....
[size=4] ACCEPT THAT SOME DAYS YOU ARE THE PIDGEON AND SOME DAYS YOU ARE THE STATUE[/size]
Alder Outlaws VW Racing - check it out on fb!!
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chunks54
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| posted on October 5th, 2009 at 11:11 PM |
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Looking great....
Happiness is a Hot VW.
1954 Bug, 2276/Turbo
Turbo lag - that split second when the other guy thinks he has a chance
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2443TT
A.k.a.: Ian
Fahrvergnugen
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| posted on October 14th, 2009 at 08:43 PM |
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Hi everyone,
Finally made some progress, having had a fair amount of parts arrive in the last week.
The pressure side of the intake with the intercooler setup is for the most part sorted out. Final welds are being done with tig tomorrow. I'll be
sorting out the turbo intakes tomorrow as well. There will be an air box above each turbo with a 2.5" or 3" pipe feeding the turbos going more or
less straight down. Once all the pipes are welded and bolted in, a mount will rigid mount the intercooler to the gearbox to prevent anything from
blowing apart when its having 30psi pushed through it.
I am still configuring the twins as a 2 stage sequential system. The left (drivers side) pipe still needs to have a valve put inline with it that is
pneumatically operated. There is a 3" valve to get welded to the 3" dump pipe on the drivers side turbo too. For the most part below 4000-4500 rpm
the engine will be running off the passenger side turbo, its only above that which the drivers side one will be pre-spooled and bought into the
mix.
Ive got the oil coolers mounted now too. After ordering a fancy one from the US, I have decided to not use it, and went back to the setup I had when
the car had the 2332 turbo setup in it. After all it worked exceptionally well and never had heat regulation issues.
Tomorrow more parts speedflow fittings are due in, so the plumbing begins.
I'd like to be spending the weekend starting on wiring but I hope to be competing in the bituamen sprints time attack event in townsville in the GTR.
Fortunatly work has slacked off so I have afternoons to work on the vw nearly every day now.
Cheers,
Ian
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Boostn
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| posted on October 14th, 2009 at 08:51 PM |
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looking good
VOLLKOMMEN ART
nick@vollkommenart.com
Speed and Style
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volkdent
A.k.a.: Jason
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| posted on October 15th, 2009 at 03:09 AM |
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Great to watch this all come together, overwhelming if you think back to all the chassis stuff!!! Little steps go a long way, just amazing.
If you don't mind me asking, after the extra weight and complexity, how much better is A/W intercooling over A/A? I seriously looked at the same PWR
intercooler before I went with a Spearco A/A, but I'm not sure I made the right decision. With the power I'm making so far (200hp), it's not been
an issue, but with the projected 300 from a GT28RS I'm not sure.
I'm thinking maybe a custom intake manifold with a center inlet, straight back like yours is, then down to the turbo would be a seriously short
trip.
Jason
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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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063bug
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| posted on October 15th, 2009 at 08:21 AM |
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Awesome work Ian, truely awesome.... and very interested in what you do with the cooling, what size lines, flexible, solid, what size pump you're
using and where you run the lines....... hopefully most of these will be answered in photos |
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2443TT
A.k.a.: Ian
Fahrvergnugen
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| posted on October 19th, 2009 at 10:04 PM |
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| Quote: | Originally
posted by volkdent
If you don't mind me asking, after the extra weight and complexity, how much better is A/W intercooling over A/A? I seriously looked at the same PWR
intercooler before I went with a Spearco A/A, but I'm not sure I made the right decision. With the power I'm making so far (200hp), it's not been
an issue, but with the projected 300 from a GT28RS I'm not sure.
I'm thinking maybe a custom intake manifold with a center inlet, straight back like yours is, then down to the turbo would be a seriously short
trip.
Jason
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Water/air arent necessarily any better than air-air intercoolers. The problem is getting the heat out of the intercooler or heat exchangers and to do
that it requires airflow.
Getting airflow to a radiator/intercooler is a problem with a bug as any place you put it the airflow isnt going to be very good. By very good i mean
in comparison to say a front mount intercooler in a front engine'd car. The more airflow the better. My feeling is that if its a front engine car
then air-air is the go. Basically above 80km/h its very hard to beat the efficency of an air-air intercooler. Water to air just allows that heat to
be dissapated remotely.
There are a few other diferences too. Water to air can have shorter piping (in some cases) which reduces lag. Heat soak can be a problem though
depending on where the heat exchanger is mounted. Away from heat is ideal, or insulated if not possible. I hope that makes sense...
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2443TT
A.k.a.: Ian
Fahrvergnugen
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| posted on October 19th, 2009 at 10:12 PM |
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Update time...
I didnt get anything done on the weekend as I was in townsville racing in the last bitumen sprint series event for the year. Was good to get out of
town and have a break.
So welding of the intake plumbing is now nearly finished. The valve that controls sequental operation is the only hold up to finishing it off now.
That will arrive this week sometime.
And what it looks like mock fitted.
And some more speedflow stuff arrived as well. This is most of the plumbing for the pressure and scavenge side of the oil system, and the water
systems for the intercooler. There is still a little more to order for the oil thermostat and oil coolers.
Thats all for now...
Cheers,
Ian
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LIFE IN THE LOW LANE
A.k.a.: Brennden Alder
Son of Jim - Creator of Good
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| posted on October 19th, 2009 at 11:05 PM |
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Finish line is just that much closer to being in sight now hey Ian?? Looking the goods mate. nice!!
[size=4] ACCEPT THAT SOME DAYS YOU ARE THE PIDGEON AND SOME DAYS YOU ARE THE STATUE[/size]
Alder Outlaws VW Racing - check it out on fb!!
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Beetspeed
A.k.a.: Walter
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| posted on October 20th, 2009 at 01:16 AM |
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| Quote: | Originally
posted by 2443TT
Getting airflow to a radiator/intercooler is a problem with a bug as any place you put it the airflow isnt going to be very good. By very good i mean
in comparison to say a front mount intercooler in a front engine'd car. The more airflow the better.
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With all due respect, but I think I have found a solution that does some justice to the bug and kind-off resembles what porsche did and actually still
does if I look at their rear 'spoiler' on the latest models:
Works extremely well according to log IAT's 
Always wondered why nobody used some sort of likewise intercooler location..
But still an awesome project, really curieus what the twin turbos will do!
'75 1303 'Renner' 2.2 T4 turbo
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2443TT
A.k.a.: Ian
Fahrvergnugen
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| posted on October 20th, 2009 at 02:11 AM |
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I'll pay that. I saw that setup on STF a while back. But Ive already got a nice carbon fibre engine lid though and dont want to go chopping holes in
it. I never really liked the porsche style wings on the beetles either. Its just a personal taste thing.
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volkdent
A.k.a.: Jason
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| posted on October 20th, 2009 at 02:34 AM |
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| Quote: | Originally
posted by 2443TT
| Quote: | Originally
posted by volkdent
If you don't mind me asking, after the extra weight and complexity, how much better is A/W intercooling over A/A? I seriously looked at the same PWR
intercooler before I went with a Spearco A/A, but I'm not sure I made the right decision. With the power I'm making so far (200hp), it's not been
an issue, but with the projected 300 from a GT28RS I'm not sure.
I'm thinking maybe a custom intake manifold with a center inlet, straight back like yours is, then down to the turbo would be a seriously short
trip.
Jason
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Water/air arent necessarily any better than air-air intercoolers. The problem is getting the heat out of the intercooler or heat exchangers and to do
that it requires airflow.
Getting airflow to a radiator/intercooler is a problem with a bug as any place you put it the airflow isnt going to be very good. By very good i mean
in comparison to say a front mount intercooler in a front engine'd car. The more airflow the better. My feeling is that if its a front engine car
then air-air is the go. Basically above 80km/h its very hard to beat the efficency of an air-air intercooler. Water to air just allows that heat to
be dissapated remotely.
There are a few other diferences too. Water to air can have shorter piping (in some cases) which reduces lag. Heat soak can be a problem though
depending on where the heat exchanger is mounted. Away from heat is ideal, or insulated if not possible. I hope that makes sense...
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Thanks Ian, yes it does, and that is my thinking too. I'm going to be putting scoops in the quarter windows and I cut my car up a lot more than you
did, so it works for me, but for a relatively conservative install I think it can't be done any better than yours! I appreciate the feedback,
sometimes it's difficult to make decisions when your doing things as off the beaten path as ours...
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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2443TT
A.k.a.: Ian
Fahrvergnugen
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| posted on October 23rd, 2009 at 04:14 PM |
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Update time...
Made quite a lot of progress this week.
The oil returns for the turbo's to the rocker covers are now finished, and ive had fittings welded onto the valve covers for the scavenge stages on
the dry sump pump. Most of the oil plumbing is now completed too. Ive got the valving for the sequential setup 1/2 finished, and the entire intake
side is finished and just needs a few silicon hoses to hold it all together now. I've just got to make a mount to attach the intercooler to the
gearbox and thats it for the intake side of things.
The rocker covers are in being garnet blasted after the welding burnt a lot of the orange paint off. I'll be re-painting them next week in a black
semi-gloss (not pink though I considered it for a moment).
So the engine comes out again this weekend in preporation for going in again next week/weekend when the new clutch setup arrives. Ive had Direct
Clutch in brisbane customise a twin plate setup for me. Its based on a chassis shop twin plate using the revmaster chromoly flywheel and a kennedy
pressure plate. The friction discs are custom and are a total of 600 grams lighter than the sinistered iron discs that kennedy had supplied. They
also fixed all the machining screwups that were done to the flywheel and made it work properly. It should drive like a stage 1 clutch now but have
holding power to handle 500+hp with ease.
Other cool news is I've just become an authorised workshop to perform exhaust coatings for Techline. Im going to be using the Turbo X and prevcor
coatings on the turbine housings and all exhaust manifolds components on the bug. The main reason I got into this though is for my OD Engines
project, so I can coat all my own exhaust manifolds and turbo's.
Sorry no pictures to show this time, but there will be a lot to show come next week.
Thats all for now.
Cheers,
Ian
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blahgab
Learner Dubber
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| posted on November 1st, 2009 at 07:22 PM |
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hey Ian, have just finished reading your inter thread, its amazing what you've been able to do . i wish i had the skill/money to do this type and of
build. bet you can't wait the get this beast on the road. keep up the good work will be following ur progess with envy
zac |
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2443TT
A.k.a.: Ian
Fahrvergnugen
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| posted on November 1st, 2009 at 10:16 PM |
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Thanks Zac.
Ive made a lot of progress since the last update, but its mostly little things and the finishing touches still need to go on a lot of it.
This weekends progress though saw the completion of the engine with the modified rocker covers fitted and the last of the dry sump plumbing completed.
There is now a scavenge stage from each rocker, and a turbo oil feed return for each turbo. Here is a few pics of the engine as it is now.
And here's some pics of the twin plate clutch assembly going together. These are the lightened friction discs that Direct Clutch made for me to
replace the sinistered iron ones that the kenedy setup normally ships with. They had to make up the spacer ring as well, as the positioning on the
pressure plate was incorrect for optimal operation.
Dave, your mate was right too. Series 5 RX7 input shafts are the same as 930 input shafts.
Ive modified the bell housing a little to clear the pinion gear on the starter motor, and am having a gear extension part machined up tomorrow to sort
out the starter motor/ring gear mesh issue. With that done the engine can be perminently bolted back into the car.
Other small things acomplished.... Ive now got a fuel cooler mounted in the middle of the front beam area on the fuel return line. Its borderline
overkill for the low boost application, but for a high boost tune a 2nd, or much larger pump will be installed and then I will be needing it as the
larger pumps tend to heat up and even boil the fuel after sustained running. Ive seen this commonly with the 044 and 040 pumps.
Started on wiring today too. The headlight wiring which is using a Xenon HID H1 setup in the 911 headlight assemblies is now installed. Im getting
stuck into wiring next week. The exhaust header will be ceramic coated next week and re-fitted to the car again too. Thats all for now.
Cheers,
Ian
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reub
Veteran Volks Folk
VWRX is gone...
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| posted on November 1st, 2009 at 10:24 PM |
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WOWSERS DUDE.... nice work
Reub
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colonel mustard
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| posted on November 1st, 2009 at 10:29 PM |
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extreme man  love it.
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Beetspeed
A.k.a.: Walter
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| posted on November 1st, 2009 at 11:15 PM |
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Love your flywheel/clutch set-up!
Very curieus how the pedal feel will be for driving off from stand-still. Heard good and bad stories about not using center springs.
'75 1303 'Renner' 2.2 T4 turbo
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dangerous
A.k.a.: Dave Butler Muffin Man
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| posted on November 2nd, 2009 at 05:17 AM |
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It looks like it is all coming together there Ian.
And that is a damn sexy engine now too!
Aaron knew all about that series 5 rx7 inputshaft, since his bus has a 20BRotary AND Porsche trans.
| Quote: | Originally
posted by westi
That's mad Alan.
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