Project Beetle !

Ohhh, hopefully I've just located a 2nd hand but unused case cut for 94MM

did have a load of stuff on stand by from CB but they came back with ubber P&P :( ($900:eek:)
 
Easy now
I do have an update for you all.

Since last post I've swapped over the drive shafts on the gearbox what a job that was, a perfect example of get the right tool for the job!, basically they have a big circlip holding them in, I do have a small set of circlip pliers that after 100's of attempts managed to get them off the old box, and was only done when I'd removed the remaining shaft with the diff!(I could get at it better then) but putting them in the new box – forget it 100's a failed attempts I thought I'll get some better pliers!. Luckily Mr snap on had a fantastic ratcheting set on special / I'll have them!, get back to the garage they are held in by 4 in the new box – bosh bosh bosh bosh 5 mins job done, after piggin about for two days!

So shafts in place, now the box has been fitted with new heavy duty mounts and a tranny strap and new boots either side.

Now engine side, I had a slight change of plans – nothing much, I went to see a local guy (rob/judgie @RNJ) and he kinda twisted my arm into needing EFI I/we know one up for sale complete with engine pretty much turnkey, but having no interest was thinking of breaking it up, I was originally only interested in the EFI and a charge cooler he had, but I weighed things up and decided to get the lot (having seen a little vid clip of his helped me with this ;) )I was really wanting to build my own engine, but the price was very good and just in case you haven't noticed I'm struggling to find time to do stuff!. + and probably the main reason 2276 turbo running at full potencial will break my box on a regular basis, so would really want to be spending £k's on a bus box + changing to IRS - which I don't really want to do - don't need any more jobs!

Prior to buying this engine, I had matched the manifolds to my heads – but that's all rather redundant now!

Today I Mock fitted my header and turbo, find two wee probs 1 – turbo doesn't clear the oil lines out of the case, so will have to sort that, and the turbo barely clears the pulley ring for the EFI, so I'll have make a spacer of some sort to place the turbo a couple more mm away.
Now ready for the mock fit of engine to see where & how it'll all fit in the engine bay.


Above pic – gearbox fitted


Above pic – mock up off header & turbo


Above pic – same but with charge cooler too


Above pic – all the odds 'n sods

engine spec:
LONGBLOCK:
New AS41 case full flowed and internally stress relieved
69mm forged/welded c/w crank - dynamically balanced with flywheel/clutch/pulley/crank trigger
Forged Chromoly 12lb flywheel + SCAT Gland Nut
KEP Stage 1 clutch with Black Magic friction disk
Berg Equalizer front pulley
SCAT H-Beam super race rods with Arp bolts - balanced +/- 0.5gram
Raceware 100,000 psi 8mm head studs
Mahle 94mm B&P's - balanced +/- 0.5gram
Total Seal 2nd rings
SCAT 043 Super-D port heads with 42x37mm SS valves
Machined for 7.5:1 CR on 0.060" deck height
Forged 1.25:1 rockers on bolt-up billet 4340 chromo shafts,pro lash caps etc.
3/8" Chromoly push rods
Engle 110 cam on Steel straight-cut gears
30mm Shadek oil pump with CSP full-flow pump cover
External oil filter
CB Performance slimline deepsump

INDUCTION:
OMEX 600 series ECU - fully programmable semi-sequential fuelling and DIS ignition
Magnetic crank trigger ignition
480cc Pico injectors - in custom welded/match-ported CB Performance EFI end castings
Jenvey 54mm Throttle body on custom 2" stainless centre section
CB Performance Billet Wastegate
Hi-Flow intake air filter
Bosch fuel pump
15/8" custom built flanged+merged header system

TURBO:
as previous engine
and now to include PACE water/air intercooler with water pump + heat exchanger + ally header tank

PERFORMANCE:
207rwhp @ 5800rpm @ 20psi boost on regular Super Unleaded 97Octane pump fuel
or 150rwhp @ 1bar - both at steady intake temps less than 60deg C
Fill the charge cooler with ICE and it'll do more…!


This is an in car vid clip with engine – bad sound / mute it – watch the speedo :)
 
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I have been managed to spend some time in the garage.
just a mock up so I can fit bits & pieces.

welded a crack I'd put in one of the drive shaft tubes getting it off the old gearbox:p
stuck engine in / mock fit
drilled holes to place for coil pack, sensors, loom, fuel line, altenator stuff and ext. oil cooler.
removed frame for the drivers seat that was sitting the seat a bit too high - its a 5GT turbo seat that is wider than std seat, well the frame work is, may replace it with a bucket seat - wait and see on that one.
may need to relocate the head temp sender, the wiring is right up against the exhaust.

anyway a rare pic of my beetle with an engine in it!! :eek:

 
had a quick couple of hrs in the garage tonight.
mock fit of the oil cooler.
messed about with the front seat, for some weird reason the mig wasn't sharing the gas, so duff welds, need to sort and weld in place properly. removed the lugs on the sliders so the seat will be removable from car when welded in ;)
 
collisster said:
I think its just cut out and stuck ontop of the distributer, if thats the correct name for the part
Click to expand...
Some do put a can over their coil. However as I've got a nice new shiny coil I havent.

Some also use a can as a catch tank from their oil breather. I've got a mini filter on it, but some smeg still gets out.
 
Today's efforts:

Sorted the damn seat out at last :rolleyes:

Made a bracket out of a number plate blank to hold the ECU + mocked the fusebox & relays

Also mocked the fuel pump / coil mount came in exceedingly useful :)







Happy Christmas !!
 
I've been up to:

Fit r/brake pipes & hoses

Fit r/wheel bearings, fine one side not the other / doesn't want to go in all the way so need to remove & re-fit - BIG PITA, possibly gearbox out again for this, not a huge drama as engine will be coming out again anyway - but would be better if I didn't have to!

Fit rear driveshaft seal to the one side I don't have to pig about with now :rolleyes:

Decided to strip all the underseal off the inner rear wheel arches few rust spots thought I'd nip in the bud. most of it came off easily with a screw driver.

Sorted out the electrics under the bonnet re-fit it all de-tangle / fit light/hazzard/wash wipe, fusebox, re-routed interior light wiring, fit wiper arm motor, arial and changed rubber tubes to f/lights.
couldn't find the interior light so sourcing another and decided to get another speedo as mine is colour coded to it's previous colour (red/white)

Prepped fuel tank for paint will paint after I've sorted out the new enlarged fuel outlet & return.

Thats it folks :)
 
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