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Yamaducci's 2498 cc Turbo Re-Build Thread
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yamaducci
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PostPosted: Thu Sep 22, 2011 8:58 am    Post subject: Yamaducci's 2498 cc Turbo Re-Build Thread Reply with quote

2498 cc Turbo that I am currently rebuilding:

After trying to put this on STF I realize it's much more of a PITA to deal with remote hosting pictures and I frequent thesamba most often as it is. Pictures are now being regularly loaded to my Gallery with detailed descriptions. I will try to include them in my posts as well. Let me know if you have questions!

AS41 Case Lifter bores bushed by Brothers Machine
Porsche Piston Oil Squirters by Brothers Machine.
All moving parts "0" Balanced by Brothers Machine
Bob Hoover oiling mods on lower half to improve 1/2 side oiling by me
Web 86C on 112 Lobe centers and clearanced
Udo Becker Tool Steel Lifters
New Magnum Straight Cut Cam Gears
90mm full circle crank Wedgemated/8-Dowelled/1-7/8" Chromoly Nut
5.7 Eagle Rods with 5/16" ARP 2000 Bolts
Long Cylinders Cut to length and honed to specific clearance
94mm Wiseco's Dished ~7.2 cc's
"0" Deck height to top of cylinder.
.060 copper gasket
~8.0:1 CR ??
Competition Eliminators with 46x38 valves and reshaped combustion chambers and ported and Polished by Performance Workshop Steve/Greg Tims
K800 Springs
Adding fins to CE Heads for added cooling (in the works)
Manton tapered Chromoly Pushrods
Bearings dry film coated at Calico Coatings
Bugpack Dry Sump system
BMD Dry Sump serpantine belt system with reduced size top pully (stock ratio)
1.4:1 Autocraft Needle bearing Roller Rocker arms
Rocker arm spray bars
MSD 6AL
CB 8-Injector Fuel Injection w/ 48mm throttle bodies (will likely switch to a 1 ECU/Coil on Plug Ignition option like Tec 3)
Turbo T04b35 with Blow off valve and wastegate
1 5/8 Header
Industrial Fan Shroud (no dog house or fresh air)
Welded fan (Currently developing wider carbon fiber fan)
Remote oil radiator and fan
Brad Penn Oil


Rancho Built Early IRS Transmission:
Regeared with All Weddles will update with 1-4 ratios
3.88:1 Ring and Pinion
1st =
2nd =
3rd =
4th = .89
26" Rear Tires
Quaife Limited Slip Torque Biasing Differential QDF4R/37
930 Porsche CV's and Axles
Hydraulic clutch w/long arm
Stage IV/ 3000Lb Clutch
Copper Head disk
LAT Oil
26" Tall 355 Street tires
28x10.5 Slicks
Wheelie bars = YES
Should Haul-the-Mail pretty good!
_________________
-John Cox
My 2498 Turbo Re-Build Thread: http://www.thesamba.com/vw/forum/viewtopic.php?p=5578697#5578697
Cox Racing Engines
Class 5-1600's; Stock 1600 to 2498cc Type 1's. Custom Built for you in Maryland
3rd Brake Light Safety Stars http://www.thesamba.com/vw/classifieds/detail.php?id=1689085


Last edited by yamaducci on Fri Sep 23, 2011 5:29 am; edited 4 times in total
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yamaducci
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PostPosted: Thu Sep 22, 2011 9:50 am    Post subject: Reply with quote

Case Modifications:
More Pics in my Gallery!
De-burred case, lifter bores sleeved, Porsche piston oil squirters, Bob Hoover cam journal modifications and clearancing for 90mm crank. Note oil hole completely through middle cam journal. Pressurized oil comes in from external line to add oil to the 1/2 side of the case.
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Internal case porting above center bearing web and stroker clearancing.
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A good shot of the porsche piston oil squirters from the saddle view. Clearancing for 90 mm crank and case porting as well.
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Case porting, Porsche piston oil squirters, line bore, lifter sleeves / bushings, German pick up tube and Bob Hoover modifications.
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1/2 side cam journal oiling modification (note 1/8" NPT hole between lifter bores) This hole will have pressurized oil going in to aid in oiling the lifter bores and cam journals.
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After the case was remachined to smooth out the oil-pressure relief bore and oil-control bore; I lapped the pistons into the bore with valve grinding compound on a dowel.
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After removing all the oil gallery plugs; the restrictor plug must be reinstalled in some fashion. Here I drill and tap the 4th main bearing to install a drilled out Allen plug. This will restrict the oil going to #4 main.
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Gallery plugs removed from the front of the case.
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Oil cooler drilled for gallery plugs to delete stock cooler.
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Cam bearing saddle gallery modification know as the Bob Hoover Modification; performed by me. Also note the lifter bores bushings / sleeves also have the inner groove cut; Bushings installed by Brother's Machine with a perfect .000" clearance.
This is the 3rd saddle area (next to gear)where the added gallery was drilled (look down into the saddle for the hole).
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Test fitting the new main Mahle Steel backed bearings that have been coated by Calico Coatings.
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Case Notched for second-half Dual Thrust Cam bearing modification. Bearings coated at Calico Coatings, N.C. Also shown are lifter bores sleeved at Brothers Machine.
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Porsche piston oil squirter and case porting.
Bored for 94's
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A good shot of the porsche piston oil squirters from the saddle view. Clearancing for 90 mm crank and case porting as well.
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Inside view of 94mm AA Cylinder in a Case Clearanced for 90mm. Notice the piston squirter hole above the oil gallery hole in the saddle.
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Staring down the 94mm barrel checking out the 911 Porsche Piston oil squirters installed.
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94mm AA Long Cylinders Cut Down to avoid a .500"+ spacer. They were also custom honed to my spec at Brothers machine Shop and measured out to .0001" perfect!
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Udo Becker Tool Steel Lifters
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90mm Full Circle Wedge-Mated Crank; Freshly Re-Balanced Properly at Brothers Machine.
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94mm Wiseco Custom Dished Pistons by Brothers Machine. Balance Checked out perfectly!
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Autocraft needle-bearing rockers get an oiling modification.
Notice the divots on each side of the rocker to allow oil to enter. Spray bars will be added to take advantage of this since they are not oil-pressurized by the pushrods. Rockers are also clearanced for Large K800 Springs and Retainers.
_________________
-John Cox
My 2498 Turbo Re-Build Thread: http://www.thesamba.com/vw/forum/viewtopic.php?p=5578697#5578697
Cox Racing Engines
Class 5-1600's; Stock 1600 to 2498cc Type 1's. Custom Built for you in Maryland
3rd Brake Light Safety Stars http://www.thesamba.com/vw/classifieds/detail.php?id=1689085
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modok
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PostPosted: Thu Sep 22, 2011 11:01 am    Post subject: Reply with quote

The case looks awesome

Speaking of oil holes I wonder how that crank was made. I know he welded over the oil holes but at 90mm stroke..............I wasn't aware that was even possible.
I wonder how it was done
Did you have it magnafluxed?
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yamaducci
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PostPosted: Thu Sep 22, 2011 11:12 am    Post subject: Reply with quote

modok wrote:
The case looks awesome

Speaking of oil holes I wonder how that crank was made. I know he welded over the oil holes but at 90mm stroke..............why not use a 1500 crank?
Did you have it magnafluxed?

It's interesting you bring up the oil holes. This was a Bergmann Special (Unfortunatley) from the late 90's and I believe it was maged but I did have to redrill and chamfer some of the oil holes to clean up the restrictions of welding.
After these photos were taken I was able to polish the mains and journals very nicely to clean them up a bit.
I should add that the crank material and journals in particular are very hard. Broke two drill bits just trying to touch up the oil holes.
_________________
-John Cox
My 2498 Turbo Re-Build Thread: http://www.thesamba.com/vw/forum/viewtopic.php?p=5578697#5578697
Cox Racing Engines
Class 5-1600's; Stock 1600 to 2498cc Type 1's. Custom Built for you in Maryland
3rd Brake Light Safety Stars http://www.thesamba.com/vw/classifieds/detail.php?id=1689085
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BDubVdub
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PostPosted: Thu Sep 22, 2011 11:36 am    Post subject: Reply with quote

Looks incredible so far. Keep us posted
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Gary Massin-Ball
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PostPosted: Thu Sep 22, 2011 12:10 pm    Post subject: Reply with quote

What is that, like a 10cc dish on those 94s?

Hmmmmm.

Gary
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Engle FK-41 with 1.25:1 street style rockers
40x35.5 stock cast single port heads
Single 40mm Kadron w/32vent
Equalizer 5lb pulley
Stock lifters
Stock aluminum pushrods
26mm aluminum oil pump full flow
*Poor mans rack and pinion up front*
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modok
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PostPosted: Thu Sep 22, 2011 2:19 pm    Post subject: Reply with quote

yamaducci wrote:
modok wrote:
The case looks awesome

Speaking of oil holes I wonder how that crank was made. I know he welded over the oil holes but at 90mm stroke..............why not use a 1500 crank?
Did you have it magnafluxed?

It's interesting you bring up the oil holes. This was a Bergmann Special (Unfortunatley) from the late 90's and I believe it was maged but I did have to redrill and chamfer some of the oil holes to clean up the restrictions of welding.
After these photos were taken I was able to polish the mains and journals very nicely to clean them up a bit.
I should add that the crank material and journals in particular are very hard. Broke two drill bits just trying to touch up the oil holes.


Despite all the badmouthing BB gets for those cranks, I used an early 76mm one myself, the welds on the braces is pretty darn good if you ask me. When I mag'd it i didn't find any flaws in the outer welds, no problems at all that way. The welded over oil holes had little cracks in them, but they looked like a flaw from the welding rather than a problem that would get worse. At 90mm stroke seems like those oil holes would be IN the radius, and that is a little spooky, but I don't even know how it was done, maybe there is a trick too it.
Anyway, you already ran that crank for awhile, so you know it will work
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aircooled356
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PostPosted: Thu Sep 22, 2011 3:50 pm    Post subject: Reply with quote

That is a work of art Yamaducci.....and then to turbo it? That's over the top. I've got one of those cranks myself but it has a few more holes in the counterweights though.
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Patiently waiting for my lottery numbers to come up unfortunately. Crying or Very sad Somedayyyyy.
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kielbasa
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PostPosted: Thu Sep 22, 2011 4:33 pm    Post subject: Reply with quote

5.7 seems short. I'd say 5.880 would give perfect ratio
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RockCrusher
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PostPosted: Thu Sep 22, 2011 8:15 pm    Post subject: Reply with quote

kielbasa wrote:
5.7 seems short. I'd say 5.880 would give perfect ratio
I vote for 6.2 for a 1.75 ratio. Holy COW what a wide engine that would be.

RC
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shag55
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PostPosted: Fri Sep 23, 2011 5:19 am    Post subject: Reply with quote

I'm still not a fan of the really long stroke on our motors unless it is for a sand drag car.
All this work looks great and my boys at brothers do a great job but what happened to the head studs? 8mm's?
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yamaducci
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PostPosted: Fri Sep 23, 2011 7:36 am    Post subject: Reply with quote

shag55 wrote:
I'm still not a fan of the really long stroke on our motors unless it is for a sand drag car.
All this work looks great and my boys at brothers do a great job but what happened to the head studs? 8mm's?

Why not a fan? They are awesome!
Too difficult to stuff it in there?
If I was to do it all over again with a New case I would probably see if 10mm studs would work but the 8's have held 30psi of boost.
I would also use a bubble top case for the added clearance and raised decks.
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-John Cox
My 2498 Turbo Re-Build Thread: http://www.thesamba.com/vw/forum/viewtopic.php?p=5578697#5578697
Cox Racing Engines
Class 5-1600's; Stock 1600 to 2498cc Type 1's. Custom Built for you in Maryland
3rd Brake Light Safety Stars http://www.thesamba.com/vw/classifieds/detail.php?id=1689085
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PostPosted: Fri Sep 23, 2011 8:28 am    Post subject: Reply with quote

I've got a 90.2 stroke from dpr sitting right next to some venolia 103's on the shelf just need case and heads. I don't see anything wrong with long strokes.... Jeff denham had a street driven 3liter for a while.
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shag55
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PostPosted: Fri Sep 23, 2011 8:38 am    Post subject: Reply with quote

Not a fan because I've built them and turbos and long strokes = broken trannys or tires that don't hook up. They also pound out the center main if used in higher rpm set ups. 6500 up.
You can make just as much power with a short stroke, it will hook up, tranny will last longer, don't need long rod, don't need long flexing pushrods and will be faster in most cases.
Sorry these are just my opinion. I've preached these for a long time and just recently the trend is to build a short stroke motor in pro mod, like The Baron 74mm and Paradise car with a 70mm
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PostPosted: Fri Sep 23, 2011 8:45 am    Post subject: Reply with quote

Most don't remember but back in the late 80s early 90s Bob Godfreys little orange ghia was running low 9s consistantly and had almost no tranny problems while the other guys were braking them left and right. Bobs motor was a 74x93. It made well over 400hp back then and only had 42x38 SE heads and old a$$ turbo.
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PostPosted: Fri Sep 23, 2011 11:35 am    Post subject: Reply with quote

The short stroke is built for sky high rpms, the huge long stroke has all its potential down low, perfect for a true street car
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yamaducci
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PostPosted: Fri Sep 23, 2011 12:24 pm    Post subject: Reply with quote

Built for torque; Turbo'ed for Top End and re-geared for everything Wink
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My 2498 Turbo Re-Build Thread: http://www.thesamba.com/vw/forum/viewtopic.php?p=5578697#5578697
Cox Racing Engines
Class 5-1600's; Stock 1600 to 2498cc Type 1's. Custom Built for you in Maryland
3rd Brake Light Safety Stars http://www.thesamba.com/vw/classifieds/detail.php?id=1689085
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PostPosted: Mon Sep 26, 2011 5:51 pm    Post subject: Reply with quote

how much boost? where do you get good 90mm cranks?
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VIN
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PostPosted: Mon Sep 26, 2011 6:45 pm    Post subject: Reply with quote

that sh!ts insane!! flame me, but i think id dump a turbo'd subaru in there before spending all that cash on a VW. looks great though, look forward to more progress, and pics.
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shag55
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PostPosted: Mon Sep 26, 2011 6:54 pm    Post subject: Reply with quote

Subbies are for Subarus, sandrails or Pu$$y VWs! You don't see subbie powered VWs out running the VW power plants.
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