Type 4 turbo: 2,2 ltr: New cooling system

[joosep84]

Maybe I´ve asked but why do you use 66 stroke not 71? (excuse my bad memory....actually it´s really good but deam short)

I got my type 4 engine now ( new heads, new 66 and used 71 crank new 83 and a bit used 84 pistons)

[Wally]

Maybe I´ve asked but why do you use 66 stroke not 71? (excuse my bad memory....actually it´s really good but deam short)

I destroyed one of my beloved alu 103 cylinders on the bottom part because of a broken rod bolt which blew a part out of it...so 66mm with a very very short piston was the only option to re-use them...

To make matters worse...I ran ceramic (Schubeck, remember those?) lifters and two of them totally shattered and little ceramic parts were send through the engine block (it was my former 2,7 N/A) making nice shapr scratches on all nikasil cylinder walls...

So, we honed the cylinder a little further then normal...and shortenend the barrels to make this 66 x 103mm engine block. Some scratches are still there though, just less deep...

Since I wanted the 220hp the 2,7 n/a made, I added a turbo (which I resented originally...) to regain some power from the lost displacement.
The original heads were also reused with just two new valves (two were bend from that one piston hitting the head at 6K rpm) and a major machining to re-flatten them (warped from the impact of that heavy piston and part rod).

As you see, this 400+hp engine is just made from a collection of freshened up (..) damaged parts.

but all fun aside, it really is

Thats how good type 4 engines really are when machined properly

[BugUgly]

Thanks for the back-story on the 66mm choice. Catastrophe, brains, open mind, engineering and machining--> A whole new spec.

[volksbugly]

This is epic, speecheless... wanted to make a comment but cant think of anything worthy..
(now I can also watch this thread).



Ordered my whale tail just recently

[Piledriver]

This is epic, speecheless... wanted to make a comment but cant think of anything worthy..
(now I can also watch this thread).



Ordered my whale tail just recently

Duck tail
(I was corrected earlier )

[dstar5000]

In America it is called whale tail, not matter what those europeans call it!


Don

[bill.est]

In America it is called whale tail, not matter what those europeans call it!


Don

der Schwanz des Wals:

[bill.est]

Maybe I´ve asked but why do you use 66 stroke not 71? (excuse my bad memory....actually it´s really good but deam short)

I got my type 4 engine now ( new heads, new 66 and used 71 crank new 83 and a bit used 84 pistons)

jeff,your pistons is 93 & 94 !

[Wally]

In America it is called whale tail, not matter what those europeans call it!


Don

Actually it isn't (i.e. don't even think of saying that at Rennlist/forums), but hey, you've always got everything "mixed up" anyways, so who's counting when your writing anything anyways

[dstar5000]

Welcome back Wally!

Don

[mikeG15]

Whale tail

Duck tail

[dstar5000]

AHA! I understand the difference now!

[Wally]

Yeah, sorry; I have posted the recent dyno numbers in the turbo-section of this forum
The dyno runs didn't go that well however as I suffered from fuel pressure problems (again). Afterwards turned out to be a restrictive catch tank inlet.
Anyways, we did get a sort-of ok-ish run at 20 psi and got 418 crank-hp with scary high AFR up top leaning out dangerously.
The runs at 20 psi with the 30R were 380 chp iirc (with good lambda) at the same dyno, so this turbo is indeed more effective

At my reference 1 bar boost (~15 psi) we were at 355 hp, so 25 psi would have been interesting, but it wasn't to be that day...

For those that haven't looked at the forced induction forums, last month I got both fuel flow sorted (for dyno runs anyways) and the spark wires remade (one lead was damaged badly from almost being eaten alive by the fan, i.e. sucked in) and a new dyno run was being made at a dyno-day. Relatively hot day (30 Celcius, ~85F), but nonetheless ran it at 23.5 psi: 396 RWHP (~460 CHP)



Also ran it on the track at 20 psi last week during dutch Time Attack competition:



and after both events drove it home on its own wheels

[Frallan]

...and with an extra really nice wing!
Congratulations Wally. You and your car continues to show excellence in design and execution!

[Wally]

Last november the engine made 458 CHP again at our end of year dynoday:


Going to try a new cooling system recently developed by MSS: This one is positioned exactly in the middle of the case and features a new generatorhousing casting based on the 964 housing with the many straight exiting air-guidance fins. Because he made his own casting, it is made a little shorter then the original very deep protruding 964 housing and uses a more common and smaller Golf generator.

Together with the curved/dented shroud, it should divide the air virtually 50/50% left and right, as opposed to the older 11-blade fan housing that throws most air to the right (1 and 2 cylinder), helped by a fan position also being off-center at the right.

I am not gonna say much about it further as a lot of internet BS exists over cooling systems and no doubt will be thrown at this again. I don't care really and won't comment, just wanted to show everybody else what I am up to

Some prelimanary pics of what were some of the parts in the box