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Tue Jan 04, 2011 10:45 pm

Marius...I agree that the auto trans is not the best for a zetec period, much less a Turbo. I did one and never did like the gear hunting aspect either. A 2.2 Subie or some such would be a better choice in my not so humble opinion as it has more bottom end than the Zetec..
Now if you could mate a newer tranny to it with a lockup comvertor and modern electronics..then definately it would work. My wifes Ferd escape runs at 60 mph at about 2000rpm with its OD..the VW trans wont ever do that. (nice try though)
Daryl

Tue Jan 04, 2011 11:07 pm

AA Transaxle wrote: Marius...I agree that the auto trans is not the best for a zetec period, much less a Turbo. I did one and never did like the gear hunting aspect either. A 2.2 Subie or some such would be a better choice in my not so humble opinion as it has more bottom end than the Zetec..
Now if you could mate a newer tranny to it with a lockup comvertor and modern electronics..then definately it would work. My wifes Ferd escape runs at 60 mph at about 2000rpm with its OD..the VW trans wont ever do that. (nice try though)
Daryl
Thanks for confirming. I'm sticking with the auto trans, but I do plan to get the Peloquin installed in it and have the trans overhauled by German Transaxle when I get ready for my engine swap, but I don't think that's the same as a lockup convertor and modern electronics. :)

I'll probably end up with a 2.2 or 2.5 Subie, if the Bostig still won't fair great with the AT.

Wed Jan 05, 2011 10:43 am

But what about the most important part? Are you going to badge " t u r b o " on the van?

Wed Jan 05, 2011 11:55 am

Heck yeah..gotta flaunt what ya got...(still grinnin when I drive it)

Wed Jan 05, 2011 12:18 pm

Dear Daryl,

What can be expected at 12 PSI of boost besides a bigger grin and more importantly, can the stock tranny/CV's tolerate 240+LB's of torque?
How about forged internals-I think its getting awfully close to the limit of what the stock internals are capable of in a Zetec
PS-how about a close-up shot or 2 of it boosting in the driveway?
Bostig hasn't shown a good close up vid

Wed Jan 05, 2011 4:05 pm

Here is 1 pic of the finished setup from the top. Will go thru all the pics and pick thru and caption them later. sorry for the long url..in a hurry
\http://picasaweb.google.com/Darylspics/TurboInstall#5558834745223156498

As far as the 12 lb boost..not there yet. I like the way it drives at even 7, so no hurry in my mind.
The Zetec was designed by Cosworth as a 2.0 T..made for a small turbo from the get go with piston oilers and a tad lower comp ratio, so it will handle most of what we can give it I think...Long term, Bradys van has had one for 2 years and he really "uses all its power" . He is not easy on it and after the original turbo with 12lbs or more boost he finally destroyed that particular high mileage motor. Thats partially why they have tried 3 or 4 different setups to get one that is easy enough on the motor to last. I just might stick to 7 to 9 lbs just for economy and longevity..will see how it goes.
The trans is said by some to be good to 200 ft lb and 150ish HP with decent (Swepco) oil and oiling plates. I do see some that wear way too fast with 3.3 or TDi power, but we are thinking its the oil more than anything else. Power does not have to currupt if youre smart and know how to use it though. Us old farts can make a car last much longer than we did at 20 for sure. Frequent oil changes will extend the life of all of it.
Nuf for now
Daryl of AA Transaxle

Thu Jan 06, 2011 5:41 am

thanks for sharing the pic-what a nice looking install-the coolant bottle looks to be the only thing that had to be moved from that pic
i'm awfully tempted after experiencing those power numbers as a passenger in an engaged syncro

Thu Jan 06, 2011 6:56 am

Now all you need is one of these!

Thu Jan 06, 2011 1:54 pm

[quote="fairweather"]Now all you need is one of these!

[/quote

nice bumpers :oops: ]

Thu Jan 06, 2011 2:34 pm

from "the brickyard":

Alpine/superwagen Turbo-bus.

The European Transporters only came with relatively small engines and in South Africa you can be at shore line one day and up in the mountains the next, with power draining altitude and a full load your in the sh*t! VW in Germany didn't want to install a bigger engine due to taxation expense for the owners which would put them of buying a new Transporter . The South African firm Alpine saw a gap in the market for a more powerful Transporter and developed the alpine/superwagen Turbobus to meet customer need for a more powerful van.
The conversion was carried out at one of the 104 superwagen engine building dealers through out the country. When the 1.9l water-cooled engine came along John Conchie took it upon himself to start work!!
the conversion involved a 8 hour transformation in one of the Superwagen workshops and each engine was tested on a dyno test bed to make sure it performed!
the spec of the engine is as follows.

Low compression Cosworth pistons (7.2:1)
Garret PB-03 turbo
Hand made exhaust manifold.
Inlet manifold modified to suit a twin choke Dellorto blow through 32mm carb.
Modified Oil pump.
High pressure roller cell fuel pump to cope with extra load.
Oil cooler..
Sadly I have no descent photos of the conversion (not worth scanning anyway) but the turbo was mounted just below the crank pulley, lots of pipes but no mods were needed to the engine bay and load bed was kept at the standard height.
Max speed - 96 mph
peak power - 105 kW (141 hp)

alistair

Thu Jan 06, 2011 4:02 pm

AA Transaxle wrote:
The trans is said by some to be ....

wait a minute, you're quoting someone who knows more about these trannies than you?

Thu Jan 06, 2011 11:30 pm

Daryl, what will be the solution for your ac compressor? Can the the ac lines fit and not be too hot?

Do you still use the modified focus air box?

The intercooler fans draw air down, rather than pushing air up?

Looks like careful attention was paid to heat shielding.

Very cool!

Fri Jan 07, 2011 10:14 am

Re: the AC fitment...I will have to modify the ac block that connects the hoses to the comp. to get the lines below the turbo. It can be done I think with some redrilling and silver soldering. My AC is not a VW setup...Its a Vintage Air under dash unit and its hoses go straight forward and may be different than a stock arangement. I figure I can get enuf clearance to below and wrap teh hoses if nec to keep it all cool enough.

The air box is the same as yours..Focus modified box.

Intercooler draws air from the D pillar and with the deck lid on, pushes over the engine top and down past the exhaust and out making the eng bay actually cooler. Seems to be a tad cooler eng temp so far as the lid is much cooler that before.
Daryl of AATransaxle

Sun Jan 09, 2011 11:36 pm

Hey Daryl,

Thanks for the great photos! Good to know what to expect. Was there a drawing/specifications as to how far down to move the electrical junction box? Just wondering as my engine compartment is stripped bare right now and I wouldn't mind putting it back together "turbo-ready".

Thanks again!
Ed

Sun Jan 09, 2011 11:54 pm

Heres the rest of the turbo bus brochure.

Wonder how long one lasted?

Sat May 28, 2011 10:37 pm

Got to drive one of the turbo bostigs today. Very very nice. Great power even at 7.5k feet. And it was only at 7lbs boost.
What an awesome kit!

Fri Jun 03, 2011 1:14 pm

Daryl, it's been a while now. Anything to report after five months or so? MPG data? AC success? Thoughts on stock gearing and/or tire size with turbo?

Fri Jun 03, 2011 3:06 pm

Hi Epaddler
I don't have a syncro but a heavy loaded 2wd Westy with a Bostig Turbo. I am in the process of trying to figure out what I am getting for miles per gallon BUT I keep letting people take it for a ride. They get behind the wheel and can't help but mash the gas pedal. I must admit that I have been known to wind it out a bit myself. For example today after getting off the cross sound ferry at Orient Point. We were travelling in a group of five Vanagons. As we were driving in a line a carat with another kind of conversion sped up next to us. We ended up being next to each other and a friendly race to the exit ramp suddenly happened. He had a hard time keeping up and I was fully loaded where he was fairly empty. Turns out he has an older HO tiico conversion. He also admitted be was taching the he'll out of his van. I was just flooring it in third not going to crazy. It was fun and not as dangerous as one would imagine. He has never seen a zetec conversion and again when I let him take my van for a spin later he was mashing the gas so what I am getting per gallon is still not accurate. I am getting tons of fun per mile though and that's what my van is all about.

Bill
87 Westy
Zetec Turbo
Currently camping on Long Island in River Head come join us...

Fri Jun 03, 2011 3:56 pm

Bill and I have both driven the same van. It is a pretty heavy syncro weekender, and such a pleasure to drive. I have the identical van with a stock wasser, and we took it through some of the common routes I take. In short, the Zetec/Turbo provided an updated and modern feeling drive, amazingly well suited to the van.

With the electronics hooked up, I was monitoring the Turbo, and the way that van was set up, you had to get on it if you wanted some Turbo. A different way of saying that is, in driving my usual routes, city and highway, I notice a substantial increase in performance without getting on the gas. Stomping on it was totally cool as well, but that just made fast = faster. I am sure there are times for that on the road, but it almost seemed excessive...although having that power available is a must, I just can't tell you why other than pure fun.

Although I got to see that van off-road, I would really like to drive it (out there) sometime to get a better idea of what it does in that lower range. On the streets it was lovely in the lower rpms, but will it power you up that steep step in Canyonlands at the next Syncro Solstice? I saw it tackling obstacles with no problem, but I still wanna play in it! :lol:

Anyway, I am signing up for the next group for a November delivery (I think it is 17?). This thing is such a no brainer for me at this point. And after driving it, I gotta say, so many of the comments I have registered in the past about this conversion (that were holding me back) are not inaccurate necessarily, more like taking a very small thing and trying to create an actual issue out of it. For instance, was it louder than stock? I think if we got some instrumentation out we may find that out, and if it was, perhaps a decibel or two? I would say it is just a different sound, and I liked it. Clearance issues, hard to work on, longevity, I can't remember them all now because I have pretty much blown them off after that drive, and combing through the actual engine and install and the support on their site. There is so much confidence and testing behind this product, and accountability...I feel like Jim and Brady have accomplished what many companies dream of with this product and service. I consult with many companies for a living, and none of them are able to service patrons like this...not the million dollar companies, and not the 200 million dollar companies...

A couple more comments on what it is like to drive:
* The range of the gear - I loved this part. That engine REVS! and you can take it way up there. You actually get some killer range in every gear. This was one of the big things that allowed me to bail on the thought of the TDi.
* Even Power - Buttery smooth acceleration, whether you are ON IT or just slowly moving through the gears. It felt GOOD.

I don't mean to create propaganda, I just wanted to provide some real world test feedback for those in my same shoes. As I reminder, I am looking for something I can service and fix myself, I don't have a lot of money to burn on this.

Sun Jun 05, 2011 3:48 pm

I have run my Bostig Turbo setup for about 3500 miles so far and love it.. No question a great improvment over the stock 130 hp Zetec.
My Syncro Westy weighs 5400 lbs or so and pulls from 2000 rpm with no lag and will pull most any long grade in 4th gear. (thats west coast grades..) Gotta be about 165 hp and 200 lb/ft of torque as the dyno said. Just feels right comparing all the others conversions I have driven.
I am still at 7 lbs of boost and not sure I want to go any higher yet. 12lbs is a kick in the pants, but will wear stuff out much sooner...
On the way to SdeM, up a 5% grade a 200hp Subie Syncro 16 Westy couldnt pass me..Dead even up to 95 mph when we ran out of road.
Mileage is getting better as Jim tweaks the tunes richer bit by bit. Got just shy of 15 last tank of mixed driving, but have gotten almost 17 by driving the speed limit at times.
Jim is being very careful to make sure we dont fry the motor and that the setup will last and be dependable..I have no problem with that, as so far, we are a still beta bunch seeing if there are any bugs.