My Megasquirt build, Volksbugly

[MarioVelotta]

Very nice! Your going to have so much more fun I just bought an aluminum case for my motor. I think it will hold up better to my right foot

[volksbugly]

oh yeah its just a stock vw case, I think its an AE ... I was going to get a auto lina case but I put the 500+$ towards turbo



Oh yeah and my turbo I'm rebuilding it, and having it re balanced, and welding up the internal wastegate

[volksbugly]

Ok here are some updates:

The motor is now built, few things changed. I went with an AutoLinea bubbletop and Scat forged race rockers 1.25
I also went with raceware head bolts

https://picasaweb.google.com/1078300117 ... directlink

I didn't build the motor I had the local VDub shop build it. I wan't my first rebuild to be a stock rebuild maybe a 1776, but something thats simple.

ok here is the porn:
Heads: DRD L5 Turbo Heads






video:
https://picasaweb.google.com/1078300117 ... 0214765650

Case: AutoLinea












Exhaust:CB Hideaway Turbo Header








Wastegate flange





Head Studs: Raceware



Rockers: 1.25 Scat

[volksbugly]

Exhaust Porn

Video of finished exhaust

So the exhaust has 4 EGT sensors mounted, a relocated wastegate at the collector and its been Cerecoated. The Cerakote is the same thing Harley Davidson uses and its suppose to give aprox 15% drop in external temperature, ie keeps the heat in!

Exhaust Album

If you cant access the album, let me know and I'll make it fully pubic, but anyone with the link should be able to get to it.

A few album image teasers

[volksbugly]

exciting times! Motor is in...!







oh and my muffler
flow master dbx

[Steve Arndt]

Subscribed. Nice looking work.

[volksbugly]

Subscribed. Nice looking work.

Thanks! this has been a long build. It was in the works 2 years prior to the first post here. I just looked and my first post was in 2011... wow! time flies

[volksbugly]

more photos of mockup

[volksbugly]

one more strait on.

[terryly]

Nice set up volksbugly! I will be watching this closely. Are those throttle pulleys from a synclink ? or something else you have going on.
Terry

[volksbugly]

Nice set up volksbugly! I will be watching this closely. Are those throttle pulleys from a synclink ? or something else you have going on.
Terry

Yeah its a synclink system. Its going to hit the CB Breather, so I'm going to have it modified to clear the cable.

[volksbugly]

Updates soon:

Current status:

on the road
failed o2 sensor, new one just came in today.
changed wastegate spring from 5 lbs to 7lbs
contemplated messing with duty cycle, probably will but want to get some tuning done first, Some rough spots and its tuned like a race car. I need to have some slower onset timing down low and potentially more air on idle.

[Clonebug]

5-7 lbs. is a good level to work the bugs out. I would stay there for a while till you get your idle, cruise and boosted tuning nice and steady.
Stay on the conservative side for now just to be safe.
I found an engine is pretty tolerant of tunes and it will still run pretty good. Once you drive it for a while you will notice the little things like a little surge at 1800-2200 light load cruising.......slight hesitation off idle.... those are what you want to work on once you get the feel of the engine.
Just do a lot of "Save As".

Most boost controllers are set up when the ground signal from the ECU is cut they are pass through and the wastegate sets the boost level.
I have mine that way. I started at 40% after 50-60% tps and anything under that is 90%.
Depending on your turbo and when it puts out boost you can only try the numbers for DC. Start out lower and work your way up.
On mine 67% gives me 22 lbs boost and my full boost hits at 3800 rpm.
60% gave me around 15-17 lbs so that will give you an idea of the sensitivity.

I have a switch on the dash that allows me to turn off boost control and gives me 6 lbs. wastegate pressure.
Find out at what boost level you can run without IC or WI and set it there for a fail safe.
Set the timing so it will drive on that boost level without detonation and you will have a nice driver where you can let someone else drive it without hurting it.

[volksbugly]

Great idea with the switch, and yeah thats exactly what I'm doing getting my base tune worked out. 7lb spring

https://picasaweb.google.com/lh/photo/u ... directlink

[Clonebug]

I have two switches on my dash.....one cuts the ground to the boost controller and the other cuts the ground signal to the Hobbs switches to activate the WI.

Turn them both off and I still have 6 lbs boost and great power with no worries about running out of water and/or detonation.

Here you can see the two switches just above the stereo......the lights indicate low water=red, 1.0 gph nozzle=blue light, 2.0 gph =green light and yellow light= launch control activated.



I can also leave the water on since the 1.0 gph nozzle comes on at 6 lbs and the 2.0 gph nozzle comes on at 10 lbs. boost.
Each nozzle has their own separate Hobbs switch and solenoid.



No blubbering or drowning at light boost loads while climbing mountain pass grades where you need just a little boost but not full water.