2109cc turbo build...

With Turbo and Super charging you can create massive horsepower with vw motors.

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Volky
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Re: 2109cc turbo build...

Post by Volky » Sun Feb 18, 2018 10:06 am

Hi again,

I finally took of the engine yesterday. I loosened the flywheel (it was super tight so I discard the loose flywheel theory) and noted the main bearing has no play and it's very shiny. To me it seems to have had some wear on that outer surface maybe to incorrect end play.

Also, my flywheel, pressure plate and disc have distinct marks on them. I'll post some pic when I reduce them since the iPad won't let me.

Thanks,
1970 VW Beetle with 2109cc turbo with MS-II v3.0, wasted spark, electronic boost controller, dual table, launch control and 3.88 tranny. All done by me...:) t03 running 48lb. Injectors, Intercooler, Water/Meth injection at 15psi.

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Volky
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Re: 2109cc turbo build...

Post by Volky » Wed May 23, 2018 8:58 pm

Hi,

I have been confronting a little clunk,on endplay at .005. I changed the bearings although the other ones were new, less than 800 miles. The case had no wear and the bearings weren't loose. You can feel a slight movement as you pull the flywheel.

Any thoughts?
1970 VW Beetle with 2109cc turbo with MS-II v3.0, wasted spark, electronic boost controller, dual table, launch control and 3.88 tranny. All done by me...:) t03 running 48lb. Injectors, Intercooler, Water/Meth injection at 15psi.

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andy198712
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Re: 2109cc turbo build...

Post by andy198712 » Thu May 24, 2018 12:43 pm

i can feel my movement too but i set it like that..... i would measure it and see what it comes out at.

i got recommended this for a performance engine

0.006 -0.008 THOU

on extremely knowledgeable terms......

mine is set at 0.16mm which is 0.0062 inch

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Volky
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Re: 2109cc turbo build...

Post by Volky » Thu May 24, 2018 2:35 pm

Andy,

I have an "old school / oldtimer" friend with a racing bug that sets his endplay that way. He recommended .007". The issue is I never had the clunk noise on it. Can the clunk be because I took off the helical style cam gear and now with the steel straight cut gears it has more play to it.
1970 VW Beetle with 2109cc turbo with MS-II v3.0, wasted spark, electronic boost controller, dual table, launch control and 3.88 tranny. All done by me...:) t03 running 48lb. Injectors, Intercooler, Water/Meth injection at 15psi.

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andy198712
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Re: 2109cc turbo build...

Post by andy198712 » Sun May 27, 2018 4:22 am

i got that advice from Richie Webb with the fast VW Cab :)

i'll have a feel of mine but pretty sure i get a clunk too, i thought it was from the flywheel end but could be wrong.....

what did you set the engine up at when building it?

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Volky
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Re: 2109cc turbo build...

Post by Volky » Tue May 29, 2018 4:17 pm

Andy,

I ended up with .0055 on the dial indicator. It is not a CLUNK, CLUNK. Just a slight movement with sound. I believe this is due to the straight cut gears not restricting movement.
1970 VW Beetle with 2109cc turbo with MS-II v3.0, wasted spark, electronic boost controller, dual table, launch control and 3.88 tranny. All done by me...:) t03 running 48lb. Injectors, Intercooler, Water/Meth injection at 15psi.

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Volky
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Re: 2109cc turbo build...

Post by Volky » Mon Jun 11, 2018 8:21 am

Good morning,

On Saturday I took the car out for a drive around 8pm with a cool night. We were on the highway and the car wouldn't boost and it felt a bit rough.NO POWER. The cruising speed was of 65 mph and the temps hit 325 on the CYL head temp gauge. I got to the place and let the car idle so it would cool down but the CYL head gauge didn't lower at all. This car would cruise at 270 / 280 before this teardown.

The car turns on quickly and without any struggle when cold or when it was that hot. You could feel the heat on it. I did not mess with my tune which I've run since 2015.

The engine was opened for a internal check and I changed the flywheel.

Thank you,
1970 VW Beetle with 2109cc turbo with MS-II v3.0, wasted spark, electronic boost controller, dual table, launch control and 3.88 tranny. All done by me...:) t03 running 48lb. Injectors, Intercooler, Water/Meth injection at 15psi.

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petew
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Re: 2109cc turbo build...

Post by petew » Tue Jun 12, 2018 8:37 pm

Did you change anything else beyond the flywheel?
Has it got plenty of oil pressure?
Is all the tinware in?
Are you leaning out?

Cos that head temp is a worry. :(

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Volky
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Re: 2109cc turbo build...

Post by Volky » Wed Jun 13, 2018 9:26 am

Hi Petew,

Did you change anything else beyond the flywheel? Yes, the main bearings.

Has it got plenty of oil pressure? Yes, idles at around 15 psi and runs at 40 psi I believe.

Is all the tinware in? Tins: Shroud, left and right cylinder tin, front plate, rear breast plate, pulley tin.

Are you leaning out? No,It's actually on the rich side cruising: 12.8-13.1. Before all this it cruised at 16-17 AFR.

One thought that came to mind last night: What if the cam / crank timing marks were off (:.)? Will it turn on? Overheat? I read a bit on this. I really don't want to open the engine again. The car turns on quickly without hesitation.

When I get home today I was going to mark with liquid paper the "V" between the crank dot marks and turn the engine until it reaches the tooth with the dot on it. If it marks the given tooth with the dot, timing is GOOD. This should work since you can see the crankgear through the gas pump mount and by taking out the alternator stand I can see the cam gear.
1970 VW Beetle with 2109cc turbo with MS-II v3.0, wasted spark, electronic boost controller, dual table, launch control and 3.88 tranny. All done by me...:) t03 running 48lb. Injectors, Intercooler, Water/Meth injection at 15psi.

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Volky
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Re: 2109cc turbo build...

Post by Volky » Tue Jun 26, 2018 2:48 pm

Good afternoon,

On Sunday I took the car on a cruise around the center of the Island to rearrange the tables and the heat issue went away. It's boosting great again. On my way home the car reached the rev limiter and lost power again. When I got home I got under the car and noticed one of the "CB graphite" gasket busted in half.

I have to use a thick gasket like that since the header CB sold me wasn't straight at the flanges. I applied heat to that area one time and managed to straighten it out a bit but I can't use not even two copper gaskets since you can see thru the other side.

What other gasket is out there?
1970 VW Beetle with 2109cc turbo with MS-II v3.0, wasted spark, electronic boost controller, dual table, launch control and 3.88 tranny. All done by me...:) t03 running 48lb. Injectors, Intercooler, Water/Meth injection at 15psi.

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Chip Birks
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Re: 2109cc turbo build...

Post by Chip Birks » Tue Jun 26, 2018 4:48 pm

Sounds like its time to cut and weld. I don't use gaskets. I use Permatex Ultra Copper. Messy stuff, but I have never had an exhaust gasket blow out.

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panel
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Re: 2109cc turbo build...

Post by panel » Tue Jun 26, 2018 11:24 pm

Chip Birks wrote:
Tue Jun 26, 2018 4:48 pm
I use Permatex Ultra Copper.
Me too :)
Subaru JDM EJ20 Turbo bus
Built by Germans powered by Japanese and brought together by Canadians

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Volky
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Re: 2109cc turbo build...

Post by Volky » Thu Jun 28, 2018 10:02 pm

Last night I got under the car and to my surprise the gasket busted because a bolt lost a nut and although it had a pressure washer on it. So, for now no welding. Luckily I have two spares since the header has 6 gaskets and CB sells them in four packs.

I will have to double nut the bolts to avoid these mishaps.
1970 VW Beetle with 2109cc turbo with MS-II v3.0, wasted spark, electronic boost controller, dual table, launch control and 3.88 tranny. All done by me...:) t03 running 48lb. Injectors, Intercooler, Water/Meth injection at 15psi.

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Volky
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Re: 2109cc turbo build...

Post by Volky » Mon Jul 23, 2018 4:42 pm

Hi to all,

It's been a while since my last post. Just wanted to say that on Sunday I went to a car show and for the first time I took the car without the lid on and the temps were very low compared to with the lid on. I was cruising at 70mph almost all the trip and the CHT gauge was at 270F. The Tunerstudio MAT temp was at 89F. When boosting it was at 125-132F.

I had to start all over a tune since VW laptop broke down. I couldn't retrieve the settings, so I started from scratch. Now I have a Surface PRO 4 which has a different resolution that makes it harder to tune. I had the boost controller settings almost there, now I hit "Overboost Protection" and been busting exhaust gaskets. I forgot the parameters I had on the table.

I have another intercooler (blacK) which is about 29" x 9" x 4" which I will change to.

It's not the cleanest engine bay but for now I guess I'll run like this:
You do not have the required permissions to view the files attached to this post.
1970 VW Beetle with 2109cc turbo with MS-II v3.0, wasted spark, electronic boost controller, dual table, launch control and 3.88 tranny. All done by me...:) t03 running 48lb. Injectors, Intercooler, Water/Meth injection at 15psi.

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buguy
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Re: 2109cc turbo build...

Post by buguy » Mon Jul 23, 2018 7:17 pm

I wouldn't be ashamed to let the world see that!

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