This is very good. :cool:

Yep, after your tales of temperature, I was a little worried. I have to tell you though, I suspect an air bubble is the culprit in more situations that airflow or water volume or radiator size. I had originally bled the air with the car just sitting. After I hit a few things, I was losing coolant rapidly so I was adding on the fly and BLEEDING on the fly, engine running. Bubbles were all over the system. Once I just let it sit there for a bit then bled it, no troubles at all. I couldn't keep the temps right before I bled it properly, it was always running a little hot, but not too hot, once the bubble were gone, perfection!

I just hope the new one will be able to cope with 300hp...

Jason

Gotta stop hittin things!

OK, long time no update!!!

Well, the new radiator is TOTALLY out of harms way, so I'm assured of no further issues there. I would seriously wreck the under belly of the nose and the frame head before the radiator would be affected.

Cooling was a little bit of an issue, as the new rad is not in airflow at all. I needed to cut one of the rad hoses a little more than I did so it made an odd angle and a high spot in the system that allowed air to be trapped there, but by manually milking the air to the bleed spot I think I got most of it out.

Still needed some airflow though, so before Bugorama(the night before in fact) I made an ABS scoop by heating and forming. It's quite lightweight and doesn't even do a particularily good job of forcing air through the rad, but it works SOOO well!!! The fans wouldn't come on at all unless I sat idleing for quite awhile. I will probably build another lightweight one like this that is the standard scoop making it completely sealed to force air ONLY through the rad, while the one I'm working on with the M3 lip would be more track only as it's lower and a higher risk of being ripped off because it's much more stiff.

http://i93.photobucket.com/albums/l4...8.jpg~original

The track runs at Bugorama went fine. The best time as shot by Humble(Will) was 13.5, but the biggest problem I was having was the shifter not being smooth due to issues with the Porsche shifter not really having a good gate setup. I'll work on that. The other problem was my little stock 1.8t intercooler sitting behind my seat. It gets no air flow, so by the end of the track it was totally heat soaked.

On Monday coming up I have an appointment at 034 Motorsport to have the intercooler plumbing squared away. I already have the intercooler and I'll fab up the mounts this weekend. Once that's squared away I can start working on the quarter window scoop that will deliver air to the intercooler plenum, then out the stock rear window ducts.

Jason

Can't wait to see pics! 034 does outstanding work So i'm curious to see what they do for you

That's sound and looks like tons of fun. 1.8T's are great little engines. Curious to see the new intercooler setup.

Pete

Volkdent,

Nice to see that this project is still alive and that you are making such good progress. Time flies by(since your last post) doesnt it eh? Plus, I didnt know that GErmanLook is online again(because obviosly I still had Germanlook.com in my bookmarks :o )

Light Wallet
 

The day was spent at 034 Motorsport. Mike did a bang up job getting the plumbing done for the turbo. I got the intercooler mounted where I think it will work out really well. You can see I cut out the space behind the IC where the hot air will exit through the stock grill. Cutting those out also gives me access to that compartment to get the LEDs installed for my 3rd brake light. There is more lag now as the path is longer and the volume larger, but the power just keeps coming. On one end the alumunim is hot, and on the outlet side it's totally cold! When the GT28RS is installed, it will be a necessity, so I might as well get used to a little more lag now.

http://images.thesamba.com/vw/gallery/pix/562347.jpg

http://images.thesamba.com/vw/gallery/pix/562348.jpg

http://images.thesamba.com/vw/gallery/pix/562349.jpg

http://images.thesamba.com/vw/gallery/pix/562350.jpg

Jason

Hi Jason,

A very impressive installation!

One query - Will the intercooler actually vent through the rear grilles under the rear window? I thought this was a high pressure area that under normal circumstances is the cold air inlet for the carb(s). I assume that you will be taking the cold air feed to the intercooler from the side windows? If that is so the air pressure/air flow is not too good and may not overcome the high pressure under the rear window.

Clive

I do hope you plan to beat on this thing for a while before any major renovations ... :eekno: I wanna hear about some street exploits :D .

Jeff-

So when willyou be offering a whole conversion swap kit? :lmao: That is so wicked... I was looking to do the same thing, but with a TDi motor, but money, little to no fab skills, and school put an end to that right quick. :rolleyes:

Clive, I'm glad you brought that up. How sure are you that that idea is true? If you're 100% I'm gunna have to change my thinking, I used to think the same thing. But the more I understand about aerodynamics, the less I think this is likely.

When I was down at 034 I explained my idea of the ducting, strictly the pathway, not mentioning high and low pressure areas. The tech who worked on my car, Mike, mentioned he thought NACA ducts in the side windows ducting into a plenum then out the vents would work great, said NACA ducts flow serious air. Then Javad, the owner, said he thought scoops would be a better bet, really trap air and force it through. Finally, Christian (Miller, KONI Challenge Series points leader) said he thought scoops and make sure that the exit duct to the rear vents was very well sealed, as he figured the vacuum created in that location was actually going to be pulling more air through the intercooler than the pressure from the scoops.

All of these guys are SERIOUSLY into motorsports, Javad has been racing and setting up racing cars for years, and Christian is a professional racecar driver with a lot of R&D experience. ALL of them had the same idea as I did regarding high and low pressure areas and airflow in general. We could all be totally wrong, so I'm going to have to do some R&D of my own, build the setup in cardboard then put little red yarn pieces on the ducts and see which way they blow.

When I think about the stock idea of those ducts, I actually think they may be there precisely to pull the hot air out of the engine comparment! Regarding the NACA ducts, I spoke with a drag racer at Bugorama a few years ago, and he had actually tested the pressure from the duct placement in the quarter windows, and he said he was seeing 5psi!!! I don't know, I hope the old idea isn't true, but if it is I certainly stand corrected. My little test should let me know if it'll work or not.

Jason

What are you talking about, all I DO is beat this thing!!! How do you think I break stuff?!!!!

Jason

Hi Jason,

I'm not at all sure about the high/low pressure areas but this was my logic:
The rear vents are the only visible inlet for cold air to the normal single carb? The flutings behind the grille imply (to me)an airflow into the engine bay whilst protecting from rain penetration. I would expect the shape of the beetle body to create a laminar airflow over the rear window. This was I understand Dr Porsche's original intent to create a tear drop shape. If he had required a solid negative pressure area behind the rear window then he would have created a kamm tail. In general all the aerodynamic aids I have seen for beetles do take advantage of the laminar flow by placing wings etc hung out of the back including integral intercoolers. If there was a low pressure area at the base of the rear window then I would have expected a roof lip spoiler above the window to enhance it.

With regard to the side scoops, I agree that they are in the logical location but I would have expected the airflow to be reasonably turbulent not least because of the flow from the edge of the front screen. The shortness of the beetle body would, I would have thought, prevented the airflow becoming laminar again to create a positive pressure. The half moon vents in the rear quarters of a beetle body are to demist the rear screen, in other cars they are extract vents. If they are inlet vents (as would be supposed with +ve pressure at that point) then where is the air extracted from within the car?
I have no proof that any of those thoughts of mine are correct and I would be pleased for someone to correct me.

Clive

PS If my suppositions are correct then the air will flow through your intercooler but in the opposite direction???!!!

Well I'm glad you are as unclear as I am, it's the bug shape that puts a real clink in the deal. If it had a flat roof or this or that, it might be more predictable, but you are absolutely right, it might flow backwards!!! I'll have to run some tests and I'll post my results!!!

Jason

I'm very interested in how this goes. Those vents behind the rear windows on the side are quite a mystery, I would love to know definitively if they flow in or out.

If all the UK contributors clubbed together we could get a bug in the wind tunnel at MIRA (Motor Industry Research Association) that's no more than 3 miles from here. From that we could get all the data we need but unless we have an aerodynamicist on board I doubt whether we could interpret the data. Ho Hum!

Clive

Exhaust
 

Finally got something going with the exhaust, and it actually turned out pretty good. It's all tacked up, and then I'll take it to a welding shop and have it either stainless MIGed or TIGed, not sure which will be a better option. I had a brainfart and ended up overtightening the V-band clamp, so after it's welded I'll have to get a new one as the nut gaulled...

Jason

http://images.thesamba.com/vw/gallery/pix/632786.jpg

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http://images.thesamba.com/vw/gallery/pix/632788.jpg

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http://images.thesamba.com/vw/gallery/pix/633485.jpg

http://images.thesamba.com/vw/gallery/pix/633486.jpg

Love that exhaust Jason. Magnaflow uses MIG on their mufflers, but TIG would work too (just takes longer).

Well I'm going MIG then, there are enough gaps that need some fill that a TIG would get REALLY hot. Thanks for the kudos, after welding I'll get it polished again and it should look pretty good.

Jason

That is off the hook, what would it cost to get a ride in your bug? My bro and I keep wanting a ride in a fast bug, ours are anything but fast, and we're torn between a big T1 motor and some type of water conversion...

I continued the build thread HERE

Jason