Baby’s first turbo. On a mystery motor!

[ct937]

Hello and howdy ya’ll! I migrated here after getting tired of the idiocy that is the samba’s engine performance forum.

The stated goals for this build are simple: practice tuning a blow through turbo. I aim to gain knowledge and experience. If I make my buggy more fun and don’t blow anything up, all the better!

I’ll be taking some shortcuts and I plan to make note of them as I go along. I’d hate to lead anyone astray with my antics.

Well... the first thing worth mentioning is that I did not tear this engine down. It’s been refreshed but I do not know how long ago in miles or years.

Without further adieu, here are the bits:

H5 case #170034 dates to Dec ‘67
1500cc+ aftermarket dual port setup
Refreshed in the past
Dellorto 40mm blow through
Borg K03 turbo
6 lb wastegate spring
Supertrapp diffuser/muffler
BOV on carb hat
New Walbro GSL392 fuel pump 210LPH @ 80psi
New Holley 12-804 boost ref fuel pressure regulator
New doghouse oil cooler
New chrome blower shroud ductless doghouse style
New K&N RU-0680 high flow air filter
New eBay intercooler
New eBay charge pipe and couplers
New Innovative wideband AFR
New oil pressure gauge
New boost gauge
New clutch and pressure plate
New intake boots
New intake/exhaust gaskets
New fuel line

I’ll be doing a leakdown on the engine when I get a chance and post up the results.

Build-wise I need to seal up the exhaust, finish bolting down the turbo pedestal, and install my IC and piping. I am currently leaning towards mounting it on top of the engine fan shroud.

I am in also in the process of building a mobile/modular VW run stand. Just waiting on the final few parts.



Edit: For whatever reason it won’t link to the photo above...

[Ol'fogasaurus]

003.JPG

A\This is a combo engine run and storage stand that I built but haven't used to run an engine on yet. Mainly it was how far to go on the electrical dash that stopped me at this point as there was several ways to wire it such as alt. vs. generator as an example. I doubt that I would go back to a generator but since the stand and fuel pump for an alt. vs. the stand and pump for a generator are different… etc. and then there is the potential turbo option now in the mix.

Lee

[ct937]

I like that setup a lot!

I’m employing a 1/2 ton hydraulic lift cart as a makeshift work table/run stand. The dash pod bolts to the handle via two screws on its back panel and a divorced trans bell housing mates with block. I can quickly unbolt the whole unit and take it to verify claims on those too good to be true “I swear it runs!” deals.

My dash electronics will feature three switches. They control power to coil, power to fuel pump, and power to the starter relay. Each one will be isolated from the others so that I can crank the engine with no fuel or spark (compression test), crank with no fuel (test the spark), etc.

The gauges I’m employing will be a tachometer, wide band AFR, boost gauge, and oil pressure.

I’ll try to upload images from my PC later this evening. I mainly need to finish wiring but there is still a little bit of fab work to do.

[buguy]

Should work fine. Although I don't know about using the supertrap

[Clonebug]

I use a SuperTrapp........For almost eight years now......



I do have about 14 discs and an off road open end on it though.......no restriction that way.

[John S.]

I thought your buggy was just happy to see me.

[buguy]

Ahhaaaaa^^^

[madmike]

Welkome to STFs we won't pick on u too bad
what are you putting the turbo motor on? street bug? off road buggy? this will help us.

[ct937]

It's a sand rail with torsion bar front and IRS rear. I'm not 100% on the model but it is a very common frame.



That was easy!



I was mocking up locations for the intercooler for the test stand. I feel like it looks so industrial this way.



I guess my buggy's exhaust feeling a bit cold...



Here's what I have on hand and put together. I also have a fuel tank off of a Miller 200LE that'll be plenty for the job. It just needs a new fitting.



Bell housing and starter.

[MarioVelotta]

Welcome to STF! You will fit in just fine around here.

[ct937]

Double posted

[woodsbuggy1]

Looks like a Berrian Warrior chassis, same as my off road buggy. You might want to consider moving the intercooler a lil further from the fan shroud to help eliminate heat soak. Your project is looking good. Where are you located?
Kenric

[ct937]

The weather finally broke and the buggy project resumed today.

Took a whopping 1 hour to get the engine back in the buggy. Most of that time was removing and reinstalling the turbo to clear the frame while mating the engine to transmission.

Played around with a bunch of intercooler positions on the buggy but haven’t made up my mind yet.

I included a before and after of the engine reinstalled. I’m not putting the cradle back in until I finish plumbing the turbo oil feed and sort out fuel lines. It’ll be much easier with that out of the way.

30015981-C09A-418D-AB7F-C222266A3C04.jpeg

C805FCB2-F4EA-4ED6-8749-EA521E175455.jpeg

I also included two rough mockups of potential intercooler locations. I think the higher one would be ideal but would prefer the lower one because it does not require more piping. Despite the angle of the photo of the lower position, the intercooler’s rear bottom edge is still slightly in front of and above the top front edge of the fan shroud. But I don’t see it being as effective in that position...

DFFD280C-AA0E-4BF0-9367-8A92153A4B7C.jpeg

35D48BEE-76FB-43E5-9961-3D8B7D8F7B4B.jpeg

[rubenski]

That oil feed looks huge!

[John S.]

As always, I will be interested in your dellorto jetting and mods. I'm still in the parts gathering phase. Keep up the great work.