Thought I'd post a couple pics...

[martin]

This bug is ahead of mine

New studs going in, not sure about the fit, but you can see one tapped without the stock insert

I'm hoping for pics showing the engine build up, cant wait.

[petevw]

Finally, you putting the pressure on Steve to get it done? 

I need to go visit, and scope out your goodies. 

[martin]

lol, ya, right. Not much to see yet, but there are some intake choices to make, trying to make it blow thru, draw thru was simpler to plumb. Did you get your heads squared away?

[martin]

Slowly, but surely, the case is coming along. It's been line bored, and rough clearanced to fit the 84 crank/chevy rods. Next comes a slight opening of the case for the 94's.

Steve said my case had "extra" metal to remove at the area under the cylinder which you can see in this pic. He uses a right angle small die grinder to get in there.

The case is together as a test. You can see where they drilled and tapped the factory stud inserts to 10mm from the factory 8mm, they're now offset.

[Marty]

Steve said my case had "extra" metal to remove at the area under the cylinder which you can see in this pic. He uses a right angle small die grinder to get in there.
[

It looks like he used a hammer and chisel!
I also HIGHLY question installing the cank/rods in the case that has not been cleaned!
You clearance, clean, install crank and rods to check clearance, remove crank and rods, clearance some more, clean, re-install crank and rods etc etc etc until done.
CLEAN CLEAN CLEAN is key!

Case also looks like it maybe could use a line bore.

[J Dotson]

It looks like he used a hammer and chisel!.....

He did say..."Rough clearanced"....Really really rough.
Sorry if we're picking on ya martin but dude!.....

[Marty]

Its going to take a case of sanding rolls to clean up all of those NEW stress risers. 

[Jason Foster]

WHOA.....

[martin]

Looks like he didn't spend weekends away from his family to do the clearancing like some people said, lol. Case is line bored now. Hopefully I'll get some more pics of the finished case soon. What do you mean by "new stress risers"? Cracks in case?

[wilbur]

Anytime you have a sharp edge such as a cut from a carbide burr it will start to crack, Marty i cant back you up enough, EVERYTHING MUST BE CLEEAAANNNNN!   Make sure that when hes done mocking it up he replaces those rod bearings and mains, mag dust will get on them and make high spots that you cant see ,,,,,,,that is till they they show you! which means broken or seized parts 

[martin]

The mains bearings are some old ones just for mockup, but the rod bearings would be the ones that came with the crank when new. He talked about checking and making the bearings clearances larger than factory VW specs. He likes running 20w50 on bug engines, along with more clearances everywhere on the engine. Does anybody else do this? How do you get more clearance, is that done by polishing the crank journal? He said he runs even more clearance on race engines, mine is street.

[martin]

What do you turbo guys think of welding the throttle body directly to the turbo housing? Obviously it would be more work to switch turbos, or TB's. This was one solution to the problem of not enough room between the Y tube and the turbo when fitting the intake under the decklid. I have an AJ Sims setup and converting it to blow thru efi. I had it setup with draw thru efi which worked great, but had a problem with oil getting sucked thru the turbo. Getting the TB to fit after the turbo is a challenge. Another bug has got this treatment and it's the one at the start of the thread. Here's a closeup pic of the TB:

[wilbur]

Becarefull it doesnt distort the blade or housing, you will have a hard time getting it to idle after that

[martin]

I like the way this engine turned out. It has a RX7 oil cooler underneath, with no cooler in the shroud.
Engine is being worked on in this pic, with the curved intake removed.
It runs very well, sounds mean with no muffler, and a super responsive cruiser with good gas economy, and lots of power. Low boost, 9+ CR, lots of squish.

Back to my engine project after more than a year....
The case has been smoothed out, compare to previous shots:

The pistons are getting dished in the bathtub shape to match the chamber. The have to match to work well.

The other three have been roughed in, and waiting for more milling.

What about using these heads, maybe? Stock type piston is for reference.

[ctach]

YIkes......

[JCquick]

That case looks like it never got the cosmoline cleaned off the 1st time it was put together.. Like everyone else said
 Needs to be clean

[Donny B.]

I don't think that is cosmoline it ought to be Alodine which is an anti-corosive used on metals like aluminum and magnesium

[melsbluebell]

Yeah what JC and Marty and others said CLEAN>>> i've clearanced a few cases in my life and attention to detail. Having another case to look at helps keep your bearings straight and sand smooth once the rough stuff is done

[martin]

The piston dish is as large as possible, and the combo is on course for 8.5:1 CR with a little bit of chamber work. Shims are next, and will be around 11 mm due to the 5.7" rods. They are large enough to have some cooling fins added to them!

[martin]

Here's an idea: take a single port head, cut it in half along the top of the combustion chamber and whittle it down to a barrel shim with a fin. Turns out the alloy is just not solid enough to handle the pressure and it moved around in the lathe.

This shows the final result: a set of cromoly spacers with thin cooling fins cut into them.

[martin]

Now for the juicy stuff, the chambers...
Here Steve used a custom tool centered off the intake valve to find those extra cc's.
Each chamber was done exactly like the others, wrt the intake valve.
Then the cut was blended into the chamber.
Note the paint to show exactly where the cylinder sits.
First shot is rough, second shot is after some blending.
Each chamber shows a different cut, indicating the differences in the chambers, and this step helps blueprint them to be closer.

[KAFUR1]

look at all that chrome and A Hot Hot Hot turbo  wow  !!!   how long until you r her running you think?

[martin]

The chrome engine is someone else's car. here is my engine's latest progress...
The chambers are pretty well done and on to the porting.
In these photos you can see the intakes ported and nearing completion.
The exhausts are almost perfect as is, but the intakes are another story.
Steve says they could have saved a pound of aluminum by casting them closer to what he wanted.

[R SEIDCHECK]

The chrome engine is someone else's car. here is my engine's latest progress...
The chambers are pretty well done and on to the porting.
In these photos you can see the intakes ported and nearing completion.
The exhausts are almost perfect as is, but the intakes are another story.
Steve says they could have saved a pound of aluminum by casting them closer to what he wanted.

   Be careful around sparkplug hole...looks like cutter hit edge of plughole. Don't want exposed sparkplug threads in chamber. Hopefully you did'nt do away with the small bumps that protrude at top of intake ports...kinda thin there and they support your intake valve springs. If these heads are for turbo...you may want to lay plugside of chambers back more and smooth out the sharp edges.....post pics of intake ports when u get a chance.

[martin]

Thanks for the advice. The area around the intakes have been cut with the tool centered in the intake guide making each chamber the same where the intake enters. I like pics of heads and ports, kinda like engine porn so here's some:
As for pics of the intakes I guess you mean the tops, nothing special there as it will bolt to an end casting for turbo. I can get that opened up if I add something else later.

One head is done and here it is:


Steve said the exhaust port on these 044s are "amazing" without much work at all. The have the snake shape, flattening out, that is just perfect!
You can see that shape in this shot. He likes small exhaust size for turbo noting the 2000+ hp Andy Frost car uses 2" OD exhaust.

[martin]

Here is an old motorcycle trick, drilling the fins for more cooling. What you can't see are the passages drilled from the top down.

[KAFUR1]

 

Here is an old motorcycle trick, drilling the fins for more cooling. What you can't see are the passages drilled from the top down.

   Hmm food for thought...

[marty hiskey]

i don't mean to be picking on your sh-t but why would you use such a large shim
under the cylinder especially in a boost application. why not just use longer than
stock cylinders like century, etc. and then you could cut them down to the length
you need. to me a lot less movement in the cylinder area.

[elmo]

I've never seen heads drilled for "extra cooling" on an a/c VW. Does anyone else do this, ever? If so, is there any test data that shows an improvement in cooling?

[turbotype1]

I've seen this done before on vintage motorcycles, but it was done for shaving weight not extra cooling

[KAFUR1]

TEST DATA LOL  thats funny  itsa  old motorcycle trick come on! give the guy a break

[petevw]

Nice to see your motor coming together. I'm sure it will run well.

Drove by the shop the other day, and saw your bug outside, wondered if the motor was done yet.

Who is Steve? Steve is a real smart guy that thinks outside the box on all fronts. He gets bored easy, which explains his many projects. A little unconventional, but knows his stuff. An unknown, that impressed Ken Fisher back in the day when his older brother won his class at a IVWA race. Steve buit the engine/drivetrain for his bother's bug at age 14. At 12 he was playing with Kawi triple drag bikes for local racers.

Steve is the guy that built that front engined type4 superchargered 2-stroke bug. He made all the pistons/cylinders/transferports. His daily was a '73 bus with a turbo'd 2.7L RSR Porsche flat6. Mechanically injected with his own 3D cam in the injection pump. NONE of the Porsche guru's said it could be done. He drove it everywhere. Some may have seen it at the IVWA east coast races back in the day. He worked with Mazda race engineers to make ceramic Apex seals using his turbo'd 3rotor peripheral port as a R&D vehicle.    

What was his daily bus:
http://videos.streetfire.net/video/VW-RSR-BUS27L-911-RSR-in_17534.htm

Test firing the 2stroke:
http://videos.streetfire.net/video/MPS-Supercharged-2-Stroke_39692.htm

RX7 peripheral port 3rotor EFI turbo:
http://videos.streetfire.net/video/MECHANICAL-POWER-SYSTEMS_39570.htm

He also built my 2332 drysumped superflo'd EFI street motor that ran well until it dropped a exhaust valve. My fault, as i didn't do any head maintenance for 5 yrs.

Martin, does he still go to England to tune Andy Frost's, fastest street car? I should visit him this week.

Pete

[martin]

Ooo, those vids give me chills, thanks for the links! Getting a ride in that RX7 was something else.
Steve is planning to go to England next month I think, and help build Andy Frost's new car.
After grenading the engine in that Vauxhall, Frost is building an entirely new car to keep pushing the records.
Good luck finding Steve  maybe I'll see you down there.

[melsbluebell]

kewl stuff, great video. Gotta luv the bus gettin it 240 kilometers! wowl

[martin]

Ya, I like how he's having a smoke while doing that run down city streets, and catching the green light at the end was a bonus.
The sound the engine makes when it reaches cruising speed gives me a rush!