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Another Type 4 Turbo Thread

Posted: Wed Apr 26, 2006 9:08 am
by Sandeep
With all of the type 4 turbos that folks on this forum are building, and people like the two Jonas's showing what can be done with a some creativity, I thought I would post my type 4 turbo specs.

Engine:

- Type 4 2.0 GA series engine, stock, has not been rebuilt, from a '73 914, using stock head gaskets
- CB performance dry sump oil pump with 8 litre oil tank
- 96 plate mesa cooler with oil T-stat
- FAT Performance 911 cooling system with custom directional vanes inside shroud for much improved air distribution
- CSP 1.5L breather box
- BAS 21152 header system slightly modified for turbo attachment

Intake / Fuel System:

- Custom intake system using 914 2.0 runner castings placing injectors in stock position
- 52mm Ford Taurus TB with IAC valve
- 4 x 40 Lb/hr (420 cc/min) Accel fuel injectors with custom bungs by www.vdubengineering.com
- MSD 43 GPH (2713 cc/min) HP fuel pump
- Carter 30 GPH (1893 cc/min) LP fuel pump
- MSD Boost sensitive fuel pressure regulator
- 1.0 L custom made surge tank
- 5/16" fuel feed line, stock return line to fuel filler neck
- 9/16" ID billet fuel rails with -6AN fittings

Electronics / Ignition:

- Megasquirt V2.2 board running MS&S - Extra
- FORD EDIS ignition system
- 8.5mm custom ignition wires
- Innovative LC-1 wideband O2 sensor and controller (not installed yet)
- Custom made 8 channel datalogger ( 4 CHT, 911 fan intake temp, ambient air temp, oil temp, rear wheel speed) Have wired up my VDO CHT gauge to this logger to show the highest CHT of the 4 cylinders, updated every second

Turbo system:

- TD04L-13T from a 2003 WRX (360-400 cfm @ 13.5 psi) stock
- PWR air to water barrel intercooler (4" x 6", 390 cfm rated to 270 hp)
- 2.25" piping from turbo to intercooler to TB
- Tilton differential/oil cooler scavenge pump to scavenge low mounted turbo
- Ford F150 Lightning intercooler water pump (not installed yet)
- Yamaha YZ125 radiator X 2 (not mounted yet)
- HKS SSQV BOV

Progress:

Everything is installed and wired up except for the LC-1 and water cooling system for the intercooler. I am just waiting for my ignition wires to come in before I can install them and perform a N/A start up and idle to make sure the MS is working. Hope to start engine in a week.

Next step is to weld up a 3" dia down pipe (not too difficult) and then install the LC-1. I am not sure about a muffler at this time as I don't think there is room for one !

Then install the YZ125 radiators and water pump for the intercooler

I am looking for about 160 - 180 fwhp for this summer (hope the motor stays together) and then will look at opening up the case winter 2006/2007 if anything needs attention.

Wish me luck !

These pics were taken about 3 weeks ago, engine bay is all tidy now.

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Sandeep

Posted: Wed Apr 26, 2006 9:57 am
by aircooledtechguy
VERY nice work!! Looks outstanding and a very clean installation thus far. Keep up the good work. Thanks for the pics!!

Posted: Wed Apr 26, 2006 10:05 am
by Rescue912
Wow, keep us posted ...

Posted: Wed Apr 26, 2006 10:43 am
by type3
Cool, looking good! :D


cheers,
type3

Posted: Wed Apr 26, 2006 2:31 pm
by jonas_linder
Looks great!!

The only problem I see is the stock head gaskets :?

Posted: Wed Apr 26, 2006 2:55 pm
by jonas n
Really SWEET header! :D the headgaskets is not a big problem, just change them every week :wink: of my own experience they work with boost up to 0,9bar but they constantly blow with 1,4 bar of boost.. (dont really know those numbers in PSI)

Posted: Wed Apr 26, 2006 4:52 pm
by Eddie Brown
Damn. That looks clean. I was possibly thinking of using the same header...

Good luck!

Wooooooooooooosh

Posted: Wed Apr 26, 2006 6:39 pm
by Steve Arndt
did you cut the body for fuel rail and injector clearance?

Posted: Thu Apr 27, 2006 7:33 am
by Sandeep
Thanks for all of the comments.

The reason I am using the head gaskets is because the motor has never been apart, and still runs strong. If I blow a gasket, then that will give me a reason to pull the motor and upgrade the internals a bit :lol:

I don't plan on running crazy boost this summer, only about 10 psi max.

I did have to cut the "shelves" on each side of the engine bay for rail / injector clearance, only because the engine "rocks" clockwise (when looking from the rear). If the engine did not rock, then the clearancing would be really minor. I had to cut about 1.5" into the shelves on each side.

A solution would be to re-weld the shelves in about 1" higher than their original position, will do this winter 2006/2007

Still have not received my plug wires .... just itching to start this up ! :twisted:

Sandeep

Posted: Thu Apr 27, 2006 2:21 pm
by Wally
Like other have already mentioned: very clean install! I always have a problem with that :oops:
The location of the turbo in combination with the Ahnendorp header looks to be the most logical one. Its also a very good one IMHO, as the heat can easily get away from the turbo in that spot.
You seem to have used all the 'right', again imho.. :wink:

So, it must work very well :D

BTW, did you make the case-ventilation part in the dizzy location yourself?
(very nice)

Posted: Thu Apr 27, 2006 6:28 pm
by MattKab
Looks great Sandeep, awesome spec. The whole Beetle is impressive!

More pics, really good to :shock: at.

Will you be resuming your cooling tuning/datalogging? Now, after turning up the heat abit? All in good time, eh? :wink:

Matt

Posted: Fri Apr 28, 2006 7:46 am
by Sandeep
Thanks for the comments :)

The future goal of this engine will be about 250 hp. I have an idea of what it will take to make this amount of hp with a T4, but will be happy with 160-180 fwhp for now.

I want to wait to see what Jake has up his sleeve with his turbo T4 program.

The aluminum dizzy plug was made by www.vdubengineering.com and is really a nice peice. The bottom part that fits in the case is spec'd to the dimensions of a 050 dizzy in diameter, including the o-ring seal, and is drilled all the way through and tapped with a 3/8" NPT. A -8AN fitting with 1/2" ID pushlok hose feeds into the CSP breather.

I am still unsure what to do with the 2 top vents that once were connected to the tops of the carbs I had. Do I just put a filter on the opennings or do I cannect them to the intake pipe of the turbo ?

I hope the refinements I made with the 911 cooling directional vanes will be enought with the extra heat but the logger is ready to go .... STILL waiting for ignition wires. :x

Will post more pics and some video when this thing is ready to fire up !

Sandeep

Posted: Fri Apr 28, 2006 1:41 pm
by Sandeep
GOT THE IGNITION WIRES IN THE MAIL ! :D

This will be a very interesting weekend for sure.

Sandeep

Posted: Fri Apr 28, 2006 4:39 pm
by jonas_linder
Sandeep wrote:Thanks for the comments :)

The future goal of this engine will be about 250 hp. I have an idea of what it will take to make this amount of hp with a T4, but will be happy with 160-180 fwhp for now.

I want to wait to see what Jake has up his sleeve with his turbo T4 program.

The aluminum dizzy plug was made by www.vdubengineering.com and is really a nice peice. The bottom part that fits in the case is spec'd to the dimensions of a 050 dizzy in diameter, including the o-ring seal, and is drilled all the way through and tapped with a 3/8" NPT. A -8AN fitting with 1/2" ID pushlok hose feeds into the CSP breather.

I am still unsure what to do with the 2 top vents that once were connected to the tops of the carbs I had. Do I just put a filter on the opennings or do I cannect them to the intake pipe of the turbo ?

I hope the refinements I made with the 911 cooling directional vanes will be enought with the extra heat but the logger is ready to go .... STILL waiting for ignition wires. :x

Will post more pics and some video when this thing is ready to fire up !

Sandeep
Put some kind of vaccum on those ports or you will have oil everywhere :( In the filter before the turbo will work! In the downpipe with the "v8" style connectors will work too ;)

Posted: Sat Apr 29, 2006 2:26 pm
by Eddie Brown
Hi Sandeep. I was wondering if you have any pics of the parcel tray area?.

Looks sweet.

E.