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GoEverywhere
Samba Member
Joined: December 13, 2020
Posts: 893
Location: Portland, OR
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 Posted: Thu Nov 07, 2024 9:33 am Post subject: Power nap: On building a 400HP Riviera Camper. |
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So in the B32 thread E1 said he wants more 'race Vanagon' content... So here we go...
Meet my 1980 Riviera Camper, Vanny DeVito.
When I purchased it it was your usual bone stock 2.0L aircooled Vanagon... Which blew it's engine on it's very first trip away from home.
I grew up in a mechanical family, and I've been building hotrods since before I could drive them, my Vanagon is actually the NEWEST car I've ever owned. So I'm used to hiccups and breakdowns. Comes with the territory.
I've always lived by the motto 'anything worth doing is worth wildly overdoing' when building my rides, and this was no exception.
So that engine came out and was replaced by a 150HP 2.2L aircooled on Megasquirt that did me fine for the next few years... Until April of this year, when it snapped a crank clean in two and locked up hard!
That engine was fine, but it was still not FAST. Not stock slow, but slower than my gasoline fueled heart wanted. So THIS round I decided to Subaru swap. But I hate doing things the same way everyone else does, so I wasn't going to go with the standard naturally aspirated 2.5L... No....
I decided I was going to import a JDM(Japanese Domestic Market) EJ20x TURBO engine from their Legacy GT and WRX STi models.
Due to some interesting emissions laws in Japan they replace motors between 40 and 60k miles, so they can be easily had with very low miles exported from Japan!
A surprisingly fast 4 days later, this showed up in my driveway...
The EJ20x has some notable differences from the American market models that were ideal for building a big power engine.
They were factory rated at 280HP, and come stock with a forged crank, rods, and piston crowns as well as big valve heads, TGV Deletes, equal length headers, all at a power producing 9.5:1 compression ratio... And the cherry on the sunday: A fancy twin scroll turbocharger capable of full boost by only 2200RPM.
I tore it down to refresh gaskets and ensure everything was good before installing ARP studs, plasma coil packs, bigger cams, and porting the heads.
After pulling the trans and doing some upgrades to help it cope with it's new source of power in it went!
It installed like most any other Subaru engine using the RMW kit... I had to fabricate my downpipe and exhaust myself as there was nothing off the shelf that fit the JDM turbocharger. But I'm handy with a welder so no biggie!
Because my chassis was aircooled, I had to install all the watercooled piping and radiator, which wasn't terribly difficult, and has been documented elsewhere...
Finally, no turbo build worth its weight is without a front mount intercooler... Rear mount intercooler? Well, an intercooler anyway...
I mounted it under the rear bumper, which works. But honestly the airflow there could be better, it will heat soak on a really long pull while in boost. intake temperatures are still ok, but I'll likely switch to a air/water intercooler in the future.
And what tuner build doesn't need a cold air intake provided by SmallCar?
I opted to forgo the Subaru ECU and went straight to Megasquirt for tuning. I went slowly on my tune, first about 300HP, then slowly pushing it upwards to see how it reacted. I ran the stock 565cc injectors out of flow at about 340HP and ALMOST left it at that level, after all a 340HP Vanagon? Awesome... But then I remembered my motto. And overdid it. A set of 1000cc injectors later, and a bit more tuning and I had it at 380HP... And thats when the clutch let go!
More power than the stage 1 clutch could handle, it would just spin at RPM. So back apart it came for a clutch upgrade.... A new Kenedy Stage 3 clutch and 6 puck disc and off we went again. This time it held beautifully and it was time for another dyno pull!
I pulled a best of 407HP at 6984RPM with a peak of 354Ft/lb of torque!
Since I was told the trans should be ok till about 400HP I'm leaving it there for now... The engine very likely has more to give, but the trans doesn't. Maybe I'll go farther in the future, after all how cool does a 500HP Vanagon sound???
Finally, in celebration I added a hint of what's inside...
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shagginwagon83 
Samba Member
Joined: February 07, 2016
Posts: 4318
Location: SWVA
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| Posted: Thu Nov 07, 2024 9:40 am Post subject: Re: Power nap: On building a 400HP Riviera Camper. |
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Ohh very nice!! Love the turbo badges.
So you're running an upgrade Vanagon trans that is said to support 400hp? Or is it a Subaru transaxle?
_________________
"Jo Ann" - '83.5 Westfalia EJ22e w/Peloquin
Instagram: @joannthevan |
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GoEverywhere
Samba Member
Joined: December 13, 2020
Posts: 893
Location: Portland, OR
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| Posted: Thu Nov 07, 2024 9:42 am Post subject: Re: Power nap: On building a 400HP Riviera Camper. |
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| shagginwagon83 wrote: |
Ohh very nice!! Love the turbo badges.
So you're running an upgrade Vanagon trans that is said to support 400hp? Or is it a Subaru transaxle? |
Its the VW Aircooled 091 4 speed, I dropped it at a local trans builder that has done my race cars for YEARS and said my target was 350-400HP. Its been in there about 6 months now, and so far its doing just fine... I don't BEAT on it, but I've done a few hard launches and I've not broken anything yet  If I do, I'll likely swap to a Subie STi trans as they're designed for more power than the old VW is obviously! |
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shagginwagon83
Samba Member
Joined: February 07, 2016
Posts: 4318
Location: SWVA
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| Posted: Thu Nov 07, 2024 9:48 am Post subject: Re: Power nap: On building a 400HP Riviera Camper. |
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| GoEverywhere wrote: |
Its the VW Aircooled 091 4 speed, I dropped it at a local trans builder that has done my race cars for YEARS and said my target was 350-400HP. |
That's awesome! Not gonna lie I am kinda interested... My EJ22 is old and strong but I love the idea of just 200hp. And a turbo! Thanks for sharing 
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"Jo Ann" - '83.5 Westfalia EJ22e w/Peloquin
Instagram: @joannthevan |
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GoEverywhere
Samba Member
Joined: December 13, 2020
Posts: 893
Location: Portland, OR
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| Posted: Thu Nov 07, 2024 9:54 am Post subject: Re: Power nap: On building a 400HP Riviera Camper. |
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| shagginwagon83 wrote: |
| GoEverywhere wrote: |
Its the VW Aircooled 091 4 speed, I dropped it at a local trans builder that has done my race cars for YEARS and said my target was 350-400HP. |
That's awesome! Not gonna lie I am kinda interested... My EJ22 is old and strong but I love the idea of just 200hp. And a turbo! Thanks for sharing |
Even if you just dropped it in and ran this engine as-is its 280HP, which is obviously PLENTY for a van that came with between 67-112HP stock There are a few gotchas I glossed over a bit if you were to do a 'normal' install with it... You'd either need to run a Japanese ECU (Or megasquirt like mine) or you lose exhaust cam control. It still WORKS with a US ECU but you lose some down low torque due to no exhaust AVCS... Its normally a drive-by-wire throttle body in a weird offset location with the JDM intake. You can swap for a US intake with drive-by-cable to solve that. And finally, you're on your own for figuring out the downpipe and exhaust. Nothing exists to use it in a Vanagon(Very little does even for swapping them into US cars!). But honestly, its a FANTASTIC swap even without going crazy like I did. |
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Shonandb
Samba Member
Joined: January 12, 2019
Posts: 2042
Location: Vancouver, BC
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| Posted: Thu Nov 07, 2024 9:56 am Post subject: Re: Power nap: On building a 400HP Riviera Camper. |
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Sweet build! Did you upgrade your brakes too? What about the suspension?
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76 Westy with a 2.5L Subaru SOHC + Vanagon (010) Automatic Transaxle
Build & Trip Thread: https://www.thesamba.com/vw/forum/viewtopic.php?t=758760
Previous 1973 Panel Bus:
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GoEverywhere
Samba Member
Joined: December 13, 2020
Posts: 893
Location: Portland, OR
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| Posted: Thu Nov 07, 2024 10:01 am Post subject: Re: Power nap: On building a 400HP Riviera Camper. |
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| Shonandb wrote: |
| Sweet build! Did you upgrade your brakes too? What about the suspension? |
I did, I've got GoWesty's big brake kit with slotted vented rotors on the front, and will be going disc rears here in the near future. All that go needs a bit more stop than stock!
The suspension is upgraded as well, airbags on all 4 corners with Strange Engineering adjustable shocks. new adjustable ball joints and poly bushings as well. |
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Crooked Designer
Samba Member
Joined: March 22, 2018
Posts: 573
Location: Chicago, IL
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| Posted: Thu Nov 07, 2024 10:01 am Post subject: Re: Power nap: On building a 400HP Riviera Camper. |
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I love it when people have the skill set to make something incredibly difficult seem incredibly easy. Well done. Also, love the name so much. hahaa.
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'85 Westy full camper, Subaru 2.5L, 5 speed SubiGears + 5speedbus shifter kit |
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GoEverywhere
Samba Member
Joined: December 13, 2020
Posts: 893
Location: Portland, OR
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| Posted: Thu Nov 07, 2024 10:05 am Post subject: Re: Power nap: On building a 400HP Riviera Camper. |
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| Crooked Designer wrote: |
| I love it when people have the skill set to make something incredibly difficult seem incredibly easy. Well done. Also, love the name so much. hahaa. |
Thats it in a nut shell, its not HARD when you know what you're doing, but the road to gaining those skills has taken a lifetime. I literally started to work on hotrods with my Dad, Grandpa, and uncles when I was 11. Bought my first one when I was 14(And second when I was 15...) and had it ready to drive by the time I got my license at 16. I sorta lost count of how many Ive built a while back but I think this one is like 35 or 36 not including engine builds I've done for friends over the years... In my peak in my 20's I was building them about 5 a year and flipping them to fund the next one. |
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Bulli Klinik
Samba Member
Joined: January 16, 2005
Posts: 2208
Location: Bulli Klinik, Colorado Springs
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| Posted: Thu Nov 07, 2024 10:11 am Post subject: Re: Power nap: On building a 400HP Riviera Camper. |
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I’d like to see the details of your air bag installation. Perhaps you can start a thread about that, if you get the chance.
Awesome engine conversion!
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PM me about quality metal-work on your vehicle.
Mike K
Bulli Klinik
Colorado Springs |
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GoEverywhere
Samba Member
Joined: December 13, 2020
Posts: 893
Location: Portland, OR
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| Posted: Thu Nov 07, 2024 10:15 am Post subject: Re: Power nap: On building a 400HP Riviera Camper. |
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| Bulli Klinik wrote: |
I’d like to see the details of your air bag installation. Perhaps you can start a thread about that, if you get the chance.
Awesome engine conversion! |
I should probably get that documented as well. It was a long road of discovery, I went through 3 different versions before settling on the setup I have now. Thats another one of those 'have to fab yourself' sorta things as there's not a lot out there that fits the Vanagons and what does really doesn't offer a huge range of motion. I've got 11 inches of travel in the front, enough to go from slightly above stock height to sitting on the seat boxes. |
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Crooked Designer
Samba Member
Joined: March 22, 2018
Posts: 573
Location: Chicago, IL
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| Posted: Thu Nov 07, 2024 10:22 am Post subject: Re: Power nap: On building a 400HP Riviera Camper. |
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| GoEverywhere wrote: |
Thats it in a nut shell, its not HARD when you know what you're doing, but the road to gaining those skills has taken a lifetime. |
Reminds me of a famous designer's quote "It took me a few seconds to draw it, but it took me 34 years to learn how to draw it in a few seconds."
I'd love to see a video of that thing moving fast.
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'85 Westy full camper, Subaru 2.5L, 5 speed SubiGears + 5speedbus shifter kit |
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E1
Samba Member
Joined: January 21, 2013
Posts: 8245
Location: Westfalia, Earth
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| Posted: Thu Nov 07, 2024 10:26 am Post subject: Re: Power nap: On building a 400HP Riviera Camper. |
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Utterly, mind-blowingly FABULOUS.
Thanks for taking the bait, brilliantly done, WICKED! 
And now I wanna know your tranny guy. Hewland race gearboxes were long built on VW cases on cars with even more power, so knew it could be done — and Man, does our niche ever need it!
Well done, will peruse your OP more closely asap.
_________________
1984 Westfailure/2.1 Digijet/5.43 Ring & Pinion/Peloquin/D-rated BFG KO2s
AI has spoken to further illiteracy, to steal, to cheat, and to replace humans
"Adding power makes you faster on the straights.
Subtracting weight makes you faster everywhere." — Colin Chapman |
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GoEverywhere
Samba Member
Joined: December 13, 2020
Posts: 893
Location: Portland, OR
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| Posted: Thu Nov 07, 2024 10:37 am Post subject: Re: Power nap: On building a 400HP Riviera Camper. |
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| E1 wrote: |
Utterly, mind-blowingly FABULOUS.
Thanks for taking the bait, brilliantly done, WICKED!
And now I wanna know your tranny guy. Hewland race gearboxes were long built on VW cases on cars with even more power, so knew it could be done — and Man, does our niche ever need it!
Well done, will peruse your OP more closely asap. |
He's one of those fabled 'old guys' you hear about in hushed whispers. He owned a transmission shop for years here in the Portland suburbs where he's done 20 or so transmissions for me, but now he just builds the occasional trans outa his home shop. He's getting up there in years, so I'll probably have to get to building my own here soon as this MIGHT be the last one he does for me. |
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GoEverywhere
Samba Member
Joined: December 13, 2020
Posts: 893
Location: Portland, OR
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| Posted: Thu Nov 07, 2024 11:48 am Post subject: Re: Power nap: On building a 400HP Riviera Camper. |
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| Crooked Designer wrote: |
| GoEverywhere wrote: |
Thats it in a nut shell, its not HARD when you know what you're doing, but the road to gaining those skills has taken a lifetime. |
Reminds me of a famous designer's quote "It took me a few seconds to draw it, but it took me 34 years to learn how to draw it in a few seconds."
I'd love to see a video of that thing moving fast. |
I've been meaning to get out and shoot some... I'll get that sorted and get back to ya  |
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ALIKA T3
Samba Member
Joined: July 30, 2009
Posts: 7179
Location: Honolulu,Hawaii and France
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| Posted: Thu Nov 07, 2024 11:59 am Post subject: Re: Power nap: On building a 400HP Riviera Camper. |
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| GoEverywhere wrote: |
And what tuner build doesn't need a cold air intake provided by SmallCar?
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Hello!
lovely build, but I have a question, is the intake manifold flipped 180°?
Makybe more pics of the engine bay would be nice
_________________
Silicone Steering Boots and 930 Cv boots for sale in the classifieds.
Syncro transmission upgrade parts in the Classifieds.
Subaru EJ22+UN1 5 speed transmission
http://www.thesamba.com/vw/forum/viewtopic.php?t=416343
Syncro http://www.thesamba.com/vw/forum/viewtopic.php?t=4...num+gadget |
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GoEverywhere
Samba Member
Joined: December 13, 2020
Posts: 893
Location: Portland, OR
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| Posted: Thu Nov 07, 2024 12:07 pm Post subject: Re: Power nap: On building a 400HP Riviera Camper. |
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| ALIKA T3 wrote: |
| GoEverywhere wrote: |
And what tuner build doesn't need a cold air intake provided by SmallCar?
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Hello!
lovely build, but I have a question, is the intake manifold flipped 180°?
Makybe more pics of the engine bay would be nice |
Doh, I did forget a final engine bay shot didn't I?? Don't mind my horrible wiring mess this was pre-cleanup...
The intake is NOT flipped, its still running stock orientation. That hose runs UNDER the manifold to the inlet of the turbocharger.
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ALIKA T3
Samba Member
Joined: July 30, 2009
Posts: 7179
Location: Honolulu,Hawaii and France
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| Posted: Thu Nov 07, 2024 12:30 pm Post subject: Re: Power nap: On building a 400HP Riviera Camper. |
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Thank you!
Oh wow, crazy it runs under, very convenient!
Do you know if the timing belt accessories like rollers and and are the same with the EJ25 DOHC found here in the US?
I gotta do a timing belt on one of these EJ20 soon for a customer, I'm wondering what car model to input to look for diagrams and part numbers....
_________________
Silicone Steering Boots and 930 Cv boots for sale in the classifieds.
Syncro transmission upgrade parts in the Classifieds.
Subaru EJ22+UN1 5 speed transmission
http://www.thesamba.com/vw/forum/viewtopic.php?t=416343
Syncro http://www.thesamba.com/vw/forum/viewtopic.php?t=4...num+gadget |
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GoEverywhere
Samba Member
Joined: December 13, 2020
Posts: 893
Location: Portland, OR
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| Posted: Thu Nov 07, 2024 12:34 pm Post subject: Re: Power nap: On building a 400HP Riviera Camper. |
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| ALIKA T3 wrote: |
Thank you!
Oh wow, crazy it runs under, very convenient!
Do you know if the timing belt accessories like rollers and and are the same with the EJ25 DOHC found here in the US?
I gotta do a timing belt on one of these EJ20 soon for a customer, I'm wondering what car model to input to look for diagrams and part numbers.... |
If its a JDM EJ20x like mine(or its close sibling the EJ20y), the US market EJ25 belt kit works. If its an older JDM market EJ20 *MOST* will use the EJ25 belt kit fine, but some have slightly different setups so YMMV... |
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space
Samba Member
Joined: November 19, 2017
Posts: 809
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| Posted: Thu Nov 07, 2024 1:49 pm Post subject: Re: Power nap: On building a 400HP Riviera Camper. |
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Which Megasquirt model did you use?
I also have a JDM but 2.5
Beautiful build btw
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82 westy
w:
2.5 JDM Subie
Rear discs |
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