The Cal-look Lounge

Hello
I wanted to build a car like this for years inspired by Frederik's (Frallan) black bug after seeing it in Warsaw, my brother's cal-look bug of course by Chris Burns (he actualy started vw drag racing in Poland).  After talking with Chris we decided to do it. I took 1.5 year to build it.
Yesterday we raced it for the first time and the result was 12.7 @170kph and 1.7 60 ft with normal road tyres and I think it's a nice time (car was finished 6 hours before races and I never did dragracing before). Everything except the cage was made by me and Chris.
Car is street legal. It's not finished yet of course.
Engine:
Autolinea case
SCAT 4340 billet 84mm crank
SCAT h-beam rods
wiseco 94mm pistons
SCAT c85 cam
Berg power pulley
Magnum straight cut gears
30mm oil pump
CB Comp Eliminators 48x40mm
k800 springs with titanium retainers
Pauter 1.5 rockers
48 IDA and 43 mm home made venturis we tried 40mm ones first but after changing them to 43 the engine feels sooooo nice
home made exhaust (I tried tig welding for the first time)
modified dog house fan shroud
singleport cylinder covers modified to fit comp eliminators with all necessary deflectors inside

Gearbox is a stock IRS unit with 3.88 R&P and quaife diff and it's mounted on urethane mounts +  home made midmount

(http://img860.imageshack.us/img860/7113/55386291.jpg)
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We picked up the diff form quaife
(http://img195.imageshack.us/img195/7393/201109161144small.jpg)
(http://img233.imageshack.us/img233/4294/201109161149small.jpg)

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Yokohama a048 185/60 13
(http://img826.imageshack.us/img826/1806/20120205136small.jpg)
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Yesterday (found on callook.fora.pl):
(http://img171.imageshack.us/img171/4287/img1414oa.jpg)
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(http://img152.imageshack.us/img152/7470/img1422m.jpg)

(https://lh5.googleusercontent.com/-RaPPZKS4qS0/T5SeEycl8VI/AAAAAAAABKg/fLVsR2_B1W8/s640/Jasio.JPG)
http://www.youtube.com/watch?v=Wh5t6u3Ldfc
http://www.youtube.com/watch?NR=1&feature=endscreen&v=3z8JDk7ds_4

There is still a lot of work to be done but we're getting there. Slicks, shorter 3rd and 4th, "launch control" and we'll have a 11 sec pass

Fantastic!  8) 8) 8)

Very Nice

RIGHT ON!
I Dig It!
TxT

Brilliant, your TIG welding is great for a first time  :)

That is awesome, I love it  ;D well done on that project guys. Say "hi" to Mr Burns for me.

Thanks guys.
Shane - Chris is reading the forum (under the name "Chris Bugster") so he will surely read it.

COOL!

Agree on the welding. I wish I could weld like that...after 20 years of TIG usage. I am lousy.
I remember these talks more than once but I am not sure from who it was. I guess you were one of the preachers of this approach.
Thansk for mentioning me. I am happy I could brainwash someone. Or should I say sorry?

Good luck with next steps! I will follow.

Cool car.   :)

Great build pictures too.

What's done is done;]
I'm certainly not the first guy with a tuned vw engine here in Poland - the scene is getting bigger and bigger here, mainly thanks to Chris but also many others. I wanted to build it for a long time but being 22 years old (when I started this project) is not easy if you want to build a car like this. I did not build it alone - there are many people that I would like to thank for helping me - my brother and Karolina, my friend Jasiek, my girlfriend who encouraged me to finish this car but most of all - Chris - it would just not happen without his help.
Now we have to prepare other cars we have here - bugeyed and bugster, there will be some nice racing this season.

I broke a cv yesterday, interestingly it broke during deceleration after I tried to show the car to my brother. Now I wonder why it broke:

-It was a used one
-There is a small possibility it was in a car that burned down so maybe metal fatigue
-the angle of my driveshafts is to big. I remember that I checked it long time ago but I don't remember now.
Anyone know what's the maximum angle they can take? Are there any cv that can take more?

I love the exhaust! And the rest of the car  8)

Please take it to SCC so we can have a closer look  :) Cool car - good craftmanship.

-BB-

Would love to but we'll see - budget is tight. It would be also  great to race against Peter Englezos one day.

http://www.youtube.com/watch?v=-UDWvf4Pct0
http://www.youtube.com/watch?v=XqDW98PnteU
http://www.youtube.com/watch?v=jeHLg6Co8ok
http://www.youtube.com/watch?v=xGWUzyUVFZM

Jago - Great job with the car!  Dare to be different!!

I think it's great that the performance aircooled hobby is alive and growing in Poland!  I'm 100% Polish but live in Florida! I'm definitely a minority here in the South! Never been to the land of my ancestors but I might just have to visit to see the Country and the HotVws in Poland!
Jeff

I had a chance to dyno it for free today. Carbs are not tuned - it's pig rich (afr 9.0)from 3 to 4.5 krpm so this part of the graph isn't relevant. It's a good result, we can (and will) easily improve it - auxiliary venturis are crap (we'll buy some jpm venturis maybe) and camshaft is down on duration and lift (it's from "no mercy")
(http://img690.imageshack.us/img690/6219/126pco.jpg)
http://www.youtube.com/watch?v=NoeG9jpfxe0&feature=youtu.be

Maybe you should translate the KM and that a horse in Polish is Koni. KM is not the speed... :-) It is the Polish Power!
Well done and more to come.

Sure, forgot about it - km=hp

Hmm that's true:
Last weekend we had a nice meeting - 2 days, Saturday was a test and tune, we could drive as much as we wanted, and sunday was a race day. Chris and I decided to take 126p and Bugeyed - it was it's first race since we bought it. Unfortunately engine in my fiat died during the first pass:( No oil pressure and we couldn't turn the engine. That was very disappointing, I was very, very upset but at least I could do my best to help Chris to get used to bugeyed. It was a good weekend for Chris and his car - only one small technical problem (oil lines started to leak a little bit, I had to tighten them), he did 8 runs, best times were 11.2 ET and 1.53 60ft on a crappy concrete airfield. Remember Chris wasn't racing for more then 10 years. He won his class after a very exciting battle with a mid-engined golf 2 with audi v8 4.2 turbocharged engine.
(http://garazbaktera.pl/wp-content/uploads/2012/05/wheelie.jpg)
Fiat engine after disassembly:

(http://img543.imageshack.us/img543/7228/20120528224935.jpg)
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Piece of a lifter broke off (I don't know why) an blocked the oil pump, the results are:
-completely fried rod bearings
-overheated rods.
Fortunately crank just needs regrinding, block, pistons cylinders heads etc are ok. Hopefully it'll be ready for next race.

That sucks man
maybe next time use a pressure controled oil switch to cut the ignition when de pressure drops
good luck .
henri

Sorry to see the damages. What do you think is the reason for what happened? Too big oil pump causing too much resistance, hence too much force on the oil pump = broken pump drive?

-BB-

No no - as I said one lifter broke in half and one small piece of it got into the oil pump>blocked it>broke of the tang that goes into the camshaft>no oil pressure>no bearings. That's why you have to have some kind of a mesh filter before the pump... well you learn something new every day. New rods are on their way to Poland together with close ratio 3rd and 4th gears, and coilovers for the back. Hopefully it'll be ready in 3 weeks for next race.

mr horsepower - I think I'll do that.

Finally the stuff from SCAT arrived today
(http://img11.imageshack.us/img11/2928/20120615131618small.jpg)

New gearbox - close ratio, 3.88 r&p, welded case and hubs, cro mo pinion nut, no diff (I'll put the quaife in there)
(http://img546.imageshack.us/img546/7606/20120615183704small.jpg)
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Rod bearings and some minor stuff
(http://img33.imageshack.us/img33/5914/20120615191534small.jpg)

H-beams
(http://img441.imageshack.us/img441/4772/20120615192834small.jpg)

Line lock:)
(http://img10.imageshack.us/img10/3836/20120614135629small.jpg)
(http://img341.imageshack.us/img341/4562/20120614140002small.jpg)



Some parts for the next engine (t4)
(http://img24.imageshack.us/img24/5854/20120615190728small.jpg)
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(http://img100.imageshack.us/img100/1011/20120615193525small.jpg)

nice work mate, looks like next engine will be a big t4 with Scat split port heads?

ben

Yes, and nicasil cylinders, efi etc. But not this year probably.
(http://img824.imageshack.us/img824/8554/20120616123155small.jpg)
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(http://img641.imageshack.us/img641/6325/20120616176small.jpg)

I need this car in my life !!  :o

It's getting close:

(http://img225.imageshack.us/img225/9391/20120620144958small.jpg)
(http://img641.imageshack.us/img641/586/20120705200615small.jpg)
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(http://img442.imageshack.us/img442/7449/20120706170132small.jpg)
(http://img803.imageshack.us/img803/8308/20120706173052small.jpg)
(http://img195.imageshack.us/img195/8512/20120707002548small.jpg)
(http://img26.imageshack.us/img26/7722/20120708025413small.jpg)
(http://img836.imageshack.us/img836/2720/20120708031914small.jpg)

The car is running, feels stronger. It did a low 8 sec 1/8 mile pass on a crappy street with street tyres last weekend. www.youtube.com/watch?v=stfKkoW-QkI&feature=autoplay&list=UUybIhopV6ipN_QmjvM1a-Ig&playnext=1

http://www.youtube.com/watch?v=w9Fo7XY1raI&t=70
The "track" was pretty narrow :o

http://www.youtube.com/watch?v=o931-2SDQ6o&feature=youtu.be

(http://img32.imageshack.us/img32/27/55699938134708484022062.jpg)
(http://img850.imageshack.us/img850/946/56133938134738484774455.jpg)

...

I'm back;) I disassembled the car almost 2 years ago and now it's almost done.
What was done;
-rear suspension was changed - I designed some custom a-arms with beetle IRS bearing carriers, Porsche 944 stub axles and CV joints at both sides (gearbox has type 181 flanges), disc brakes and adjustable coilovers. It now should have 0 camber gain (that was a big problem on a previous setup) and better a-arm angle (it's adjustable)
-The engine now has titanium valves, compression is raised a lot, heads received some small porting job.
-Carbs are empty inside (they only act as a throttle bodies) and the engine is now fuel injected with interesting f1 style stand off injectors. I'm using a new polish ECU called ECUMASTER EMU - It has a great functionality, like built in egt sensor controllers, built in wideband lambda sensor controller, built in MAP sensor, knock sensors support, full sequential ignition and fueling, speed sensor input, nitrous control, parametric outputs, traction control, launch control, wireless throttle support, very nice and easy to use interface and many many more - and it's very cheap - around 470 euros (but I can get it much cheaper)
-the car should be also much lighter - fiberglass engine cover and front bonnet, lightweight doors, lexan windows, a lot of unimportant parts cut out

The electric system is pretty advanced:
 - there is something like CAN bus so there is no need to have 30 wires going from front of the car to the engine bay - most of the communication is done by 2 wires.
- There is a small screen on the dashboard that is connected to the wheel speed sensor and calculates  60ft, 1/8 mile, 1/4 mile, 0-100km/h times etc. It also shows oil temp and pressure and various other readings (with a possibility to set a very loud warning sound if for example temperature is to high),
- steering wheel has it's own, very small microcontroller that is powered by a wire that originally powered the horn. The interesting thing is it also communicates withe the reciver-microcontroller under the dashboard by THE SAME wire - thanks to that I can have as many buttons on the steering wheel (launch control, nitrous, linelock etc or LEDs or displays) without having any addition wires connected to the steering wheel - that's is always a problem.

The car fired up, it run for 20 mins (some new lifters needed break-in) now I have to finish some small things, tun the injection and test it somewhere.

Here is the video how the injection works (without air filters) - it's a first fuel map written by hand so it doesn't work perfectly

https://www.youtube.com/watch?v=eZzQVBPd3yI

(https://lh5.googleusercontent.com/-KHzOh5jK6Zw/Uuqm3u3A4BI/AAAAAAAAAok/20wINL_PrR0/s800/WP_20140124_019.jpg)
(https://lh5.googleusercontent.com/-VD8ritndClE/UiPQMlv3SpI/AAAAAAAAAYE/I6gl0dh19rI/s720/DSC_0580.JPG)
(https://lh3.googleusercontent.com/-MgGrLN7yhIk/UnsAxSSen4I/AAAAAAAAAjA/C2ggm8Gx-A8/s640/SDC10183.JPG)
(https://lh5.googleusercontent.com/-GYmXN0ZTlGY/Unr-MhQcK-I/AAAAAAAAAiU/Ekm0T9XzMig/s640/SDC10198.JPG)

Stainless steel
(https://lh4.googleusercontent.com/-uaPO46241v8/UatdKNEQt3I/AAAAAAAAAEU/2e6IMzVlQYI/s720/DSC_0352.JPG)

Titanium
(https://lh3.googleusercontent.com/-mFvqicTnVaY/UatdGZ_i06I/AAAAAAAAAEM/whkEt-XIJXE/s720/DSC_0350.JPG)

Coil
(https://lh3.googleusercontent.com/-h5dD8FltRHc/UbuagJP7A3I/AAAAAAAAAKI/A2w0YBkqxk0/s640/20130614_233029.jpg)

TPS sensor
(https://lh5.googleusercontent.com/-oqR74kpHvWQ/Ubuaa28q58I/AAAAAAAAAJ8/FBbY4nyAfHU/s640/20130614_233725.jpg)

Before painting the tinware
(https://lh6.googleusercontent.com/-zSThro9H-J8/U_jt5qWPs-I/AAAAAAAABKo/kAO5jDcRIuA/s720/DSC_0126.JPG)

Some assembly pictures
(https://lh3.googleusercontent.com/-LCyII98hL-g/U_jtzpswlsI/AAAAAAAABKg/Y6h_MsPMUcQ/s720/DSC_0132.JPG)
(https://lh4.googleusercontent.com/-waq9Q9QieIg/U_juOWqquXI/AAAAAAAABK4/RQCK5r2h2ag/s720/DSC_0139.JPG)
(https://lh4.googleusercontent.com/-LmbEOT65j_0/U_jryALTuUI/AAAAAAAABJU/eIuphkL70ls/s720/DSC_0014.JPG)
(https://lh6.googleusercontent.com/-sGrZFmeTECo/U_jr9LF52TI/AAAAAAAABJc/xrpctr1OOfU/s720/DSC_0018.JPG)
(https://lh5.googleusercontent.com/-a4yLhCxNVM0/U_jszKYYLEI/AAAAAAAABJ8/OzwzuPURmvU/s720/DSC_0031.JPG)
(https://lh3.googleusercontent.com/-bXHMuNB3wz4/U_jtIedZ3JI/AAAAAAAABKU/pkXepUol8lk/s720/DSC_0032.JPG)

Thanks to my buddy Janek for all the electronic gizmos and for a helping hand and to Chris Bugster for inspiration, parts and much more

Playing with injection/launch control:
https://www.youtube.com/watch?v=VuqScLBb8mw

(https://lh6.googleusercontent.com/-ikYB3z7AZec/VAUhKqhmNiI/AAAAAAAABNg/rLjcbjjJ_gA/s720/DSC_0228.JPG)

You should brag more often [attachment=1]

Fantastic -- -- Nothing like a Fiat starting on the bumper

 https://youtu.be/zudwarlk0Hc  (https://youtu.be/zudwarlk0Hc)