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 ratbug
A.k.a.: Andrew Todd
Wolfsburg Wizard
aka toddy101
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| posted on April 17th, 2016 at 10:28 PM |
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Manxster with FA20T engine
Hi, thought I would share my manxster build here on AVD. The project started in August last year when I picked up the new Manxster body with the aim
to build a modern dune buggy using most of the latest mod cons found in new cars. I purchased a salvaged current model WRX that was just 9months old
that had the new FA20T motor, which is the latest generation subaru engine that has taken over from the older EJ series. The FA20 features variable
cam timing on intake and exhaust and is direct injection. It puts out 198kw in standard form. The aim was to try and re-use as much as practically
possible from the WRX to save on purchasing aftermarket parts and to give it the OEM look.
The manxster was ordered with the manx hardtop roof and cage, side and front bars, however a custom rear bar was made to suit the FA20 engine. The
only manxster modifications was to integrate a pair of BRZ led tail lights instead of the standard manx lights.
Parts used from the wrx include:
Engine (air-air intercooler replaced by PWR water to air cooler with radiator in side vent)
6speed gearbox (modified by Subarugears)
Front seats
Rear seat (cut down to suit)
Steering column and wheel
Brakes (for disc brake conversion)
Instrument cluster
Multifunction display (boost gauge, mpg display, reverse camera)
Stereo with handsfree
Pedal box, master cylinder and brake booster
Heater box (cut down to remove condensor) and controls (no air con, but has heated demister for ADR compliance)
Side mirrors
Fuse box's and wiring (modified by AGT Engineering)
Other features include a Holden Camira steering rack
The aim was to have this at the Nationals next month, but still waiting on a few components, so new target is for Valla.
The barwork is currently out getting powdercoated and the body prepared for painting.
Anyway, some photos.
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ratbug
A.k.a.: Andrew Todd
Wolfsburg Wizard
aka toddy101
Posts: 439
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Registered: January 14th, 2003
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Location: Newcastle
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| posted on April 17th, 2016 at 10:29 PM |
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I also have a video of the engine running
http://youtu.be/9IQ5-vw4GnI
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baywindowbandit
A.k.a.: Mats J
Seriously Crusin Dubber
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| posted on April 17th, 2016 at 10:57 PM |
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Damn, that's a lot of work.
A bad day cruizin is better than a good day at work!
1. 1958 11 window project bus.
2. 1971 Beetle lowered on Empi 8 spokes.
Sydney NSW
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beetleboyjeff
A.k.a.: Jeff Walsh
Custom Title Time!
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| posted on April 17th, 2016 at 11:31 PM |
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Well done.
From your ole' mate Jeff
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karmann141
Wolfsburg Wizard
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| posted on April 18th, 2016 at 08:09 AM |
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Very impressive build - will be a weapon.
Just one question: where are you locating the fuel tank?
1961 K Ghia - Porsche 5 sp, EJ20T, Brembo's, Dble A arm susp
1974 L Bug - Porsche 944 brakes, Boxster 16's
1974 Bay Camper - EJ20, twin radiators, Boxster 16x7's
Half Beetle trailer with Boxster 16x7's
2011 Tiguan TDI 4Motion
2010 LR Discovery 4 TDV
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Camo
A.k.a.: Kev
Custom Title Time!
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| posted on April 18th, 2016 at 11:16 AM |
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Amazing, all credit to you.
Cant wait to see the finished product 
Kev
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wombatventures
Wolfsburg Wizard
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| posted on April 18th, 2016 at 07:34 PM |
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No Words left!
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nbturbo
Veteran Volks Folk
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| posted on April 18th, 2016 at 08:18 PM |
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| Quote: | Originally
posted by wombatventures
No Words left!
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No-three words left-(FFS) or that is unbelievable.
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ratbug
A.k.a.: Andrew Todd
Wolfsburg Wizard
aka toddy101
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Registered: January 14th, 2003
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Location: Newcastle
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| posted on April 19th, 2016 at 10:41 AM |
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Thanks guys. The fuel tank is in the front keeping the brake booster company, its an L shaped tank that goes to the side and in front. Lucky the buggy
has a 2" body lift, so I have 2" of extra tank depth to make up for the lost area taken up by the booster and master cyl.
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seagull
Compulsive Aussie Vee Dubber
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| posted on May 1st, 2016 at 12:04 AM |
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This is very cool, good work !
Looking for that special lady : PM me for coffee & cake
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Jak Rizzo
Insano Dub Head
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| posted on May 2nd, 2016 at 07:55 AM |
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Hi Andrew
Have you done any measurements on the new FA20 motor in comparison to your old EJ20 motor? The area around the quad cams looks by eye to be much more
compact. Also how low does the new turbo location sit in comparison to the depth of the sump?
thanks
Jak
PS your old gearbox is still in my bug! Amazingly
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Birdman
Wolfsburg Wizard
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| posted on May 2nd, 2016 at 12:10 PM |
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It's definitely smaller in the heads Jak. I've been over and had a good look but that intake, turbo and cat are not only the lowest parts of the
engine, they are also the furthest back. It's not affecting Andrew much in this raised car but it's the reason we just decided against putting one
in a mates Ghia and are sticking to the EJ.
Imagine dragging that lot along the ground! They are lower than the sump and headers.
Andrews has done a kick ass job of making it all work though. Smart bloke that one.
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tracash242
Officially Full-On Dubber
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| posted on May 13th, 2016 at 02:38 AM |
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wow that's gong to be one tough buggy
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ratbug
A.k.a.: Andrew Todd
Wolfsburg Wizard
aka toddy101
Posts: 439
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Registered: January 14th, 2003
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Location: Newcastle
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| posted on August 15th, 2016 at 09:27 PM |
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Hi Jak, actually I havnt really taken any notice on the FA to EJ quad cam differences. I still got my old buggy with the EJ20 DOHC, i'll have a
compare tomorrow.
Yeah turbo sits about the same depth as the sump (same as the EJ), however its further back away from the axle. You would need to raise the motor
somewhat I would imagine in a beetle.
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ratbug
A.k.a.: Andrew Todd
Wolfsburg Wizard
aka toddy101
Posts: 439
Threads: 30
Registered: January 14th, 2003
Member Is Offline
Location: Newcastle
Theme: UltimaBB Pro Blue ( Default )
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| posted on August 15th, 2016 at 09:34 PM |
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Ohh and forgot to mention, it is now on the road! Made it to Valla (just).
Have a done a small video with some finished stills and a running video.
https://www.youtube.com/watch?v=W8ltIlhm5ko
I have to say the low down torque of the FA20T is out of this world. It doesnt really feel like a turbo car, more like a V8. It builds boost very
quick and hits full boost (20psi) at around 3500-4000rpm. For anyone wanting to do a turbo converion I would highly recommend the FA motor. Even the
non turbo FA would be a good engine, they have about 150kW standard, which is pretty good for a 2L N/A engine.
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baghall
Custom Title Time!
Ben Hal Outlaw Bushranger
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| posted on August 15th, 2016 at 10:20 PM |
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Hey Toddy. It looks awesome can't wait to see it in real life!
68 Baja - It's a growing pain!
58 Baja ute - and the pain spreads!
85 T3 Kombi - still growing
89 T3 Kombi - parts car
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nbturbo
Veteran Volks Folk
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| posted on August 16th, 2016 at 11:18 AM |
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Unbelievable- and awesome.
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