downsizing project

[my_medusa]

right...they are in the gt15-gt20 range depends on model.

[my_medusa]

today first start with the ms...it runs....but then the crankshaft clamped....
poop!!!that happened if you don't do everything at your own.
tom the guy who started this project built the block.

now i can put everything out and see what the flip is wrong with the crank/block.

how happy can a man be after such a day??

[itawolf]

get it apart Chris ---so we can see what went wrong---and you can keep up to speed and get to kicking butt on that dyno challange

watching this build close--i really like the idea

[my_medusa]

sorry, forgot to post what went wrong.

11 days ago i put ot apart.
first view show's it looks kind of too less end play, but a kind of strange because just to see on the opposite sides and
to the exact center ofthe pin. but for that must be a reason

the scratches was easy to find out, the bearing wandered so the pin pushes metal and so the scratches and the clamping crank come together.

but why did that happiend. lets messure the bearings and the case. case everything in good shape. bearings also. but the middle bearing shows some strange scratches too. only on the sides...hmm. and damn...bingo. the bearing on the flywheel was amazing 2/10mm smaller than it should be. 64,8mm outside diameter. the tollerances from vw are 1/100- max. 5/100 play between biggest case and smallest bearing diameters. tom who put the case together did't messure out the bearing and that he although knows how bad bearings are on the market. the most stupid mistake you can do in engine building. the engine last for 30 -40 sec. via that mistake and coast me about 3-4 weeks in time and alot of money

so now:
had a crank at home with all 0.25 over.
flywheel is now a unter 5kg one.
machined the crank a little like 69mm cranks.



all together goes to fine ballancing.

did some more work on the heads, portet the exhaust arround the valve guides, more shape on the intake and chamber.
stainless exhaust 33mm

intake 34,5mm


this weekend bulding hopefully water/ice-tank , catchtank and some other stuff so that during the week when the stuff come back i put the engine together and next weekend building the stainless exhaust.

that is the plan now.

[Poloeins]

Wally said:


My TB04L is similar sized as the T03 and you know what 'they' said about that turbo on a 1200...

Good choice therefore. Its a Challange! Go big or go home!




"they" = Lars:-D

[Piledriver]

Can you tell what brand bearings were used?

[my_medusa]

Holla lars aka popo
I think alot of others would told this. But a turbo could be never big enough.
Just the engine too small to spool it

And the bearings. I have to ask, but i belive ks repros. Totally stupid thand 1 bearing.
Now i will use silverline, they are not that bad.

[Poloeins]

The Artist formely known as Popu:-D

Enough spam

[my_medusa]

long day.

water/ice-tank:
steffen at work


also leftovers have its place

made of 2mm

in car and can get about 15+ liter

need some color, but its also the cover


catchtank:



and 2 oil sumps changed from typ1 to 36hp. for a friend


changed the pressure tin of the turbocharger to normal wastgate. the original one was vor vacuum pump and ecu control.

[my_medusa]

puh. engine is together, intercooler stuff is done...just need to change the intercooler "again" for the new old place...grrr

and we did the header yesterday. alot of work but it is really nice and build for our goal. welded by my friend steffen "stahl-in-edel"

stainless.
35mmx1,5mm into 38x2mm into turbo.
muffler fit into the header, we build it when the engine is inside the car.





hopefully we can start the engine next weekend.

wishes from germany
chris

[Chip Birks]

This looks familiar Looks good!

[my_medusa]

engine back on its place.
header wrapped with old thermotec looks like the car now
turbocharger fits perfect it its space and is now on a very good height. a little higher than center of the oil pump.
and alot of space for the muffler.




wishes
chris

[panel]

Is that a secret turbo ?

[my_medusa]

Yes sorry for that, but only until the end of April.
our biggest rival in the 1200cc challenge hides his stuff, so do we also.
end of April we tell all the rest. camshaft, turbo and some other interesting stuff.

[WickedWagens]

Thats what I though when you showed the first pics and the turbo was blurred out. Good luck and hope it performs as expected.