Happy birthday Wally and congrats with the impressive results on the dyno. There is potential there for whole lot more when you get everything under control and increase the boost.
Take care my friend and enjoy the day and remember: pedal to the metal!
-K-
2,4 type4 turbo 500hp -on gasoline- goal
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Wally
- Posts: 4563
- Joined: Mon Oct 28, 2002 12:01 am
Re: 2,23 ltr type 4 turbo build-up
First test runs at our local track and national event at Wanroij, Netherlands. Just a 125meter 'track'.
It was fun nonetheless. Boost set at 0.65 bar
Good test as some small issues came up, but we drove to and from the event on our own wheels without problems
It was fun nonetheless. Boost set at 0.65 bar
Good test as some small issues came up, but we drove to and from the event on our own wheels without problems
T4T: 2,4ltr Type 4 Turbo engine, 10.58 1/4 mi
www.apfelbeck.nl
"Mine isn't turbo'd to make a slow engine fast, but to make a fast engine insane" - Chip Birks
www.apfelbeck.nl
"Mine isn't turbo'd to make a slow engine fast, but to make a fast engine insane" - Chip Birks
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buguy
- Posts: 6209
- Joined: Wed Jan 26, 2005 8:53 pm
Re: 2,23 ltr type 4 turbo build-up
Sounds great!!
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Udo Airbus
- Posts: 196
- Joined: Thu Oct 23, 2014 6:22 am
Re: 2,23 ltr type 4 turbo build-up
wauw gaaf Walter! Very cool!
VW T1 1964 - Mouse Grey - Pearl White OG paint
Bagged, Porsche steeringrack/brakes..IRS, 1915cc
Bagged, Porsche steeringrack/brakes..IRS, 1915cc
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Wally
- Posts: 4563
- Joined: Mon Oct 28, 2002 12:01 am
Re: 2,23 ltr type 4 turbo build-up
Unfortunately, the one-off cast alu cylinders proved to be too soft/weak as the material was compressed somewhat probably and also the bore openend up top and as a result of this finally a desastrous leak occured, which drew in fresh air on suction and made a torch of the mixture in that cylinder:
Damage is one cylinder, one head and one Raceware stud. Pistons are (fortunately) in great shape however.
All bores had a pretty big taper, so material was obviously not strong enough despite 9mm (!) wall thickess.
The taper also explained the somewhat excessive blow-by I encountered under boost..
New cylinders will be 98mm birals from AA with new regular JE piston rings.
I could order 1 new stud from Raceware (tnx guys!) and Jacob fixed the head: awesome!
The 98mm AA's are just 3,5mm wall thickness, so I am a little concerned there, but 94mm type 1's aren't much thicker afaik, so fingers crossed...
Learned something the hard way, but other (to me new) things in the engine did work out very well, so lets move on!
Damage is one cylinder, one head and one Raceware stud. Pistons are (fortunately) in great shape however.
All bores had a pretty big taper, so material was obviously not strong enough despite 9mm (!) wall thickess.
The taper also explained the somewhat excessive blow-by I encountered under boost..
New cylinders will be 98mm birals from AA with new regular JE piston rings.
I could order 1 new stud from Raceware (tnx guys!) and Jacob fixed the head: awesome!
The 98mm AA's are just 3,5mm wall thickness, so I am a little concerned there, but 94mm type 1's aren't much thicker afaik, so fingers crossed...
Learned something the hard way, but other (to me new) things in the engine did work out very well, so lets move on!
T4T: 2,4ltr Type 4 Turbo engine, 10.58 1/4 mi
www.apfelbeck.nl
"Mine isn't turbo'd to make a slow engine fast, but to make a fast engine insane" - Chip Birks
www.apfelbeck.nl
"Mine isn't turbo'd to make a slow engine fast, but to make a fast engine insane" - Chip Birks
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andy198712
- Posts: 2433
- Joined: Wed Apr 13, 2011 1:01 pm
Re: 2,23 ltr type 4 turbo build-up
Nasty way to learn 
When your pushing the design of these engines to new highs I guess you’ll find some limits of certain parts.
Keep up the good work
When your pushing the design of these engines to new highs I guess you’ll find some limits of certain parts.
Keep up the good work
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rubenski
- Posts: 2033
- Joined: Mon Jun 30, 2014 3:28 am
Re: 2,23 ltr type 4 turbo build-up
I cracked 3 pistons, I know the feeling!
Its a PITA but learn the lesson and move on!
Greetz!
Its a PITA but learn the lesson and move on!
Greetz!
Better to be blown than to suck!
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mactaylor
- Posts: 33
- Joined: Tue Jan 18, 2011 12:50 pm
Re: 2,23 ltr type 4 turbo build-up
Tune was fat Wally?
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Wally
- Posts: 4563
- Joined: Mon Oct 28, 2002 12:01 am
Re: 2,23 ltr type 4 turbo build-up
It was turbo-rich so to speak 
AFR was not the issue here..
AFR was not the issue here..
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mactaylor
- Posts: 33
- Joined: Tue Jan 18, 2011 12:50 pm
Re: 2,23 ltr type 4 turbo build-up
Thought the lining in the cylinders may have been good enough! obviously not!
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Wally
- Posts: 4563
- Joined: Mon Oct 28, 2002 12:01 am
Re: 2,23 ltr type 4 turbo build-up
No, lining held up, that wasn’t the problem either. If the tension between head and cylinder gets less and less, this is what will happen. And it wasnt the studs either. Cause is in my original post before just to be clear on what happened
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ssrt
- Posts: 3
- Joined: Tue Jan 06, 2009 10:42 am
Re: 2,23 ltr type 4 turbo build-up
How much did you touque those raceware studs?
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Wally
- Posts: 4563
- Joined: Mon Oct 28, 2002 12:01 am
Re: 2,23 ltr type 4 turbo build-up
The original value (23 lbs.ft iirc)
T4T: 2,4ltr Type 4 Turbo engine, 10.58 1/4 mi
www.apfelbeck.nl
"Mine isn't turbo'd to make a slow engine fast, but to make a fast engine insane" - Chip Birks
www.apfelbeck.nl
"Mine isn't turbo'd to make a slow engine fast, but to make a fast engine insane" - Chip Birks
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petew
- Posts: 3920
- Joined: Sat Oct 07, 2006 4:05 pm
Re: 2,23 ltr type 4 turbo build-up
So what's your plan for the rebuild? Iron cylinders? What about Deuz cylinders?