Turbo 1600 Super Beetle

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Jamesl
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Joined: Sat May 23, 2020 5:09 pm

Turbo 1600 Super Beetle

Post by Jamesl » Tue Jan 19, 2021 2:58 pm

I've been lurking awhile on this forum and decided to post something. I picked up a '74 Super Beetle last year and have been slowly restoring it. I initially thought I would keep it stock, but couldn't resist the urge to add fuel injection and a turbo. I've done a few turbo projects over the years and was an early adopter for MegaSquirt, completing my first project in 2005. This will be my first air-cooled project.
I stripped and painted the car and have it mostly back together. The engine received a stock rebuild with new jugs and refurbished heads. I had it completely assembled and ready to go into the car, when I decided to dump the carb and go EFI using the Speeduino system.
Right now my focus is on building the exhaust system so I can mount the GT15 ebay special under the tin for an outwardly stock appearance. Here are some photos:
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I painted the car in my garage with single stage enamel. Only my second paint job ever, but came out okay. It's back on the pan and a roller now.

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I stitched together the exhaust system using 1.5" exhaust tubing and way too many pie cuts. This is my first attempt at pie cut bends. Seemed like a good idea but I'm going to get up close and personal with the welder for the new few days...

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The little GT15 is small enough I should have no problem fitting inside the rear apron.

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I've got a little side-mount intercooler from a 1.8t I'm hoping will fit above the alternator with a small fan drawing air thru the engine lid vents. At this point I'm not 100 percent certain there's room. Fingers crossed...

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panel
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Re: Turbo 1600 Super Beetle

Post by panel » Tue Jan 19, 2021 11:45 pm

How is your crank sensor going to attach ? Seems like you might have a hard time picking up the teeth for a reading.

And how will you take the header off the heater boxes ?
'65 Bus with a JDM Subaru EJ20 Turbo
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Jamesl
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Joined: Sat May 23, 2020 5:09 pm

Re: Turbo 1600 Super Beetle

Post by Jamesl » Wed Jan 20, 2021 7:33 am

Both excellent questions. My plan is to attach the crank position sensor to the engine tin facing the trigger wheel instead of along the edge like most installations. Unlike a normal, flat trigger, the teeth on this one stick out at a 90 degree angle. I'm hoping/guessing the sensor will be able to differentiate between the teeth and the flat surface of the pulley. This wheel is off a Ford truck and I simply drilled out the center hole to match the pulley bolt and bolted it on. At $15 for the wheel, I figure it's a cheap experiment.

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For the heater boxes, right now the header pipe just slips on the boxes. I initially thought I could clamp them in place but I'm considering adding flanges to the boxes so I can easily bolt on/bolt off.
Last edited by Jamesl on Wed Jan 20, 2021 2:14 pm, edited 1 time in total.

madmike
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Joined: Mon Jul 24, 2006 5:11 pm

Re: Turbo 1600 Super Beetle

Post by madmike » Wed Jan 20, 2021 1:54 pm

I was going to suggest flanges also, slip joints leak :wink:

Clonebug
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Joined: Fri Feb 16, 2007 12:28 am

Re: Turbo 1600 Super Beetle

Post by Clonebug » Wed Jan 20, 2021 3:31 pm

Slip joints will hold to 22 plus lbs.......
Stripped66 wrote:The point wasn't to argue air temps with the current world record holder, but to dispel the claim that the K03 is wrapped up at 150 HP. It's not.

Jamesl
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Joined: Sat May 23, 2020 5:09 pm

Re: Turbo 1600 Super Beetle

Post by Jamesl » Wed Jan 20, 2021 4:08 pm

I've used slip joints on turbo projects in the past, but never stopped to consider how boost pressure on the cold side would affect exhaust pressures and leakage on the hot side. I've never boosted above 14 psi and that would be my upper limit for this project.

Jamesl
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Joined: Sat May 23, 2020 5:09 pm

Re: Turbo 1600 Super Beetle

Post by Jamesl » Wed Jan 20, 2021 5:48 pm

Well, since I had a new set of donut gaskets to mount a muffler to the heater boxes, I decided to go that route. It gave me a chance to use my high-tech flaring tool and will be fine for now. I can always come back and install flanges at a later date. Still a lot of welding, grinding and fiddling to make everything fit....

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Clonebug
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Re: Turbo 1600 Super Beetle

Post by Clonebug » Wed Jan 20, 2021 6:46 pm

You should probably build a bracket on the top that bolts to the fuel pump mount or two alt stand bolts. I'm thinking you will have too much flex and vibration if you mount to the engine tin. You need to keep your gap in a pretty tight tolerance.
Stripped66 wrote:The point wasn't to argue air temps with the current world record holder, but to dispel the claim that the K03 is wrapped up at 150 HP. It's not.

madmike
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Re: Turbo 1600 Super Beetle

Post by madmike » Thu Jan 21, 2021 6:50 am

22lbs,, on a Mouse motor :lol:

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John S.
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Re: Turbo 1600 Super Beetle

Post by John S. » Thu Jan 21, 2021 8:05 am

Thanks for the trailer ball idea, or as they say nowadays “hack”. Lol.

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