Project X, engine #2 2056 cc turbo

[Frallan]

It seems I might become owner of another Super.
One nice car with very few miles on and a lot of Swedish VW street history.

It will need an engine.
My Blue Carbon car and engine is #1 in priority, so I call this project #2.

71 X 96 turbo TIV engine
Goal, a bottom level strong 300 hp. All in by 6000 maximum 6500.

Stock crank 71 mm
T IV length H profile rods and 200 mm conversion flywheel from Jake Raby
200 mm Kwik lock six puck disc.
AA 96 mm Biral with JE forged pistons 22mm
My TIV heads that I have tried to sell for quite a while but now will be core of the engine.
A twin scroll turbo good for 400 hp.
Short non equal length 38 mm stainless exhaust primaries
Burns collector
Either a new JPM or a Web cam I have on the shelf
FBO ceramic tipped lifters
CB drysump
T1 style cooling with shroud from CSP Sweden
DTA S60 injection
Single 3" throttle body by Hilborn.

[Frallan]

[Frallan]

I have pictures but since Photoshop migrated to new version, I hate it!

Double slip twin scroll 38 mm collector

[modnrod]

I have pictures but since Photoshop migrated to new version, I hate it!

Yep, me too. Especially when they lost all the links I had to forums like this one on the changeover. 

Anyway, cool motor build. It always amazes me how you guys keep gearboxes up to these things! 

[Frallan]

[Frallan]

Well never T1 in my case.
I am amazed at the patience so many people have in replacing gears and differentials.

Only 002/091 or better.
Stock 901 in the dragster and 915 in the 1967 beetle with Porsche 228 clutch.
In my older car it was a in fact a Bus automatic 090.

Subary is beginning to interest me.
The differential cannot be flipped but they do sell gears (I have been told) for reverted positioning. I have to check this.

[modnrod]

OK, here you go......
http://www.subarugears.com/

Just remember that a 1100kg WRX running 12s will pop boxes too.

[Frallan]

Thanks for the link.
Well that is too much money for just the R&P kit.
Rather do a well built 002/091 or step up to next model, a 911 or Mendeola.

[Frallan]

The AA biral 96 mm set with with JE forged looks good and measured round and nice. Al fins on steel liner
The Kennedy conversion flywheel looks good too, so far.

[Frallan]

So Wally, should I build with this turbo i know very little about or go to a T3/T4 or something else?
I tend to wish to start with this one and see how it works.
14-15 psi I have set as max boost.  Probably I will sneak up on it starting much lower.

Two air to water intercoolers in series in the back seat and a large motorcycle watercooler up front.
Pictures on those coming later.

[Frallan]

This is how it started...........many moons ago.
Now that engine never got further...until now and in slightly different design.

[Airspeed]

So Wally, should I build with this turbo i know very little about or go to a T3/T4 or something else?
I tend to wish to start with this one and see how it works.
14-15 psi I have set as max boost.  Probably I will sneak up on it starting much lower.

The birals are 'interesting' to use n/a to say the least, let alone for turbo use, but you have used parts that were against the odds before and they worked well for you  
I can't see what size that turbo is?
Can you supply sizes of the compressor and turbine wheels?

Cheers,
Walter

[Frallan]

Robin G. look!
IKEA soup spoons just weeks after you gave me that tip in 2005.

[Frallan]

What is it you need Wally?

Do I need to take the housing apart to measure?
I can do that easy for the compressor but turbine is more complex, I think.
I can then give you compressor inlet diameter too? Right?
Nope, I am not a turbo man....in that aspect.

[Frallan]

Look,  it was easy.
Does this help?









and this one but I can only read the 7683 number.
Turbo is a Garret Air Research.

[Frallan]

Compressor diameter 68 mm
Inlet small diameter 54 mm
Turbine diameter 74 mm
Turbine small diameter 58 mm

[Airspeed]

Those are the ones Fredrik!

I'd say that is indeed a 400hp turbo, but on an aircooled that would be pretty maxxed out (very high boost) to reach that I think. 350 real hp would be its ball park under more sane boost levels in my guesstimate with the references I have.
But yeah, should be able to do the job 

[Frallan]

Thanks!
Suits my 300hp target.
Good news. Looks like new inside.  1-3 and 2-4 paired? right?

[Airspeed]

Good news. Looks like new inside.  1-3 and 2-4 paired? right?

Yep, plus try at least keeping 1-3 primaries and 2-4 primaries equal length as that works very well for spool and power on twin scroll turbines.

[Frallan]

Here are the two water intercoolers that will be mounted in series in the left back seat space.


These are the two engine blocks. the magnesium one to the right will be used.
I know it is not the stronger but it is almost 7 kg lighter.
Been looking in to a slim steel plate conversion on the sides. Yes it adds weight..... hmmm thinking. But it keeps the timeserts for the stud in place and stiffens things up.
Maybe.



This is the good outcome of beginning to sort and keep my stuff in order.
I found a lot of Raceware studs. They fit this short stroke engine.
All I need is to order Timeserts and the 12 point nuts/washers.

[Airspeed]

Nice 'find' on the studs! 

[modnrod]

Been looking in to a slim steel plate conversion on the sides. Yes it adds weight..... hmmm thinking. But it keeps the timeserts for the stud in place and stiffens things up.
Maybe.

Is this the same type of thing as the steel backing plate I used on my SSP 1303 box, between the main housing and the end housing to reduce the shaft/bearings walking?

Would it be a plate on either side of the cases, under the barrels?

[Frallan]

My dragster engine from 1978

[Frallan]

So we have a little bit of progress.

Crank is balanced with pulley, flywheel and pressure plate.
All balanced individually and then added on one by one, balance check on each added component and than as one assembly. Nice work Murre! Thanks!

Crank is checked and journals polished. Thanks Patte! I owe you one. (did you get the Aladdin box :-) ? )

[Eddie DVK]

Nice parts Frallan, but what dit you do with the oilholes on the mains on your crank?

Regards edgar

[BeetleBug]

Nice parts Frallan, but what dit you do with the oilholes on the mains on your crank?

Regards edgar

Nothing is my guess. Perhaps VW thought that a T4 engine could use some additional lubrication?

-BB-

[Frallan]

Yeah, that is OEM VW.
I did not even react to it. Seen it for years (35) like that.

[Type4turbo]

Hi Frederick, how is this build going?
Looks likeit ccould be a beast.
Love it.
Hermann.

[Frallan]

Ohh hello Hermann!  i was just going to update and I saw your post.
Nothing has happened as I have begun enjoying my engine current 2413 cc high rev engine until last week.  I think I have either run a cam lobe flat or a lifter failure.
So with that in mind I decided to start building this one... or rtaher just assemble. It is pretty much done.

Using my mag case I now updated it with timeserts for the Raceware studs.
Then brake in and run it for a while with carbs, still turbo exhaust as pictured, then turbo.
More soon.

[Shag55]

Nice. Keep it coming