Safari Turbo/Megasquirt Fuel Injection Project

[Clonebug]

Hey everyone,

I am finally in the position to get serious on my turbo project.

I have been gathering parts for almost 2 years now and can now say that I have almost all the pieces to go for it.

It will be a budget build of course and I have been following Mike Thompsons build posts with a lot of interest.

The list.

DP 1600 stock engine.

Ihi RHB5 turbo vf-48709 from a late 80's gl-10 Subaru as far as I can tell

Weber IDF 44 single carb for blow thru. I would guess that this carb is a little on the large side but it was too cheap to pass up. It does have the smallest venturis in it that are available.

Baja style upright exhaust for now to test and make sure it will work, Then possibly have a new header built later.

I have a line on a stock Beetle injection system that I would like to get, but that will be in the future if I can talk the owner out of it for a cheap enough price.

Pic of turbo






I am looking for some flanges if anyone would know where to get them. I emailed Subie John and he does not have the exhaust dump flange for this turbo so I would like to find both flanges and a set of gaskets for it from one place to save shipping.

Thanks for the interest.

Pic of buggy







Clonebug




Carb

[Turbo60VW]

I have that same turbo on my Buggy with a 1600SP and I have been very happy with it. I make all my own plates/flanges, not hard and very cheap. As for you carb.... I once put a 40IDF on my Turbo 1600DP with 28mm Venturies and it seemed to work ok...not optimal. Good Luck with your project.

[Clonebug]

Hey turbo60,

Do you have any pics of your buggy with the turbo??

Always interested in seeing how everyone goes about solving plumbing challenges..

Clonebug

[74slug]

I'm very interested in seeing how you modify the carb for blow through. Especially sealing the throttle shaft. I've heard it can be a real pain. I also have an idf that I've considered for blow through. The buggy looks great!

[Turbo60VW]

As far as prepping the IDF for blow-thrugh, I didn't do anything. Just different jets and at the time different venturies. My 40 IDF doesn't start to leak fuel past the throttle shafts until I get to about 15lbs of boost and even then its not much at all. So, I have never worried about it leaking just a small bit of fuel, it evaporates by the time I stop and get out to check anyway. I will take some pics tomorrow of my engine/set up.

[seabeebuggy]

I'm very interested in seeing how you modify the carb for blow through. Especially sealing the throttle shaft. I've heard it can be a real pain. I also have an idf that I've considered for blow through. The buggy looks great!

no real need to seal the shaft. unless it is in really bad condition.

[74slug]

No leaks until 15 lbs? Sounds great to me. I guess I just might shelve the 34pict and go for the IDF. Thank you.

[Turbo60VW]

Well, I currently have a 31pict on mine and it works great. Also, it was really easy to tune! That IDF will take some trial and error. Also, is your IDF new/used, Italian, etc. My IDF is relatively new, thus I don't have much play on the throttle shafts, where they can leak from. How many pounds of boost are you looking for? Do you have a fuel pump and fuel pressure regulator?

[Turbo60VW]

I have the IDF on my 1960 street sedan with a turboed 1915. The solex 31pict is on my 1600 single port (i read my previous post, and wanted to clarify).

[74slug]

The idf I have is well used. I have no idea of it's age or if it's a 40 or 44. "made in spain" is stamped onto the side. The 34pict3 is basically new with very little run time on it. My engine is a dp1600 that I will go through and freshen up. Cam will be changed. Either a new stock grind or tcs10.

[Clonebug]

So it's been a bit since my last update and I have done a little work.

Built an inlet flange and had the other built by a friend.




The outlet flange just needs a little grinder shaping on the outside in order to be a great fit.



Started work on the fuel pump base as per Mike Thompson's build.
JB weld on the existing vent hole



Drilled a new pilot hole on the outer side of the base and will be drilling and tapping to accept a 1/8" brass nipple for a hose fitting.



Installed my $25.00 baja header and my low profile Weber intake.



I ended up cracking the header trying to straighten it a bit since it seemed that it had been hit and bent.
So much for good deals at a swap meet.
I have a neighbor that is going to weld the cracks up and I will reinstall it when I get it back.

While I am waiting I have been cleaning up my electrical on the buggy body trying to make it a little less like a rats nest.
Rear Taillights and tow lights




Thats it for now.

[seabeebuggy]

Looking good. Keep us updated. Love the photos.

[Clonebug]

Hey All,

I managed to get a few other things done.

Added boost reference to the fuel pump.



Did some test fitting of the turbo to the cheap header I picked up at the swap meet. It is not ideal but better than spending big bucks and finding out it didn't work.

It sits higher than I would like but when I find out if it works then I will probably build a custom header.



And now everything comes to a screeching halt........I thought the carb was a little high but had no one to help me set the body back on until last night.
I do NOT want to cut the body.....This is pretty depressing.

How short could I make the top hat???



I am open to any suggestions.... I am even thinking about switching to a german FI system. I have the stock FI end castings already.

Clonebug

[sandhopper]

you could go to dual carbs

[miniman82]

Blow through a PICT, it's what all the cool kids are doing these days.