madmike wrote: ↑Thu May 20, 2021 1:12 pm
Hope you have a one-way-valve on the crankcase vent to the intake?
Curious why? It goes to the intake before the turbo, so will only see vacuum, no pressure. I had thought about adding an oil separator to keep oil mist out of the intake, but it would be a tight fit. Here's a close shot of the BOV and vent from the oil filler. If you see a problem with this setup, let me know. Not my first turbo project, but is my first on an air cooled VW.
JamesL, I'm afraid the throttle body mounting flange on your intake plenum is WAY to thin and will not seal against the throttle body enough to compress the gasket. This flange needs to be 1/4" to 3/8" thick to function correctly. Overall you're looking really good.
Oh, and I love the trailer ball / pipe flare tool!!!
Lo Cash John wrote: ↑Thu May 20, 2021 7:52 pm
JamesL, I'm afraid the throttle body mounting flange on your intake plenum is WAY to thin and will not seal against the throttle body enough to compress the gasket. This flange needs to be 1/4" to 3/8" thick to function correctly. Overall you're looking really good.
Oh, and I love the trailer ball / pipe flare tool!!!
The photo of the intake was early on. I agree the flange was too thin. Here's what it looks like now. Nice flat solid surface for mounting. I used a flange cut from a scrap intake. The flange throat is larger than the one on my throttle body, but the bolt spacing is the same. I don't think that step will matter much, since the TB diameter matches the intake throat.
Im really digging the way you packaged everything. Home brewed turbo setups are so much fun to watch come together. It's a level of intimacy to you can have with your car that no "kit" can give you.
Here is my latest setup to show how I tackled the "intercooler problem"...
nbuscemi wrote: ↑Sun May 23, 2021 11:30 am
Here is my latest setup to show how I tackled the "intercooler problem"...
-Nick-
Nice! How does it cool? I'm going for the stealth look with everything packaged under the hood. The jury is out on whether that small intercooler will provide any benefit. The IC sits directly in line with the vents on my '74 Super hood and I theorize the engine fan will pull enough air thru that region to keep air intake temps down. We'll see once I get it running. Couple more pics of the hood and IC.
Hood fits fine with no interference.
The hood vents line up with the Intercooler. The IC is 7" tall vs the ~4" vents, but still expect plenty of air flow provided by the engine fan.
Last edited by Jamesl on Sun May 23, 2021 2:50 pm, edited 1 time in total.
Without an intercooler, during the North Texas summer (90-100*f) I was seeing around 200-210* MAT at 10psi boost. With the intercooler and the decklid in place I was seeing no more than 10-15* above ambient at same boost pressure. Given that I'm using a cheap tube and fin Ebay intercooler I'd call that a WIN!!!.
Here's a pic with the decklid attached. I figure the "stand-off" catches some air when I get up to speed. Not "pretty" but certainly functional.
The engine fan insures there is plenty of ambient air flowing through the engine bay. With the stand off example, the high pressure area in front of the intercooler will push air through it, just like front mounted intercoolers. With the intercooler behind the decklid out of airflow that is not the case. The engine fan will pull air into the engine bay but air will perhaps take the path of least resistance and flow around the intercooler instead of through it. With the aircooled 911 turbo, there was a rubber seal around the intercooler so cooling air for the engine had to be drawn through the intercooler. You could try the set up as is, but if the MAT is high, you could try adding a fan or create a duct / rubber seal that routes the decklid vents to the intercooler.
Bruce.m wrote: ↑Sun May 23, 2021 11:54 pm
You could try the set up as is, but if the MAT is high, you could try adding a fan or create a duct / rubber seal that routes the decklid vents to the intercooler.
You pretty much outlined my thought process.
Easiest would be to add a foam "donut" to seal the intercooler to the decklid. I'm using Speeduino for engine management and it offers the ability to control a fan -- either to run when the engine is on, or only turn on above a selected temperature. There's room behind the intercooler to add a draw thru fan if needed, but I'm hoping to keep things simple. Of course, nothing about this project has been simple...
Last edited by Jamesl on Mon May 24, 2021 11:35 am, edited 1 time in total.
nbuscemi wrote: ↑Sun May 23, 2021 1:07 pm
Without an intercooler, during the North Texas summer (90-100*f) I was seeing around 200-210* MAT at 10psi boost. With the intercooler and the decklid in place I was seeing no more than 10-15* above ambient at same boost pressure. Given that I'm using a cheap tube and fin Ebay intercooler I'd call that a WIN!!!.
Here's a pic with the decklid attached. I figure the "stand-off" catches some air when I get up to speed. Not "pretty" but certainly functional.
-Nick-
100+ degrees is a lot of heat to take out. That's impressive!
Just saying, but that's a v big intercooler, the turbos gunna be working hard and the engine rpm will be up high in order to get the boost pressure to the heads due to pipe size and cooler size. I got loads of lag when I had a set up like that, ended up taking the whole lot off and going water injection instead.
Regards G. C
So, finally got the Super running. I'm a long way from finished with a Lot of final assembly still to come. Still, I'm super stoked to actually get it started and hear it run.
