2270cc type 4 EFI Turbo: my first engine build

[split1950]

Got my dry sump tank back from the laser cutter, it needs metal finishing but I am stoked it is just like the CAD model.
I just need to weld on some mounts and also mount the oil filter/thermostat.

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I also finally sourced some genuine Cup 1 wheels, they tuck under nicely thanks to the narrowing of the A arms, in fact I had to use 20mm spacers in the end, but I think once the car is done I might change them to something like some cool 3 piece BBS.....hmmmmm, stay focussed.
The car is on axle stands so they're hanging, but you get the idea...

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[split1950]

Got the dry sump tank in on Saturday, I'm quite happy with it

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Even though the oil goes through the filter, to the front of the car, then through the cooler and back into the tank I had this idea as a deaerator to plumb in just before the return into the tank (which is well baffled inside)

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I suppose it can only help.
I have in my pocket I could vent it and mount it in the car as a last resort, but want to try it as is first and keep it outside.
The tank has a big cap so I can see the state of the oil inside quite easily.

[Chip Birks]

Dude, I love this build! So much thought into everything. So much careful custom work going on! Keep it up!

[split1950]

Dude, I love this build! So much thought into everything. So much careful custom work going on! Keep it up!

Thanks Chip. Sometimes I feel like I stand there looking at things and thinking about how to execute for far too long, but I think the results do show the thought that has gone into it. I'm a Freelance Engineer so it kind of comes with the territory that you have to do things right......
I do have to say though, Fusion360 has been a godsend. Once you get the hang of it you realise if you have a local laser cutting guy you can do almost anything and it look OEM. Then get into CNC (my next task - front Brembo caliper brackets!) and you are limitless.
It helps a lot I have some good friends (Lloyd/Deluxe Metalwork, Steve) who without their help I couldn't have done this.

[split1950]

Slow progress, stuff seems to be very slow to arrive recently, I've been waiting 2 weeks for a Turbosmart dual port actuator for the EFR....
Anyway, my new improved fan holder for the oil cooler is finished

3D view oil cooler fan mounts v1.png

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I also mounted my Turbosmart fuel regulator with a homemade bracket, trying to keep everything neat and tidy

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I have designed a front Brembo caliper bracket and got it 3D printed for mockup, but unbelievably been waiting 1.5 weeks for some M10 countersunk screws to test it and confirm the proper centring of the caliper on the disc.......I can't commit to CNC without being certain it's OK....

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[Steve Arndt]

That is the slickest DS tank I have seen!

[split1950]

I've been working loads on the car but it has been very time consuming and looks like not much was done. I suspect the last 10% is going to take 90% of the time......
I was not happy with the accelerator, it was draggy, stiff and frankly dangerous.
The Split Beetle uses a solid bowden cable that doesn't even have a flexible outer cable from the chassis to the engine tins.
So I made up some solid guide tubes and use a stock Bug flexible inner and outer, much better. Just waiting for a new roller pedal arm to arrive as it's on back order.
I was so happy I bought this bolt on billet pedal lol

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Joking aside, with the mods I did it is really OK now, but it burned so much time, engine and trans in and out a couple of times, you know how that goes....
Actuator, custom bracket, and clearance to the inner arch (the ONLY mod on the whole body for all this to fit).

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I tried to make it look stock by putting the inner lip on there

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I also mounted my custom breather box (top RHS) to match the chargecooler header tank top LHS

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and closed in around the fan belt

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Next is the custom airbox with appropriate heat shielding from the headers.......

[Chip Birks]

As always, the work going into this thing is top notch! Looks incredible!

[split1950]

As always, the work going into this thing is top notch! Looks incredible!

Thanks Chip. Sometimes I wonder if I should just cut a few corners to get it done quicker (I do feel like the rule of "Pie" (the 3.141592.....) thing applies to a lot of the jobs), but I'm not that kind of guy so I'll keep going as I am.
I'm currently experiencing the joys of PTFE AN -8 lines getting the fuel system plumbed in....

[Chip Birks]

As always, the work going into this thing is top notch! Looks incredible!

Thanks Chip. Sometimes I wonder if I should just cut a few corners to get it done quicker (I do feel like the rule of "Pie" (the 3.141592.....) thing applies to a lot of the jobs), but I'm not that kind of guy so I'll keep going as I am.
I'm currently experiencing the joys of PTFE AN -8 lines getting the fuel system plumbed in....

This build deserves the attention to detail it's getting! Keep at it, it'll be worth it in the end.

Gotta love those awful fuel lines.

[split1950]

As always, the work going into this thing is top notch! Looks incredible!

Thanks Chip. Sometimes I wonder if I should just cut a few corners to get it done quicker (I do feel like the rule of "Pie" (the 3.141592.....) thing applies to a lot of the jobs), but I'm not that kind of guy so I'll keep going as I am.
I'm currently experiencing the joys of PTFE AN -8 lines getting the fuel system plumbed in....

This build deserves the attention to detail it's getting! Keep at it, it'll be worth it in the end.

Gotta love those awful fuel lines.

Yeah, I thought, PTFE, great, if we ever get E85 I'm all set, it'll be better.
They don't bend, the ends don't swivel and you really have to take care when you tighten them that they're correctly orientated once routed through whatever way you thought would be good but isn't.....so I had to order some more "Olives", say no more....
I'm hoping the oil lines will be less of a fight...(although I'd better use PTFE in the hot areas...)

[V8Nate]

As always, the work going into this thing is top notch! Looks incredible!

Thanks Chip. Sometimes I wonder if I should just cut a few corners to get it done quicker (I do feel like the rule of "Pie" (the 3.141592.....) thing applies to a lot of the jobs), but I'm not that kind of guy so I'll keep going as I am.
I'm currently experiencing the joys of PTFE AN -8 lines getting the fuel system plumbed in....

This build deserves the attention to detail it's getting! Keep at it, it'll be worth it in the end.

Gotta love those awful fuel lines.

Yeah, I thought, PTFE, great, if we ever get E85 I'm all set, it'll be better.
They don't bend, the ends don't swivel and you really have to take care when you tighten them that they're correctly orientated once routed through whatever way you thought would be good but isn't.....so I had to order some more "Olives", say no more....
I'm hoping the oil lines will be less of a fight...(although I'd better use PTFE in the hot areas...)

I think it depends on what brand of ptfe fittings you have, I have only bought "cheaper kits" off of Amazon and ebay I'm sure china made and have built 3 different engines worth of remote oil lines(-8) and feed and return for efi in my bug and I have had great luck. I think only 1 fitting I got didn't swivel but once you get a rhythm down they go pretty quick. I even made a leak tester out of a -6 or -8 gauge tee, then installed a 1/8 npt tee with a Schrader valve on one side and a gauge on the other. It's always nice to test before fluids get put in them:)

Sent from my SM-N975U using Tapatalk

[split1950]

As always, the work going into this thing is top notch! Looks incredible!

Thanks Chip. Sometimes I wonder if I should just cut a few corners to get it done quicker (I do feel like the rule of "Pie" (the 3.141592.....) thing applies to a lot of the jobs), but I'm not that kind of guy so I'll keep going as I am.
I'm currently experiencing the joys of PTFE AN -8 lines getting the fuel system plumbed in....

This build deserves the attention to detail it's getting! Keep at it, it'll be worth it in the end.

Gotta love those awful fuel lines.

Yeah, I thought, PTFE, great, if we ever get E85 I'm all set, it'll be better.
They don't bend, the ends don't swivel and you really have to take care when you tighten them that they're correctly orientated once routed through whatever way you thought would be good but isn't.....so I had to order some more "Olives", say no more....
I'm hoping the oil lines will be less of a fight...(although I'd better use PTFE in the hot areas...)

I think it depends on what brand of ptfe fittings you have, I have only bought "cheaper kits" off of Amazon and ebay I'm sure china made and have built 3 different engines worth of remote oil lines(-8) and feed and return for efi in my bug and I have had great luck. I think only 1 fitting I got didn't swivel but once you get a rhythm down they go pretty quick. I even made a leak tester out of a -6 or -8 gauge tee, then installed a 1/8 npt tee with a Schrader valve on one side and a gauge on the other. It's always nice to test before fluids get put in them:)

Sent from my SM-N975U using Tapatalk

The tester is a great idea - I'll make something up, I can test my -8 fuel hardlines I ran through the chassis too as it's better to find out now if there's any leaks

[Ol'fogasaurus]

For what it is worth:

If you have any bends in the tube, make sure that they are not too tight of a bend (short radius) or too close to a join as a too tight of a bend can fail when putting a load on it such as when you are tightening up the connections. As I am sure you already know but when the bend fails it usually ends up as a crease/fold reducing flow through the bend of the tube.

I have seen this happen several times and got a good deal on a car once (many years ago) because of problems and this was one of them.

Again, for what it is worth!

Lee

Also remember that when you bend metal the outer part of the bend's material stretches while the inside of the bend gets compressed. The same thing happens to a tube; the compressed part of the tube can give up and collapse and the material at top of the tube can thin out.

While it may not be very obvious, as I remember the neutral part of the but (the sides) can spread out some. Some times the bulge is very obvious some times the bulge is not so much.

https://www.bing.com/search?q=minimum+t ... 7145db26c6

Something I had to deal with when I was still working. A lot of things have changed since I retired in 2000 and there are tables on the web for most everything... as long as you get the question correct.

Lee

[split1950]

I have been working mostly on AN lines recently, I like the idea of PTFE (due to Ethanol compatibility) but dislike the lines. The other rubber type are on the other hand not bad, easier to put the fittings on and a bit more flexible.
AN10 Oil lines all done

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[Sorry, this pic is upside down for some reason]
Sorted the leaking oil pickup gallery with a 3/4 NPT plug (will it never end!)

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AN8 Fuel lines, pumps, filters almost done (except the hard lines, I ripped them out of the tunnel for serviceability later on, not taking engine and gearbox out to get at them it was a bad idea...). You can see the oil cooler lines on the right side, I will do similar for the fuel on the left.
I will put the Flex fuel sensor on the return from the swirl pot back to the Beetle tank, so there's some flexi lines missing for that too.

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Next is the breather lines, waiting for UPS delivery.......
Airbox done (you can remove the bottom panel to change the filter)

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Just waiting for a delivery from Injector Dynamics for my new 1050X's then these Siemens 630cc are history

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