hey there everyone, and newbies!

long time ago I posted here...
been busy with alot of things (cars :P ) like my baywindow..


I'm working on my 2,4 type4 flat4 engine. ordered a megsquirt2 v3.0 and a garrett gt32 turbo. here are the first pics:








bailey's dumpvalve, unknown intercooler, innovate lc-1 wideband lambda controller...


and yes, this will be scary fast :wub:

progress on the inlets!





throttle body of a golf vr6 B) should be big enough..


ty to fit it..


this is to lower the compression to 1:8,0 and should also help to flow more around the valves, because normal they are near the "cilinderwall"

Now that really does look nice.

cracking,i really like that :D

Thanks guys :D

In a week I get some other parts to try if it will fit.
Someone is now modifying my MS ecu for some applications I'd like to use like;

-ford pwm idle valve support. thats easy to make the engine idle smooth and it will regulate itself then.

-boost control: always easy..

-launch control/flat shift :ph43r: why would that be ? :wub:

Made my own triggerwheel today.
It was a universal wheel. its steel so you can't weld it to the alloy pully.
I don't know the name of the machine, but made it fit so good that it""clamps" itself to the pully. used 3 bolts for security..

That looks impressive.

It's nice when a plan comes together.

Hi Rutger - looks like your doing a fine job I must say, one thing you may want to take into serious consideration is the piston temperatures, even if you are using a trick forged race piston, its worth engineering a piston cooling jet spray bar set-up which will take oil from the main gallery and aim it at the underside of the piston nearer to the exhaust valve, but any area under the piston will generally suffice.....you may find you need an oil pump of about double the current mass-flow capacity (longer pump rotors), sounds like grief I know, but doing all this is better than melting your pride and joy, being air cooled its a pretty bad starting point to be honest......every turbo engine I have ever worked on (I have designed turbo engines for LMP900 LeMans and WRC) always has a set of piston cooling jets, and they are also now standard fitment on all turbo road car production gasoline and diesel engines......I have seen such systems retro-fitted to V8 pushrod engines which have since been heavily turbo charged, so it can be done, if you need more advice please just ask.

But otherwise it looks like your doing a fine job......make sure you form some kind of duct around the intercooler in order to force the air through it!

Knighty, what about water injection? There is a train of thought that says you inject a alcohol / water mix?

Hi Tigger - I have no personal experience of running it, but a friend has run it on a V6 24v Cosworth granada engine, which he supercharged and put in a sierra 4x4, he did a pukka job of it too (to a point - see below), forged JE pistons, re-bored the block, lowered the CR, used an eaton supercharger from a straight-6 jag, did a nice belt system and some good maths.........he was running a water and "something" mix (ethanol/alcohol????) and I know he was real happy with the results, I think he used an aquamist system, he was mainly using it to keep th intake temperatures as low as possible, which gives better volumetric efficiency, therefore produce good power, it was pushing well over 300bhp and a skip load of torque, and he raced it in the national sprint series and was class leader on many occasions wiping the floor with lancers and subarus!!!

unfortunatley the engine let go in a big way while on a goodwood track day, his diagnosis of the exploded engine (it was a real mess) was the main bearings moved and the crankshaft snapped in half....upon showing me the photos it became aparrent that he had been using a cast crankshaft, which has gotta be the worst choice for a serious race motor.

anyways, I seem to remember him saying he would monitor exhaust temps, then when they got to about 1100DegC he would have to back off......I know he was very happy with the aquamist system, but it did sound very dodgy having to mix the stuff up, but this was quite a serious race car, but with an MOT!!!

I think he was also skating on thin ice regarding piston temps, as the cozzy V6 24v does not have piston cooling jets, being a normally aspirated engine.......turbos or superchargers = piston cooling jets, an absolute must have in my book, he probably got away with it as the sprint race runs are less than 1 minute or so running time.

Rutger - sorry to steal your thread!.......if you want to post some images inside your crank case I will willingly point you in the right direction..........also, what engine is that garret turbo from?......do you have a compressor map?..... whats your general boost pressure and power expectations?......

Rutger - from what you say above the RPM is racing away uncontrolled????......if so you may want to consider scrapping the single throttle system and going for 4 port throttles right near the heads......as I suspect there is still alot of pressure in the twin-plenum system even after you have backed off the current single throttle - but I could be wrong.

Flames - sounds like lots of un-burnt fuel - are your injectors spray pattern aimed directly at the back face of the intake valves?........otherwise it could be hitting the port wall opposite the injector and dripping un-vaporised........what engine did the injectors come from? are they a split or a single spray pattern? you need a single spray for your 2-valve engine

just rying to help fella! B)

Hi Knighty, wow fella I will bow to your knowledge on this subject :D

Rutger, What boast are you thinking of running, and what is the project Bhp ?

Hi Guys,

sorry for the late reply :rolleyes:
I'm doing my best to understand the whole message!

I am considering the aqua-mist system for cooling of the pistons.

about the launch-control, I think I wrote it down so badly that you don't understand.. :unsure: The engine isn't ready, so also never started. I hope this summer.

About the turbo: at www.turbobygarrett.com you can find the maps!
There are JE- forged's in the engine now and lowers my compression to 8.0:1
The max boost will be 0,6 bar for now :ph43r: The guy that helps me with this everything desings stuff for turbo's, so there is an expert for in emergency-situations :lol:
With this i estimate the bhp will be around the 250 :ph43r: wich will be enough..

Thanks for your input anyway ^_^ It's always easy when more people think with you!

about hte injectors, these are red bosch 590cc/min@3bar multispray (4)
this is a movieclip where they test "my" injectors:
http://www.youtube.com/watch?v=7oTirEZNRw8

more pictures soon!

regards, rutger

Started again at the fug.. Sometimes you need to get some money before you can spend it... :lol:

Made some brake-bleed nipples fit for the vaccuum/pressure connections.

From both "plenums" they will go to a "box" and from there the rest to the ECU, dumpvalve and the fuel pressure reg.


Still need to think about the exhaust... :angry: room enough in a fugg, but the turbo is really big B) so a problem to mount it somewhere...

and made a turbo header myself this week B)

@ knighty:

Someone I know, pushed 400+bhp out of his type4 2.2 with only water injection+big turbo. He does trakdays on the nurnberg ring. I probably will only do some drag days.. so i'm sure that the engine will survive :huh:

I've read your question again, but the launch control and flatshift retards the ignition so much, that there's no power. but enough pressure in the exhaust for boost buildup B) so with shifting with the flatshift ON you will get flames :lol:


Sorry for the sometimes bad english...

refurbished my brakes. also upgraded:

http://www.youtube.com/watch?v=BZbyQ6YosaI

Rutger, I very much like your style and take on things. Thing is, the fabricator I use is really skilled, but he's not great at doing exactly what I ask. Sometimes I like an opinion, sometimes I just want what I've asked for.

As I'm in a low industry area of England, skilled tradesman are hard to find so I'd have to travel or mail order. Would you potentially be interested in making things for me as and when required. I'm happy to buy/pay through Ebay/Paypal so it's all above board. Can also supply drawings, and all the details and explanations would be written in fluent Netherlands.

Let me know if you're interested...........Bob

Hi Bob,

Thanks for the confidence in my work ;)
I would like to help you with some things and ideas! But I'm not in metal/fabric industrie.
I'm an car mechanic that also looks a lot on the internet.

I make a lot myself, But sometimes I need a lot of time for this kind of things.

If you need something made or thought-over (right words?)then let me know. Maybe I can help you. I can also show the ideas or drawings to someone that also fabric a lot for me... Thats a guy called: CNC-Wizzard ;)

Rutger.


(in perfect dutch would be the easiest for me) :lol:

installed my new seats B) and the hydraulic handbrake. thats easier to throw him around :lol:


here you can see some things, including the new rear calipers. there from a porsche 993. coming week I will get the adapterplates for the front. THese will be 964 calipers. so 4pistons all around :wub:



A porsche trans.has the hockeystick on the underside of the torsionbeam. I used a steering coupler from a old 911. (fits on the beetle&porsche shaft.. ) welded the gap to make it stong, and made a hole with M8 thread for the bolt.

you can also see the nut/thread on it. this makes it easier than cut&weld&fit&cut&weld&fit and so on..

Looking good. I want those seats!!! :P

Thanks ;)

I bought them on a trackday from the dutch kitcarclub. I've bought them from Harm f33fan B)

Lookin' goooood, Rutger!

Could do with some advice from you at some point re. brakes: forgot half of what you told me when I came to visit, you kind of bombarded me with information :P

Thats ok jon!

I order a new ecu today :( the old "new" ecu had a real burn-out <_< and the PCB was damaged so much, that I have to get me an other one...

But we managed to run the engine :lol: (with the MS2 of someone else)
Got it idling, still some small issues to solve. some heatshields, isolating some connectors from the exhaust heat. Solved my LC-1 WB controller probs.

So still.... pretty hopefull about it

Got the new computer this week. :lol:

http://www.youtube.com/watch?v=QebjjfQ8k40

got it runing now. some small issues to solve. new brakes and need to "modify" my wheels. need to put 16"on it :( and then also need new tyres <_<

here are the new front brakes :wub:



I ordered toyo r1r's for all corners B) I found a "cheap" adress

Hey Rutger,

I see vented discs there, isn't that overkill?? Will they get warm enough to be effective?

I was looking at simply fitting the std 1600 discs/calipers to my Fug. Have checked with a beetle specialist who seems to think it should be enough given the low weight. Can't help thinking it'll not be enough.

Hi Jon,

Standard beetle discs front and maybe "normals" disc rear gives a good balance.
And should be enough for "recreative purpose"/little offroad ;)(wich I think, you will do)
but for trackdays it's better to have a size bigger (and for my top speed). Also, most of the parts, were already laying around here.


And uncle bob's tip of the week:

"there's no better thrill, then overkill !" :lol:

Ohhhh maaaaaan, was hoping not to have to replace the rears :( Guess it makes sense with a whopping great lump of metal behind the rear wheels :P

Yeah, I'll be using the Fug mainly for road use and every now and then lifting her skirt and getting the undercarriage muddy...would be rude not to, really!

>> "there's no better thrill, then overkill !"
Ha ha, bingo...that's why I've gone for the v8 B)

New wheels B)

:wub: :wub: :wub:



also played a little with the wheelgeometry. 1 degree neg. on the front.
1,5 degree neg at the back B)

Looks awesome!

thanks :lol:

Here's my third testdrive. it's pretty slow, cause I only did drive at about 50% throttle. my internal wastegate is to small. so The boost still gets to high. Monday I will go further with new modifications :ph43r:

http://www.youtube.com/watch?v=A6xeclgmT24

Here's my "new" turbo... :wub:

garrett gt3067r ballbearing monster :)

Good job, Rutger...looking and sounding GOOOOOOD!!

Great timing too, right on time for the nice weather...

Thanx again. B)

Installed an external wastegate today, cause the int.gate from the gt32 is to small... <_<

So after this.. I need a new clutch !! :lol: already had a sachs stage2. I think i'm going for a stage 3 or 4 now.... ;)

http://www.youtube.com/watch?v=WRUYHfGiZdM

brrrr.... :ph43r:

friday to the european bug-in. but the stage3 is still in the delivery/post system somewhere :angry:

Annoying waiting for parts, eh? I'm still waiting for confirmation of postage for the Rover -> Renault UN1 bellhousing I ordered two months ago and should have been here early-mid June!

Silly 'cos I ordered three flywheels from Japan earlier this year and they were on my doorstep in 3 days!!

yep, dutch customs... :(

but today i got it B) got the engine out today. and tonight pick up the new flywheel and fix the damn thing :lol:

Working overtime... tomorrow morning to the EBI belgium and fix the ecu mappings when i'm there :P

and everything worked out :lol:
on the vid it looks slow.. but it's going really good now

http://www.youtube.com/watch?v=5Yn3vHi-Kfo