2270cc type 4 EFI Turbo: my first engine build

[split1950]

Car looks great. Not easy to do that well with bare metal.

Yes there's no bondo in my car!

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[split1950]

New hand made panel on the right.
Tea bag version on the left!

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[buguy]

Wow! That's impressive!

[rubenski]

Skillzzz!

[split1950]

A bit of progress whilst the body gets finished off and we are confined to the house (read: busy work)....
Chargecooler water jacket(?) and AN-12 fittings welded on by Steve (thanks, you're awesome!)
Despite this being an OEM Audi intercooler the Aluminium was full of impurities and didn't weld nicely.

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Plonked it in a bucket of water with one AN-12 blocked and the other with a PCL fitting, stuck in 15psi from my compressor and two things happened;
1. A small stream of bubbles came out in one spot that looked like a minute pin spot in the weld (impurity?)
2. It bulged a bit......note to self, 15psi is a bit high for this water cooling jacket leak test.
Back to Steve for a quick zap here

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Picture is weird, it was stood on an Orange bag when I took it lol

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Tested again, no leaks and I pushed the bulges down.
When I can get to do the engine mock up I can figure out the pressure / end caps and tube layout in & out.
I had mirror polished the fan and shroud, coated them in WD40 and left them in my garage over winter. Now they look like crap in comparison. I hate polishing so plan B.

Fan as initially disassembled.jpg

I drilled out the aluminium rivets and sent the steel parts for Zinc with Black chromate conversion (being done as we speak), threw in the glass lifter channels for the hell of it

Parts sent for Zinc BEFORE.jpg

I'm going to Satin Black powder coat the fan and shroud, so had to take 0.4mm off the radius here to allow for paint thickness (thanks again Steve!)

Fan where to clearance for powder coat thickness.jpg

Fan pre machining for powder coat.jpg

Not sure when I'll be able to visit the powder coater unfortunately.

[andy198712]

how are you planning to reattach the centre? i considered this too with mine....

[split1950]

M5x15mm countersunk Ti screws.
The rivets were aluminium and although that's possible with a rivet snap bolts are better for me.

[andy198712]

M5x15mm countersunk Ti screws.
The rivets were aluminium and although that's possible with a rivet snap bolts are better for me.

nice

[split1950]

Got my Zinc plated (with Black Chromate conversion) parts back, they look amazing

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Looking at this I will go with Satin Black powder coat on the fan and ring, I can't go there whilst we are on lockdown so it has to wait.

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First shot at Colour sanding my petrol tank that I sprayed last autumn - it's good enough I think, I want to leave something on there to polish back in the future

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Made a pop up spray booth inside my garage out of a gazebo with 4 sides, works great! You need to use an air fed mask as there's no extract.....
Cleaned up and sprayed my steering column (still in gun finish)

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Made my gauge pod (like a false glovebox door) out of some Aluminium sheet and used a standard model blank for the Rev counter, then painted them

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[buguy]

Very nice! I did my tank like that last year and then a few months later my in-tank fuel pump seal split and the fuel destroyed the paint. Was pretty for a little bit!

[split1950]

Very nice! I did my tank like that last year and then a few months later my in-tank fuel pump seal split and the fuel destroyed the paint. Was pretty for a little bit!

Oh, bad times.....did you use 2K?
Part of the reason I didn't polish it any more is for when (not if!) I drop the fuel cap on it, or something like that
I've got a 044 Bosch pump mounted elsewhere so apart from the outlet and return AN fittings there shouldn't be any scope for leaks / spraying out petrol.

[buguy]

Yeah I used 2k. I also run E85. Seems to be a little harder on it. Also my 65 tank is different. It has a little recessed well in that area and the fuel just sat in there eating away at it.

[split1950]

I've spent a while looking at ignition coils and had thought I'd get some LS2 / D585 but I've read you need the one's with White epoxy because the others are fake / crap quality. Trouble is I can't find any …….
Mario (the dub shop) is showing some, I assume genuine as he wouldn't sell crap.
On the other hand, are the EDIS or VW 4 post type coil pack in wasted spark enough for my 400BHP target?
I have a Cam position sensor (Dub shop) and will go sequential injection, I had planned same for ignition but I suppose if the coil is good enough that doesn't matter.
Can anyone help before I waste my money lol?

[buguy]

I would email Mario @ thedubshop. He has done some real live testing on this subject and can steer you in the right direction. He told me once but now I don't remember the specifics. What's nice about Mario is he will give you honest answers usually with data. He's not just trying to sell you. Most likely he will have what you need too though.

[Steve Arndt]

Great build. The body work is amazing the fitup.
I polished an 11 blade fan a while back. They look great for a minute then the magnesium alloy tarnishes quickly as you noticed.

I need to get back on my T4 build. I have parts for a 78x103. 48x40 six stud heavily welded heads, etc. Been collecting parts for 20 years for the build