Wally, any other pics of the new transmission mount? It's my next project on my build, after I get caught up around the house.

Walter, what size are your header tubes.

Francelle: they are 39mm inner diameter and 42mm outer diameter (1,5mm wall stainless 304).
Still on the large side for the engine size and anticipated power levels, but its what I could get the parts for most easily and the same size as the former 2,2 engine had.

I'll try and look up some other pics of the tranny mount and combined scatter shield. Its basically the steel upgrade engine lower mount from Gerd Weiser (GWD.de ,others sell it too), where I have flexed off the flat part and substituted it with 10cm wide and 6mm thick plate to serve as a scatter shield. Its protocol here to enter dragraces if you drive under 11.99 iirc...

Intake building this WE:

https://farm1.staticflickr.com/981/4...863abcd9_o.jpg

Can’t wait for the new numbers!

Jason

I can’t believe how much this has changed since I was last on the forum! Great work Walter it’s truely inspiring! In fact I’m still drawing inspiration off your original boosted 914 set up!! Now that was a long time ago! What figures are you expecting from your
New set up and what boost are you going to be running? Will you be running with the duck tail intercooler or something different?

Thanks for these nice words man!

My goal from the beginning has been to achive 400hp (crank) at no more then 1.0 bar boost (14,7psi).
For that the engine should have been at about 190-200hp N/A. Since I came close, but not exactly made those numbers, it will be 'nerve wrecking' to learn what the actual results will be..

Tbh, the engine was hardly tuned and still had some flaws (rockers hitting valve cover stands, exhaust leak, hence AFR readings were off), so maybe a little more would have been possible.

For now, I have put in the smallest wastegate springs there were in the box (7 psi or 0,5 bar), so on wastegate I hope to make 300hp. There is no wastegate exhaust fitted at all atm, so it dumps on top of the gearbox for now. Hope that doesn't kill some parts or whatever...Still lots to do therefore.

For an intercooler I was dead set to keep everything inside the engine lid, but that would mean a custom intercooler ($$) and that is just not in the books for now.
So I have indeed dug out my old intercooler and ducktail set-up and fortunately, everything seems to still fit and the needed piping was easy to build from tubing I had lying around.

To my immense satisfaction, I also finally was able to attach the twin spark and made the wiring work with how I wanted the coils to be positioned (le-ri either side of the engine bay) :)

http://www.keversite.nl/fotoalbum/fotos/145410.jpg

Intake piping for the ducktail intercooler finished as well:
http://www.keversite.nl/fotoalbum/fotos/145408.jpg

Keep us posted on the progress!

Love being back here to see this coming together again...

Surprised you decided to run the hot side of things up above;
Figured you would want it 'downstream' of the cooling air..
What made you decide to go this way?

Its a combination of factors to route the headers that way: mainly the orientation of the type 1 ports and my desire to construct a equal length system with as short pipes as possible.

The horizontal cooling made it then possible. It also neccesitated that the turbo was placed over the transmission and hence the need for the firewall to be replaced further backwards.

It took a LOT of work to accomplish those goals, but thats why its a hobby right? ;)

In the meantime I got it running and drove it to our annual dynoday on its second drive :lmao:
So, no tuning, no safety connected, but it did 0,5-0,7bar and got to 270hp at just 5000 rpm when the ignition fell out due to me not installing the twin spark wires in the correct way..

https://farm1.staticflickr.com/976/4...74af56de_b.jpg

Compared to the N/A run, it already doubled its hp, so I have good hopes for the 1 bar shootout one of these days :cool:

After the dyno I rerouted the CAI to just under the car. Should help the intake temps some more I hope/suppose.
https://farm2.staticflickr.com/1751/...a5d8ddc0_b.jpg

Downpipe and the wastegate exhausts are now also wrapped, which should do s/th for the heat as well. Plus a new lambda sensor. so I can finally tune the b*tch!
https://farm2.staticflickr.com/1723/...9a2b432e_b.jpg

https://farm1.staticflickr.com/901/4...5d08c749_b.jpg

That’s awesome Walter, great work. Somehow I missed out on your change of heads.....must have been half asleep reading your thread!! Really excited to see what you manage at 1 bar!!

Tnx!
Well, I am not at 1 bar yet, but at 0,65 bar she was already fast(est) at our national beetle event this year (IKW Wanroij http://www.ikwwanroij.nl/index.php/activiteiten#sprint)

Found some issues with lambda monitoring, ignition and a wrongly installed breather :o
But that was the reason I went (finding issues) ;)

https://youtu.be/mORbikvqoy4

Wally, can you save me scrolling through 100 pages? What fenders are you using, and how was the fit?

Haha: just the usual: Kerscher, awesome fit (because german :-))
fronts +3cm outside, rears +7cm inside&outside widenend

Awesome! Thanks for that. The awesome fit being the most important part of buying fenders ;)

Hi

The Kerscher Fender are the best you can get.
My brother in law already bought from several manufacturers, but those of Kerscher are by far the best fit.


Only for the short front end there is no version with horizontal headlights.

Cool avatar 412STi !
Would like to see a project topic about your car ;-)

Wrt my issues: I think I have got the lambda issues (so closed loop fuelling wseems to work again) covered now (PID values in the settings needed a different values then before somehow) and did not get any blow-outs anymore last time I went WOT on twin-spark and wastegate springs... so maybe the blow-outs (with the plug wires correctly installed) were AFR related (way too fat or lean) after all?

I'll keep you guys updated on any progress made :-)

Hi Wally
Thank you

You know me.
I contact you for infos about the brakeconversion to your former 412 sedan.
My project is progressing very slowly.
At the moment a Subaru gear is being prepared and in a few days/week I will get an almost new 2.0Ltr. Turbo (ex 2010 Forester XT)
I can not keep up with the brakes because the parts from Lanner / flat are missing.
But first I have to do a lot on the body.

If there's really something to show, I'll describe the conversion here.



Gerold

Ah, I know now ;-)
Sounds great mate! I'll be awaiting your results patiently!

I do, but as written, it's only going very very slowly.

Is your car running?
Then fill up the gastank and come to our meeting next weekend in Groß-Gerau http://kbcgg.de

CU

Gerold

Had a great track day for the first time after 6 years together with a good friend of mine in the grey german style 1303 with 2 ltr T4 and some Porsche friend of him.

https://farm1.staticflickr.com/840/4...f3971f92_b.jpg

https://farm1.staticflickr.com/923/4...cdc314c2_b.jpg

https://farm2.staticflickr.com/1782/...4495b095_b.jpg

https://farm2.staticflickr.com/1766/...07887679_b.jpg

https://farm2.staticflickr.com/1783/...86254733_b.jpg

https://farm1.staticflickr.com/940/4...ab27e250_b.jpg

Zandvoort!!
thumbs up; thumbs up;
(smilies did'nt work!!)

You live my desired life, Wally!

Haha! I'am sure it isn't that desired ;) but thanks for the nice reaction :)

I did find an issue with the limitations (lets hope its just that) of the breathing capacity of the engine as on contineus high revs plus boost, too much oil fumes came out of the breather box.
Just added the little can under the oil plate so sump is a little bit deeper, so the dry sump can do its job better. Also ordering a larger breather box.
Hopefully both these will keep it under control.

My girl driving shotgun, made this small clip :)

https://youtu.be/032bzvlWbLg

Nice video, my wife would probably freak out on track going that fast!

Nice video, your gearbox sounds like mine:D

haha, I WISH mine sounded that good :P Everyone who rides in my car asks if it's about to explode.

She's awesome: wasn't even that impressed with our speed... :lmao:

We run the same gearbox obviously hey Steve ;)
It is indeed pretty loud on lift-off. Since its still in one piece after all these years and abuse, I'll leave it be :)

Love my G50 it still works after all hell I give it

That sounds delicious!

H2OSB

Well, not everything works out with my builds too as these pics prove:

https://live.staticflickr.com/856/43...c7a95aaa_b.jpg

Torched a cylinder and head big time!
Root cause probably the one-off cast cylinders. No matter how thick the walls were...
Partly also my own fault as I didn't retorque the heads more often, which would have been more wise because the cast cylinders did need more 'seating' then I usually am customed to. I noticed this when disassembling the engine: head torque was too little on the other cylinders, so thats probably what started this.

Still, all other cylinders also showed a much larger bore up top then bottom of the cylinder (!), so they just didn;t stood up to the cylinder pressures I ran anyways. That also explained the excessive breathing I experienced: the rings just couldn't keep it sealed up top in the cylinders..

Anyways, for a 'quick' fix I bought a set of the AA 98mm birals so I could reuse at least my pistons.
Head is fixed at the moment already and I am reassembling the engine again :)

Walter, what happen to your Ottinger Cylinder?

Walter, what happen to your Ottinger Cylinder? The width of the sealing surface looked thick enough. :mad:

I sold that 66x103 engine about 7 years ago and started building this new 74x98 one, which is partly what this thread is about. Pay a little attention brother :rolleyes: ;) :D

Hi

Bad luck. A VW performance shop I worked in years ago used make seamless steel sleeves to fit over the top section of 92mm barrels to stop them from spreading, could something like that be used on your barrels?

Steve

Whooo!! Like a cutting torch!!:eek:

Rebuild process started a while back, but I just had the long block back together with the 98mm AA birals.
Other small difference with the former set-up is that I could and have installed under cylinder tins again. They only needed a little shortening, but no biggie.

Oettinger crank, Pauter rods, Pauter cam and gear:
https://live.staticflickr.com/65535/...1759e2c6_b.jpg

https://live.staticflickr.com/65535/...da74f1ce_b.jpg

https://live.staticflickr.com/65535/...26180308_b.jpg

https://live.staticflickr.com/65535/...3d0568a4_b.jpg

Yessss,eye candy

Sorry to hear you’ve had issues wally, did you ever get back on the dyno and up to boost to 1 bar or did this happen before you had the chance?