My new 1641 Turbo is ALIVE!

Post pictures of your pride and joy here!
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cosmobug
Posts: 325
Joined: Mon Jul 22, 2002 12:01 am

My new 1641 Turbo is ALIVE!

Post by cosmobug »

Winter project is almost done...I've upgraded my 1641 to a turbo setup. I'm going to dyno the motor on a Stuska in a couple of weeks to get the carb jetted and dialed in and to see what kind of power it'll put down...I'll try to remember to post the results! The car it's going into is in the background.

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And a pic of my car...

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A little background info:

-1972 Bug, full custom with 66 hood/decklid and aprons and britax ragtop
-1641 with unknown mileage...top end has maybe 15K on it
-Basically stock longblock except for 87mm bore
-Compufire DIS-IX Ignition
-Solid rocker shafts, stock 1:1 rockers
-7.9:1 C/R
-Kennedy stage-1 clutch
-Custom turbo setup fabricated mostly by my brother...Garrett T-3, Dell DHLA 40, external wastegate

Thanks to my brother Danny at Performance Specialists, Int. (PSI) in New Orleans...this was hist first VW effort...usually works on Jap imports.

Also a hearty thanks to Randy Bowen and Jay Schumacher at SportCar in Colorado Springs for all their quality work and attention to detail. They fabricated the wastegate pipe and modified my downpipe and also did many other small things. Jay rebuilt and modified my carb and will work his magic on it on the dyno. I also want to thank them for always taking time to give out friendly advice. They are really a stand-up quality team at SportCar.
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Orange65Turbo
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Joined: Mon Sep 13, 2004 4:47 pm

Post by Orange65Turbo »

I like that set-up... Nice and clean. How much boost do you plan on using? With that ignition do you have boost retard? Exhaust and waste gate pipes are a great match. Good luck with that and post some numbers.
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cosmobug
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Joined: Mon Jul 22, 2002 12:01 am

Post by cosmobug »

Thanks for the kind words! I currently have a 5.8 lb spring in the wastegate and also have an 8.7 that I'm going to put in it on the dyno to see how much more it'll be capable of and to test for any detonation problems, though I don't expect any. With this motor, since it was not originally built for a turbo, I don't intend to go any higher than that. This car is going to see mostly street time to local club and car events with a few trips to the track during the summer months. The bug used to be my daily driver but now my Jetta TDI takes me to work and back.

I don't have any type of boost retard system, but the 009 has been modified to allow only a total advance of 10deg (just bent the secondary tab in enough to no allow the second weight to add any additional advance). I will have max advance set at about 24...we'll have to see how it does on the dyno before we arrive at a final number.

BTW...the copper 45s are a temporary solution to the drain hose kinking...the hose is simply pushed through them to help it retain its shape and not kink. I need to stop at the local fittings place and get some aeroquip or ss-braid hose instead of the flimsy heater hose. Lowes was the only thing open at 8 on a Saturday night! :lol:

Thanks, and I'll post numbers.
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cosmobug
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Joined: Mon Jul 22, 2002 12:01 am

Post by cosmobug »

Here's another shot...the Fram filter is "temporary." I've got a NAPA Gold Wix filter on the shelf waiting to go.

Image
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Orange65Turbo
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Joined: Mon Sep 13, 2004 4:47 pm

Post by Orange65Turbo »

You should share the set-up pics and details over in the forced inducton forum.
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brianwheelies
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Joined: Thu Feb 05, 2004 3:14 pm

Post by brianwheelies »

really badass.
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Bugzlife
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Joined: Fri Sep 27, 2002 12:01 am

Post by Bugzlife »

Nice test stand, looking at the Pulley blurr, that thing is running sitting on a piece of plywood on a creeper. :shock:

what was the dyno output, like to know.
what crankshaft, and rods? what heads?
thanks
looks real nice!
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brianwheelies
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Joined: Thu Feb 05, 2004 3:14 pm

Post by brianwheelies »

Bugzlife, who's in your avatar at thesamba?
j/k, nice tho.
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Bugzlife
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Joined: Fri Sep 27, 2002 12:01 am

Post by Bugzlife »

Image

Have no clue, just some dude walking around the pits when when the picture was taken.

You can't miss me I'm 6' 5" tall.
I'm the goofball in the back with the hat on,
standing infront of me is Dave, owner of the Bug Baja ("Mang")an his Nephew.



Image

:lol:
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Kenny2428
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Joined: Thu Aug 22, 2002 12:01 am

Post by Kenny2428 »

Cosmo, thats a really nice setup. I like it! Put that thing in your Bug, and let er rip!! :D
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cosmobug
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Joined: Mon Jul 22, 2002 12:01 am

Post by cosmobug »

Bugzlife, yes, nice test stand, eh? Temporary, to say the least...engine actually outpaced the test stand project. It is firmly bolted to a full tranny case (also on the creeper) and the "plywood" is actually a frame of particleboard and 2x4 lumber that supports the weight of the motor on the original sump rather than the deep sump. It also is my jacking support with a cutout through one of the layers for the jack pad.

It moved nary a millimeter while running. The creeper allows me to move the motor around the garage safely.

Also, thanks for the suggestion, Orange. I have a full thread following the build process at http://vocs.net/VOCS/forum/viewtopic.ph ... sc&start=0. I'd really rather not reproduce the whole thing here. So you can hop over there and check it out. You should not have to register to see the pics in that particular forum...I'm the admin and I set the forum to display pic to all, even guests. Please let me know if you don't see any pics there.

Dyno time is set for 5 March...we'll see how she does!
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cosmobug
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Joined: Mon Jul 22, 2002 12:01 am

Post by cosmobug »

Oh, missed your other ?s Bugzlife...stock bottom end with 87mm jugs. Basically using it on my 1641 as-is until I can afford to build a bigger, beefier bottom end. The heads are also stock. Only mod to the valvetrain is solid shafts. Not an optimal motor for the turbo, but it can be the sacrificial lamb to iron out any bugs before I put a lot of money into a new motor.

Have not dyno'd it yet...hoping for about 100hp (remember, I'm at 6000+ft altitude which cuts HP by about 15-20%).
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Kenny2428
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Joined: Thu Aug 22, 2002 12:01 am

Post by Kenny2428 »

Man, I love your engine. Very detailed. Makes me want to get all my stuff ceramic coated, lol. I couldnt afford the coating when I bought the header. Should make for a fun engine... :D
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cosmobug
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Joined: Mon Jul 22, 2002 12:01 am

Post by cosmobug »

Thanks...I wanted it to stay clean, so the non-stainless got coated, including the cast steel wastegate body and the turbine housing. It wan't too bad...$250 to have those 4 pieces coated and the stainless header media blasted to remove welding discoloration and a run through the ball burnisher. I expect the header to blue or discolor, but that's OK...so long as it doesn't rust! :lol: You can see in the running pic it is actually already starting to discolor near the heads.

Thanks for the kind words! Your setup looks really kick A$$! I'm dying to drive mine!
69bug
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Joined: Sun Nov 18, 2001 12:01 am

Post by 69bug »

HOLY CHET!!!


what size exhaust pipes u running?
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