I have chosen this setrab 490x136x40 oilcooler, it will be mounted to the mendeola bulkhead. It isnt straight at the airstream, so i may need to make ducting to the oilcooler, is there any front spoiler for that has hole or "mouth"r?



http://img35.imageshack.us/img35/429...abthinline.jpg

I am thinking exact location and angle for oilcooler, hot air does need to be displace somehow. Maybe making few round holes to the mendeola front plate(!)

I might go also for custom made front spoiler that has hole and airchannel that directs air to the cooler.


http://img404.imageshack.us/img404/8403/08082012.jpg


This went to order, at the moment only 3 kits left :) So many ratios to choose between 2-5th gears..

http://www.thesamba.com/vw/classifie....php?id=504197

http://bearsmotorsport.co.uk/volkswagen-parts-gear-sets


With albins/weddle gears including mainshaft and strong transaxle case, trans should be quite strong.


http://images.thesamba.com/vw/classi...ix/2211187.jpg


These ratios were recommended by Rancho, speeds are at 3000rpm

Choice 1:


R&P 4.13

1. 3.11= 28.28 km/h

2. 1.93 = 45.57 km/h

3. 1.3 = 67.66 km/h

4. 0.93 = 94.58 km/h

5. 0.77 = 114.23 km/h


RPM drop when shifting to bigger gear

1-2 1240rpm

2-3 980rpm

3-4 850 rpm

4-5 520rpm






Choice 2:


R&P 4.13

1. 3.11 = 28.28 km/h

2. 1.93 = 45.57 km/h

3. 1.35 = 65.15 km/h

4. 1.04 = 84.57 km/h

5. 0.77 = 114.23 km/h


RPM drop when shifting to bigger gear

1-2 1240rpm

2-3 900rpm

3-4 690 rpm

4-5 780rpm





Choice 3:

R&P 4.13

1. 2.90 = 30.33 km/h

2. 1.86 = 47.29 km/

3. 1.26 = 69.81 km/

4. 0.93 = 94.58 km/h

5. 0.77 = 114.23 km/h


RPM drop when shifting to bigger gear

1-2 1080rpm

2-3 970rpm

3-4 790 rpm

4-5 520rpm

Okay, i went with these ratios ( 3000rpm ), theoritically 250km/h is achieved at 6570rpm.



1. 3.44= 25.5 km/h

2. 1.93 = 45.5 km/h

3. 1.3 = 67.7 km/h

4. 1.00 = 88 km/h

5. 0.77 = 114.2 km/h

Also been talkin to Thorsten Pieper, i am going to buy his bare heads and stuff them with type 4 48x38 valves and JPM springs and retainers. And little porting :)


http://img145.imageshack.us/img145/6784/anhang1x.jpg

http://img545.imageshack.us/img545/3558/anhang4.jpg


One finnish guy said by looking the pictures that JPM heads are a lot of better and theirs intake ports are better flowing and more straight than Thorstens heads. Yeah right:lmao:

I cannot see the difference..

http://img404.imageshack.us/img404/8796/883280.jpg

Nice!
I agree the ports and heads look very similar, just more fins with Thorsten's heads :-)
Thorsten doesn't have a flow bench himself, so i think with some porting done with a flow bench at hand, the head flow will be easily matched by a good head porter.

I asked more about the heads, valves etc and how they flow etc. :) If i am correct at calculations, he has over 245 engine hp :D

(215/87)x100=247

Hello Alex,

if it´s possible to get 240cfm / 25", I don´t know (but I think so).....all I can say is, that my current motor have 215HP at 6300rpm and 271Nm at the Wheels!!!!!!

It´s an 2,7l WBX with my heads (46x39), an 328° german cam, twin spark, 50mm throttle bodys, and 45mm CSP Python.

In this time I´m build an 2,8l (86x101,6) and my heads (48x39).
I think into 4 weeks the head comes on the flow bench and than we see how good it´s flow with the 48mm intake......

If you want, I can produce your heads without the O-ring seals!! So you can port much as you want....


http://img515.imageshack.us/img515/1...ungwbxkopf.jpg

In a few weeks i am getting my heads, this is new improved version of the billet head, intakeports are much better on this than on older version.

Also the case is almost ready from Todd at Precisionalloy, case is now at Roger Crawford for installation of bronze trhust bearing setup and porsche oilsquirters. Todd says that these newest batch of cases has some improvements over older ones.


Case will have different type of bronze thrust bearin setup, first bearing on 1st main web and second on 2nd main web, there is more metal left to the case then.


Heads

http://img163.imageshack.us/img163/2...1806custom.jpg

http://img811.imageshack.us/img811/2...1746custom.jpg

Old

http://img22.imageshack.us/img22/8871/oldchannel.jpg

New

http://img7.imageshack.us/img7/139/newchannel.jpg



http://img803.imageshack.us/img803/9...3148008526.jpg


http://http://img89.imageshack.us/im...8108163838.jpg

Got some valvetrain parts, JPM Ti retainers, Manley 48x38 117mm valves, Berg locks, 13/12mm guides.

Later JPM dual springs and seats, and then to the headporter.

http://img689.imageshack.us/img689/8175/xqt9.jpg

TF-1 case arrived with hoses, it looks so nice compared to autolinea cases. I checked the hoselenght to car and it seems there is enough for front oilcooler mount and drysump installation. BMW main bearings and bronze thrustbearing came with case. I did trial assembly with crank, cylinders and heads.


The camshaft, connecting rods and oil pump are still missing. I did order from demontweeks a 360x190 (5.7 liters) drysump tank with Mocal thermostat.

End play is pretty tight, about 0.05mm, i will have to sand a bit bronze bearings on the glass. Due to a TF-1 case through bolts and 4 "bore cylinders i had to take a little bit material from cylinders, and possibly to get smaller diameter washers under througbolts.

There was also problem with TF-1 and LN engineering / ARP headstuds, because TF-1 case has no provision for 3rd cylinder deepstud, and ARP kit has one deep stud like stock or normal performance studs.

I am also thinkin to make cad designed rear mount, because case has bus style rear mount.

Also ARP studs for type 1 nickies arent available any more. Todd Francis does not recommend the make the thread deeper - but no problem, fortunately Raceware has suitable equal lenght headstud set that is approved by LN Engineering and they also use them now.


http://img543.imageshack.us/img543/1516/y8zm.jpg

http://imageshack.us/a/img20/7724/xamb.jpg

http://imageshack.us/a/img838/6460/fms1.jpg

http://imageshack.us/a/img600/634/9xhz.jpg

http://imageshack.us/a/img89/4054/7akb.jpg

http://imageshack.us/a/img825/7763/pe7c.jpg

http://img194.imageshack.us/img194/4115/34wq.jpg

:lmao::lmao: First i was lazy after posting this to finnish VW forum, so i translated this text with google translator:




Lohkokin already arrived with hoses, hienohan it is. Hoses seems perfectly adequate to get away and are really flexible teräspunosteflonletkuiksi. BMW main bearings and bronze päittäisvälyslaakerit block. I heaped a trial basis in the crankshaft, cylinders and lids with.

The camshaft, connecting rods and oil pump are still missing. 360x190 (5.7 liters) in size kuivasumppusäiliö ordered Mocalin with the thermostat.

End play pretty tight, about 0.05mm, will have to grind a bit päätymmäisiä bronze glass. TF-1 block through bolts and 4 "bore cylinders because had to take a dremel stuff and possibly lower sweepings through bolts.

LN Engineering kansipulttien with became a problem, because in three bowl long tiller bolt, Todd Francis does not recommend the thread to do deeper - no emergency, fortunately Racewarelta can be found in ST Engineering's recommended preferably suitable cover bolt kit and that the LN engineering using T1 and T4 engines, I understand that the ARP brought kansipulttien price time briskly.

That looks as awesome as promising! Tnx for the update.

Yeah, its a big leap compared year ago - more parts at the garage :lmao:

Also, tinman/painter :lmao: promised to get working again with beetle, after all normal collision repair etc. Now its time to concentrate with beetle, then A-group Volvo 240, then Ex-Biela Audi 80 supertouring...talk about work :lmao:

Last week i got from demontweeks a new moonshine tank :D and a Mocal thermostat. Also got one missing ARP stud from LN engineering :)

http://img854.imageshack.us/img854/7470/hyf9.jpg

Nice! What volume does it have?

It is 1,5 gallon, total volume is around 9 liters.


http://www.ahfabrications.com/index....2trptbnbrbqum4

Soon i get my transaxle, berg 5-speed 091, it should be finished at week 45. I'll get berg custom mounts, since i will center the transaxle, otherwise it would sit 10mm off the center.


http://img585.imageshack.us/img585/7610/zqkq.jpg

http://img17.imageshack.us/img17/1706/23tj.jpg

http://img818.imageshack.us/img818/3714/bl8p.jpg

http://img40.imageshack.us/img40/8559/cqp.JPG

http://img5.imageshack.us/img5/3139/hj55.jpg


I might be in trouble with Mendeola A-arm suspension here in Finland, because it has welded spindles and i might need a document that tells its meant for beetle and most important, its factory made. Billet or Forged spindles would be nice.

No help from Kevin unfortunately anytime soon, but i might have source for special one piece spindles, or just use stock spindles and have made my own upper arms to correct caster and camber..

Allthough i do have also a sketch about the document..it is pretty simple and i could try it first.

Ok, these are things that i should worry when the car is running :)



Soon will have new Megasquirt MS3 based ECU, it has splash proof automotive aluminum box and 56pin automotive connector, unlike typical megasquirt MS3.

Also the relays are built in to the box and it has most if not all the MS3X features.


http://www.autotune.fi/tuote/370/atd...n-ohjainkortti

http://www.autotune.fi/tuote/69/ms-3-prosessori-moduli

Also getting two wasted spark VAG coils for twin plug heads

http://www.autotune.fi/tuote/623/syt...asteella-4-syl



http://www.autotune.fi/data/th/c_atd...pg_35c_2a8.jpg

http://www.autotune.fi/data/dth/at/a...pg_860x860.jpg

http://www.autotune.fi/data/th/c_huk...pg_35c_2a8.jpg

Gearbox looks to have pretty stout gears!

We got some work done finally, installed Mendeola bulkhead, little rust repair work done and after all rustrepair work is done, rollcage will be tied from mendeola a-arm bulkhead to rear.

I did also recently sell my wilwood front 330x28 rotors, as their manufacturing was discontinued, i got 0,65kg lighter AP racing rotors with larger pcd with DS2500 pads all around.

I heard that mendeola is building over 500hp car with 6 inch wider mendeola suspension, sounds scary fast, and illegal here in finland :D Well at least mine has the best brakes for us small hp guys, only power only half of that.. :)

Not exactly a rust free california car :lmao:

http://img194.imageshack.us/img194/1717/fyx2.jpg

http://img12.imageshack.us/img12/6921/ucq1.jpg

http://img689.imageshack.us/img689/50/o3gq.jpg

http://img547.imageshack.us/img547/3010/3auk.jpg

http://http://img23.imageshack.us/img23/2764/x9v9.jpg

http://img46.imageshack.us/img46/6865/xyhf.jpg

http://img69.imageshack.us/img69/7616/hg54.jpg

Done some more bodywork - all should be done in two - three weeks including gage, then after a month or so, paint will laid - two colors i am thinking:

Porsche wimbledon green (darker)

https://www.google.fi/search?q=porsc...ml%3B808%3B606


Porsche ocean jade metallic (lighter)

https://www.google.fi/search?q=porsc...w=1575&bih=750


http://img607.imageshack.us/img607/3484/3de8.jpg

http://img196.imageshack.us/img196/5082/vszs.jpg

http://img23.imageshack.us/img23/5716/kce6.jpg


Also rethinking to support torsionbar tubes by rollgage. I do have also coming a 5-bar käfer cup shock tower support like in a picture, built from kerscher3-bar system.


http://img545.imageshack.us/img545/4650/75jz.jpg

http://img19.imageshack.us/img19/4300/igyg.jpg

Bodywork continues....not exactly a MAT standard, but good enough for me.

Will be smoothed and finished before paint.

Got a really bad rap about the work on Finnish VW forum from "Pro's" :rolleyes:

https://imagizer.imageshack.us/v2/82...0/843/24oo.jpg

https://imagizer.imageshack.us/v2/82...0/839/o949.jpg

Sheetmetal work done more, just now left some small welding and rollgage. I got those inner panels from Avery's Aircooled, now the inside looks so clean.


http://imagizer.imageshack.us/v2/128...0/844/hk33.jpg

http://imagizer.imageshack.us/v2/128...0/836/2pwn.jpg

http://imagizer.imageshack.us/v2/128...0/845/8jh8.jpg

http://imagizer.imageshack.us/v2/128...0/841/7npi.jpg

http://imagizer.imageshack.us/v2/128...0/836/03q5.jpg

http://imagizer.imageshack.us/v2/128...0/836/592v.jpg

Might try to fit different drysump tank, which i'd like to fit near the transaxle outside of cabin. Only problem is that there will be a 5 bar shock tower support, so i designed a slim one..

http://imagizer.imageshack.us/v2/102...0/843/ipcg.jpg

Also found nice steering wheel, not too much tuning style, or too retro ;)

http://www.z1auto.com/images/OMPASSO350mm.jpg

Hi Alex, did you get the 091 5-speed mounted? I'm looking at a G50 or 091 5-speed, and was curious how your install turned out.

Thanks!

excellent work!

I sold the steeringwheel, it was not the OMP wheel what i wanted (it was made in china), not as nice as black OMP wheels are usually. I just recently ordered JPM Wasp stage 2 exhaust (220-290hp) and Raptor 282@0.050" cam with changed LC, both recommended by Johannes :)

I will change JPM lifters to Udo Becker lightweight tool steel lifters what i have already, also a nice gesture from Udo, that he wants to change this older set of lifters to a newer batch of lifters, eliminating all worries about heattreating etc :) :)

But we havent yet installed the transaxle, car is not in my garage, only 40% of parts are at the moment. I have all the berg mounts for 091, but it pan and body might need modifications. At same time we check the fit of 5-bar shock tower support.

http://www.csp-shop.com/cshop/images...nify/26370.jpg

http://www.csp-shop.de/cshop/images/...nify/24951.jpg

Probably forgotten to show transaxle, here it is:

https://imagizer.imageshack.us/v2/67...0/838/c17k.jpg

https://imagizer.imageshack.us/v2/67...90/69/0nl1.jpg

Sheetmetalworks almost done, we are now fitting the rollcage. Door, seatbelt and baars to the mendeola and rear will be added. Doorbaar will be littlebit lower than before, because car will be streetcar and trackdaycar.

http://imagizer.imageshack.us/v2/102...633/xfzZXb.jpg

http://imagizer.imageshack.us/v2/102...540/F0Odb0.jpg

http://imagizer.imageshack.us/v2/102...538/4WIFa7.jpg

http://imagizer.imageshack.us/v2/102...661/A2zPtN.jpg

Also ordered today Racers Edge adapter bolts for 944 aluarms to get QA1 coilovers to fit.

http://www.paragon-products.com/Race.../re_mc7000.htm

Nice work Alex! I'm building an 002 transmission for my car, but missed the last 5-speed kit from Berg. Interested to see how you mount yours, as i have the the two rubber mounts (641E/643E) that center the cv joints, instead of the engine.

I dont know what driveshafts will fit, but thinking to use 944 turbo ones.
Yeah, i wanted the engine to be at center, and at some point i am also going to get fabricated a new 911 style front mount, one that doesnt need front rubbers like berg one. Demontweeks sells machianable hard black urethane washers at size 75x25x32, sounds big enough for custom made mount.

http://imagizer.imageshack.us/v2/102...904/WymUgf.jpg

Very cool. I should have time over the next month or so, to start working on my install/mounts. I'm not very happy with the Berg front mount, so keep me posted on yours.

Thanks!

Sheetmetal work has been a little slow at start, but now were are doing fine, but as usual, i suspect that getting it painted may take 3-5 weeks.

I sanded half of the roof and sides, a lot less now old paint left, ugh :lmao:

Few days ago we test fitted the seat, fits well and good position with prototype seat frame, i might get eventually a shorter one. Otherwise Recaro seat is tight fit at beetle, sidebars need one bend at least. I insisted to put sidebar front end to low enough, because i am not building a full racecar.

We did put some support from main hoop to rear torsionbar tubes, straight trough hot air vent holes :D

Probably at tomorrow we fit the transaxle and 5 bar käfer cup brace.

Would anybody recommend tube / brace from rollgage to mendeola suspension frame to get extra protection at side / front collision?


http://imagizer.imageshack.us/v2/102...673/u1P8Ex.jpg

http://imagizer.imageshack.us/v2/102...910/1A90EL.jpg

http://imagizer.imageshack.us/v2/102...538/hoshkY.jpg

http://imagizer.imageshack.us/v2/102...538/Wj0Bvv.jpg

http://imagizer.imageshack.us/v2/102...633/JtoZEl.jpg

Now fits the seat with doorbars, and doors can be actually closed. Seats are quite wide, so doorbars had to be bent from two locations. Testfitting rear coilovers..


http://imagizer.imageshack.us/v2/102...674/jJ8ZlK.jpg

http://imagizer.imageshack.us/v2/102...905/K3GAoM.jpg

http://imagizer.imageshack.us/v2/102...538/Ib9kUd.jpg

http://imagizer.imageshack.us/v2/102...742/xzgZSa.jpg

http://imagizer.imageshack.us/v2/102...901/mX4uv5.jpg

Nice, keep up the good work!
Those 3piece gold rims look sweet on the last pics ;)

So far here we are, 99% of sheetmetal work done, and yes, we did put plastic body filler, but only a thin layer, because lines were so straight at repaired places. Unfortunately, i have to postpone painting to next year when budget allows.

http://imagizer.imageshack.us/v2/102...910/xfp6UM.jpg

http://imagizer.imageshack.us/v2/102...537/9AdsAz.jpg

http://imagizer.imageshack.us/v2/102...661/GEiXAI.jpg

http://imagizer.imageshack.us/v2/102...661/iO3UAn.jpg

Very nice!!

Nice progress,I like the brace on the cage from the bottom of the main loop to the torsion tube,I have not seen that done before,clever…:D

I fully agree! Wondering if there is really movement at the outer torsion tube on heavy acceleration or s/th..?

Hi

There is already an unused factory mounting on the outer end of torsion bar tube.

Steve

There is indeed, VW deleted the fixing hole and bolt with the 1303, but the torsion tube still has the threaded mounting pad, early 1302's did have the fixings, probably why the 03's handle worse than a shopping trolly;)
And yes, the end of the torsion tube can move, but I use a very simple way to stop it because some more complex methods are not allowed in many race series regulations, first thing is drill the hole and fit the bolt in the stock location, a suitable spacer needs fitting between the body and the torsion tube to snug the bolt down solid, both sides obviously, next, remove all the rubber and the bolt ferrule from the inner wheel arch bracket and make it a solid fixing with suitable square steel plate spacers, in the cup cars, I made a 3mm bracket to support the top shock bolt, this in turn bolted through the inner wheel arch with fixings inside the car, simple and effective, but above all, weighs nothing.