AMR500 on a 1600cc - V2

grelland · Post by **grelland** » Mon Feb 08, 2021 2:25 am

Wow, I see I have not updated this in a good while, so I guess it is time

Last post was in August, and even though more or less the entire show season was cancelled last year, we managed to get together a fantastic trip around the Norwegian fjords and mountains, so after some conciderations, I decided to t1ke the SC off for this trip. We are talking some 750 miles up and down Norwegian mountains and fjords over 3 days, and the weather forecast said 25-30 °C so I concluded that the heat issues could potentially destroy this wonderful experience.

So here are a couple of pics from the trip

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As you can imagine; a fantastic experience

During the long light nights on that trip, I have a chance to talk to a lot of great Norwegian fellow VW-nuts, so when I came home, I decided to finish up my 2110cc oxyboxer, so that I could have some fun before winter came, so I focused on that engine for a couple of weeks, and finally managed to install it in the car:

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Interesting color choice, but since I always try to involve my boys in the builds, they were in charge of the paint, and that is the result

grelland · Post by **grelland** » Mon Feb 08, 2021 2:37 am

The oxy worked great, and it pulls quite hard

https://youtu.be/Ib-BZKQ5Gnc

But winter came and the car was put in storage, so that we could start planning and working on the supercharged 1600 v2

The main challenge from my side was the heat management, and I soon concluded that I wanted to add some sort of charge cooling. After some thinking and again discussions with fellow VW-nuts, I wanted to look at a solution using a water-to-air intercooler. More on that later.

First I opened the engine and inspected all the oily bits. I had no idea how many miles it had run, so when I decided to supercharge it last spring, I was well aware that there was a certain risk linked to that.

grelland · Post by **grelland** » Mon Feb 08, 2021 2:50 am

In general, the internals measured out ok. End float was within tolerence, and the only thing I ended up doing was a line bore to bring everything back to spec.

I also opened the case up for full-flow and performed the "hoover mod" while I was at it.

Most of this is standard stuff for most of you, so I will not spend too much time on sharing pictures of this.

When it came to the heads, they looked good (no cracks) so I cleaned them thoroughly, and my son got his CNC-mill up and running so he machined them down a tad so that I ended up at 8.5:1 in static CR.

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I also had to replace a couple of the exhaust valve guides, as they were way outside the tolerence.

Then I did a mild porting job, as I have no clue what I am doing, so I limited myself to match-porting to the CB end pieces, and cleand up the exhaust ports a little. I also made a couple of brass inserts to ensure the end pieces and heads matches up every time:

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So aside from the regular problems with cam bolts fouling the oil pump etc, I finally could conclude that I now have a decent longblock:

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grelland · Post by **grelland** » Mon Feb 08, 2021 2:55 am

So the spec on the engine itself is as follows:

Stock 69mm crank and rods
Stock pistons and barrels (new rings)
All new bearings
JB200 cam (from JoeBlow in Australia)
mildly ported stock heads
scat 1:1.25 rockers
chromoly pushrods

This means that my redline will still be in the 5300 rpm range, so max drive ration to the SC will be about 3:1 (as I used last summer)

grelland · Post by **grelland** » Mon Feb 08, 2021 3:50 am

So back to the intercooler.

I toyed with the idea of adding an air-air intercooler, but concluded that even though thay may have worked ok, I think that even though I have quite a lot of space in my engine compartment, the IC would heat up the intake air that is being used for cooling the engine, so that would not be optimal. Alternatively i would have to make a separate air intake that led cold air directly to the intake of the fan. That could be done from underneath the car, but i decided that that would become too much work, so I landed on a water-air solution in stead.

So after some search and head-scratching I landed on an intercooler from siliconeintakes.com, that is rated up to 350 hp, and with a pressure loss at 0.1 psi.

It looks like this:

http://www.siliconeintakes.com/front-mo ... p-210.html

So before I pulled the trigger, I made a rude 3D-model an 3d-printed a mock-up in order to check the available space in the engine bay:

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Even though I have my dry sump oil tank inside the fender, I still have some space left.

So a quick mock-up on the engine stand revealed that this could certainly be a viable solution:

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So the credicard took a small hit, and I could start preparing the rest of the auxillaries.

The next generation is still head of the paint department so the SC got a shower:

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But I wanted a bit more toned down look overall, so the rest of the tins and hw received some satin black powder coats:

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grelland · Post by **grelland** » Mon Feb 08, 2021 3:58 am

After some debating on what fan shroud works the best, I ended up deciding to use a late model doghouse model where I have removed the outlets for the heater. I think the 36-hp ones look better, but since heat management is/will be an issue, I dont want to cut corners there.

So the oil system will be a quite standard one, with stock cooler in the doghouse, and a full flow system with an external filter and additional cooler under the car.

Then we are almost up to speed on the project, as I spent the weekend fabricating alu intakes and flanges, so the following images shows where the project is today:

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My son made the flange on his cnc-mill

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So the next on the list now is to weld the flange to the intake pipe, and then add some bungs for some sensors.

I intend to add two IAT-sensors; before and after the IC, in order to see the cooling effect.

I also need to source the rest of the water system: radiator, pump and an expansion tank, so any hints as to good sources for this will be highly appreciated.

Stay tuned for more

buguy · Post by **buguy** » Mon Feb 08, 2021 10:21 am

I got my radiator and fan at silicone intakes. http://www.siliconeintakes.com/
For the pump i got a "Rule" 1200 gpm pump. It's a Marine bilge pump. I think i got that on Amazon.
Made my own tank out of aluminum sheet. I just used a 5" boat deck plate for a screw off lid. Big enough you can get your hand in to it to mount the pump and to accept ice when needed!

grelland · Post by **grelland** » Mon Feb 08, 2021 11:31 pm

buguy wrote: ↑Mon Feb 08, 2021 10:21 am I got my radiator and fan at silicone intakes. http://www.siliconeintakes.com/
For the pump i got a "Rule" 1200 gpm pump. It's a Marine bilge pump. I think i got that on Amazon.
Made my own tank out of aluminum sheet. I just used a 5" boat deck plate for a screw off lid. Big enough you can get your hand in to it to mount the pump and to accept ice when needed!

Thanks, I will have a lokk. What size radiator did you end up with?

grelland · Post by **grelland** » Mon Feb 08, 2021 11:51 pm

Short update from yesterday's activity.

My oldest son moved out this christmas and took with him a lot of his machines, but he only lives 5 minutes from my house, so he drops in every now and then. So yesterday when he stopped by, I had him weld the flange on the intake tube:

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I am still not a friend with the TIG, and I know that the only thing that helps is practice, but is is so much more conveniant when he just does it

We also decided to have a look at the other short intake tube; the one between the TB and the SC, and from last year, I know there is some optomising to do. One of the issues was that the tube is 48mm, but the flange on the TB is some 60mm i diameter, so we set the tube up in the lathe (that machine is mine, so it remains in my garage

) and made a nice taper out to the 60mm opening. I will face off the flange also to ensure a good seal to the TB:

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Next on the list is to make some brackets to hold the IC in place, and then I will powder coat all the bits and pieces.

Great fun, and still snow on the ground here in Norway, so no immediate rush to finish.

grelland · Post by **grelland** » Tue Feb 09, 2021 11:52 am

Only thing I got done today was to face off the flange so that it will hopefully seal well against the TB

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chickensoup · Post by **chickensoup** » Tue Feb 09, 2021 12:00 pm

This thread incorporates lathe tools and fabrications!?!? I'm in!

btw just curious but what lathe?

buguy · Post by **buguy** » Tue Feb 09, 2021 12:07 pm

Right. I love that stuff even though i don't know how to do any of it!

grelland · Post by **grelland** » Tue Feb 09, 2021 12:28 pm

chickensoup wrote: ↑Tue Feb 09, 2021 12:00 pm This thread incorporates lathe tools and fabrications!?!? I'm in!

btw just curious but what lathe?

Thanks for the kind words

a small chinese one

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buguy · Post by **buguy** » Tue Feb 09, 2021 2:38 pm

We have a big one at work. I was going to use it one weekend but i couldn't figure out how to turn it on. Figured that was a sign that maybe i shouldn't be messing with it!

Chip Birks · Post by **Chip Birks** » Tue Feb 09, 2021 4:33 pm

buguy wrote: ↑Tue Feb 09, 2021 2:38 pm We have a big one at work. I was going to use it one weekend but i couldn't figure out how to turn it on. Figured that was a sign that maybe i shouldn't be messing with it!

Lol, good thinking. Watch a couple lathe oops videos and you'll be unconverted real quick. Definitely not a machine to mess with if you don't know what you are doing.

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