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CLKWRK's build
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didget69
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PostPosted: Sat Sep 15, 2018 8:18 am    Post subject: Re: CLKWRK's build Reply with quote

CLKWRK: Have you verified that the oil passages from pump to case match up without obstruction?

I've had some pumps with holes that don't line up to the case openings.

bryan
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CLKWRK
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PostPosted: Sat Sep 15, 2018 11:17 am    Post subject: Re: CLKWRK's build Reply with quote

Ya i checked that, its full flowed like a t1, output has a plug in it and pressure is sent out through the pump cover
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1971 ghia build:
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Type 4 upright build:
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CLKWRK
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PostPosted: Fri Sep 21, 2018 3:25 pm    Post subject: Re: CLKWRK's build Reply with quote

Air conditioner update ...
I finally gor the vacum pump and tested it for leaks, none were found so filled it up with R12a
It kind of cool in montreal now so its hard to test out, ambient was 68f in the cockpit it was 57f , i was expctingmore drastic temp drop.
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1971 ghia build:
http://www.thesamba.com/vw/forum/viewtopic.php?t=336744&start=0
Type 4 upright build:
http://shoptalkforums.com/viewtopic.php?f=1&t=134056
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CLKWRK
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PostPosted: Sat Sep 29, 2018 6:53 pm    Post subject: Re: CLKWRK's build Reply with quote

Here is an update ...
Looks like the weather is getting too cool to test out the a/c so I am going to let it rest till next season. I think the system is undercharged so I will be adding more refigerant.

I have turned my attention to the turbo, the Garrett TB0382 was always meant to be a place holder, its old (from a 1989 SAAB 900), too small and smokes.
So I have bit the bullet and picked up the correct turbo for my setup, Garrett GT2860RS (aka Disco Potato), its big, and spools fast on ball bearings, however its watercooled so I have to figure something out for it. Probably a simple cooling system

I am also hooking up the a/c and water injection to be controlled by my Electromotive ECU, and setting up proper boost control with my ECU. I am using its general purpose output features (GPO)
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1971 ghia build:
http://www.thesamba.com/vw/forum/viewtopic.php?t=336744&start=0
Type 4 upright build:
http://shoptalkforums.com/viewtopic.php?f=1&t=134056
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didget69
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PostPosted: Sun Sep 30, 2018 3:46 pm    Post subject: Re: CLKWRK's build Reply with quote

Re: your Turbo water cooling - an option you might consider would be to use a Mercedes or BMW (Bosch) Auxiliary Cooling Pump to run coolant in a closed loop through a small oil cooler with an electric fan. I am not sure of the duty cycle on the Aux pumps, but it's an option to investigate since it's designed for antifreeze/coolant.

Another possibility may be an external fuel pump to circulate the coolant, but I'm unsure of the fuel pump seal compatibility with antifreeze.

I'm working on a similar project, in reverse... I need heated coolant.

Bryan
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TDCTDI
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PostPosted: Sun Sep 30, 2018 3:59 pm    Post subject: Re: CLKWRK's build Reply with quote

didget69 wrote:
Re: your Turbo water cooling - an option you might consider would be to use a Mercedes or BMW (Bosch) Auxiliary Cooling Pump...

Also found on ‘02-‘04 Golf/Jetta 1.8t.
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CLKWRK
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PostPosted: Sun Sep 30, 2018 6:04 pm    Post subject: Re: CLKWRK's build Reply with quote

good idea, I ordered one
I can program a general purpose output in my efi to manage the pump, eventually there will be a chargecooler added to the setup.
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1971 ghia build:
http://www.thesamba.com/vw/forum/viewtopic.php?t=336744&start=0
Type 4 upright build:
http://shoptalkforums.com/viewtopic.php?f=1&t=134056
Instagram:
https://www.instagram.com/vantageaircooled/
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CLKWRK
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PostPosted: Mon Jun 10, 2019 6:44 pm    Post subject: Re: CLKWRK's build Reply with quote

So Last weekend I had a dyno day scheduled, my goal was to get 300hp out of a mostly stock type 4 long block.
Image may have been reduced in size. Click image to view fullscreen.

Image may have been reduced in size. Click image to view fullscreen.

I had to do some creative fabrication to get the air/water intercooler to fit without cutting the body and keeping my decklid

Even though peak hp was 29 shy of my goal, I think we were doing pretty good until my clutch started to slip (the red line on the graph stops where the clutch slipped)
Image may have been reduced in size. Click image to view fullscreen.

I am planning on changing my KEP stage 1 clutch to a Stage 3 and returning in a few months, I think I can still hit my goal
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1971 ghia build:
http://www.thesamba.com/vw/forum/viewtopic.php?t=336744&start=0
Type 4 upright build:
http://shoptalkforums.com/viewtopic.php?f=1&t=134056
Instagram:
https://www.instagram.com/vantageaircooled/
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DORIGTT
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PostPosted: Tue Jun 11, 2019 8:08 am    Post subject: Re: CLKWRK's build Reply with quote

Nice work!!!

Was that horsepower @ the wheels, or extrapolated to crank horsepower?
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CLKWRK
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PostPosted: Tue Jun 11, 2019 8:41 am    Post subject: Re: CLKWRK's build Reply with quote

Thanks, thats 271hp and 245ftlbs at the wheels!!
This is a mostly stock vw bus mongrel engine:

71mm stock crank x 94mm 914 2L mahle pistons (7cc dish)
web 86a 112LC camshaft
Unported bus 1.8L "S" cylinder heads
Garrett GT2860RS turbo
Electromotive EFI
23psi of boost

I ordered a Black Magic 6 puck clutch disk and Kennedy stage 3 pressure plate (the clutch was slipping and we had to detune it with electronic boost control)
Its going back to the dyno once that stuff gets the break in, gotta hit that 300 wheel hp goal of mine Twisted Evil
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1971 ghia build:
http://www.thesamba.com/vw/forum/viewtopic.php?t=336744&start=0
Type 4 upright build:
http://shoptalkforums.com/viewtopic.php?f=1&t=134056
Instagram:
https://www.instagram.com/vantageaircooled/


Last edited by CLKWRK on Wed Jun 12, 2019 1:27 pm; edited 4 times in total
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didget69
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PostPosted: Tue Jun 11, 2019 10:53 am    Post subject: Re: CLKWRK's build Reply with quote

CLKWRK wrote:
Thanks, thats 271hp and 245ftlbs at the wheels!!
This is a mostly stock vw bus mongrel engine

I ordered a Black Magic 6 puck clutch disk and Kennedy stage 3 pressure plate (the clutch was slipping and we had to detune it with electronic boost control)
Its going back to the dyno once that stuff gets the break in, gotta hit that 300 whell ho goal of mine


Nice!

But, is this Canadian or U.S. horsepower? Laughing

Is there a conversion rate?

bryan
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CLKWRK
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PostPosted: Tue Jun 11, 2019 10:59 am    Post subject: Re: CLKWRK's build Reply with quote

Canadian horsepower actually works out to be higher than American hp, we use maple syrup instead of engine oil Smile

I think the Canadian weather helped a bit, it was 50F that day
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1971 ghia build:
http://www.thesamba.com/vw/forum/viewtopic.php?t=336744&start=0
Type 4 upright build:
http://shoptalkforums.com/viewtopic.php?f=1&t=134056
Instagram:
https://www.instagram.com/vantageaircooled/
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DORIGTT
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PostPosted: Sat Dec 14, 2019 7:18 pm    Post subject: Re: CLKWRK's build Reply with quote

Updates...UPDATES!!!!
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CLKWRK
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PostPosted: Wed Jan 01, 2020 10:09 am    Post subject: Re: CLKWRK's build Reply with quote

Here is a Jan 1st 2020 update (Happy New year!), there is lots to cover so I will keep it point form ...

- During the dyno run I noticed some excessive blow by, so shortly after I pulled the engine to address the clutch and investigate the blow by
- Upon disassembly I found that the 40 year old stock #3 Mahle piston ring land had cracked, so I ordered some Weisco pinto pistons (which have 24mm wrist pins), and installed some low compression (11cc) modified bus pistons to finish the season
- I drove it up to the Wolfsgart show in Vermont and managed to spin a rod bearing ... towed it back to Montreal in shame Sad
- Upon 2nd disassembly, I discovered that a 26mm pump will drain the sump dry if you send it for a sustained 7k rpm rev limiter bouncing hooning session, this will lead to oil starvation and spun #1 rod bearings ... its time to start thinking about dry sumps again
- I put the engine is back together with forged pinto pistons and a deep sump, I set my rev limiter to 6500 which is fine since power output drops off after 6500 anyways
- I also chucked the iron clutch disk in the used parts pile because I HATE it, too heavy so it shifts crunchy if you don't baby shift, and makes a loud squealing noise every time it engages. I went with a cushlok disk and KEP stage 3 pp, I had to beef up the pedal cluster and throwout bearing lever ... we will see how this works out

Also during all of this I built two more engines, an identical spec spare engine for quick swaps should I decide to blow the fresh one up, and a 2.5L turbo spec T4 that I plan to upgrade to once the transmission is upgraded

Transmission upgrade
Up until now I have been running a beefed up dual side cover irs bug transmission with a ZF LSD and thing axles, it has the late bug 002 gears in it so it is pretty strong and I am not having any issues with it yet, however I know that I will be pushing the limits of this transmission with 300hp at the wheels and all that glorious torque, radial tires do help keep it alive.
I have an 091 transmission being built to fit in my ghia with weddle gears and a ZF LSD, once that gets installed I will be ready for the 2.5L turbo T4 which is capable of 400hp ... this is a 2021 season goal
(also 228mm clutch disk will be a nice upgrade with this combo too)
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1971 ghia build:
http://www.thesamba.com/vw/forum/viewtopic.php?t=336744&start=0
Type 4 upright build:
http://shoptalkforums.com/viewtopic.php?f=1&t=134056
Instagram:
https://www.instagram.com/vantageaircooled/
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70 140
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PostPosted: Fri Jan 03, 2020 7:05 am    Post subject: Re: CLKWRK's build Reply with quote

Bonne annee

Cool to see you still at it with this car.
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John Moxon Premium Member
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PostPosted: Fri Jan 03, 2020 8:16 am    Post subject: Re: CLKWRK's build Reply with quote

70 140 wrote:
Bonne annee

Cool to see you still at it with this car.


Cool to see YOU putting your annual appearance. Wink

Happy New Year.
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didget69
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PostPosted: Fri Jan 03, 2020 9:00 am    Post subject: Re: CLKWRK's build Reply with quote

As for saving the transmission, I'd run 155R15 tires as a fusable link...

Laughing

Happy New Year!

bryan
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will t
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PostPosted: Thu Sep 02, 2021 1:45 pm    Post subject: wood rig for Ghia body Reply with quote

CLKWRK wrote:
Dropped by the shop today and the bodywork has started
Image may have been reduced in size. Click image to view fullscreen.

I am expecting it to be in its first coat of primer by Friday


Hi, I would like to make a frame on wheels out of wood like the one in the picture of your car at the body shop. Any idea as to the dimensions of the rig?

Thank you so much,

Will
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PostPosted: Thu Sep 02, 2021 4:34 pm    Post subject: Re: wood rig for Ghia body Reply with quote

will t wrote:

Hi, I would like to make a frame on wheels out of wood like the one in the picture of your car at the body shop. Any idea as to the dimensions of the rig?


I used the seach box at the top of the topics list and typed the words "wood" and "frame" then pressed the "search" button alongside.
This one looks pretty good just by the title....
https://www.thesamba.com/vw/forum/viewtopic.php?t=144717


Nicholas
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PostPosted: Sat Sep 04, 2021 10:13 am    Post subject: Re: CLKWRK's build Reply with quote

Hey Clkwrk,

Any updates on your engine / clutch saga? I'm curious how the Kennedy disc worked out for you, as I've got a similar spec setup and was looking at the sintered metal discs as well. Then saw your post, and since this is primarily a street car, I don't need a God's Grip clutch disc.
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