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Wally
July 20th 2018, 04:43
Had a great track day for the first time after 6 years together with a good friend of mine in the grey german style 1303 with 2 ltr T4 and some Porsche friend of him.

https://farm1.staticflickr.com/840/43514737231_aff3971f92_b.jpg

https://farm1.staticflickr.com/923/43514739001_96cdc314c2_b.jpg

https://farm2.staticflickr.com/1782/43467722282_a64495b095_b.jpg

https://farm2.staticflickr.com/1766/43467720982_e007887679_b.jpg

https://farm2.staticflickr.com/1783/42610118645_6e86254733_b.jpg

https://farm1.staticflickr.com/940/43514733411_cdab27e250_b.jpg

412STi
July 20th 2018, 15:37
Zandvoort!!
thumbs up; thumbs up;
(smilies did'nt work!!)

H2OSB
July 20th 2018, 18:26
You live my desired life, Wally!

Wally
July 21st 2018, 05:26
You live my desired life, Wally!

Haha! I'am sure it isn't that desired ;) but thanks for the nice reaction :)

I did find an issue with the limitations (lets hope its just that) of the breathing capacity of the engine as on contineus high revs plus boost, too much oil fumes came out of the breather box.
Just added the little can under the oil plate so sump is a little bit deeper, so the dry sump can do its job better. Also ordering a larger breather box.
Hopefully both these will keep it under control.

Wally
August 23rd 2018, 17:08
My girl driving shotgun, made this small clip :)

https://youtu.be/032bzvlWbLg

rioprelude
September 7th 2018, 23:51
Nice video, my wife would probably freak out on track going that fast!

Steve C
September 8th 2018, 01:53
Nice video, your gearbox sounds like mine:D

owdlvr
September 8th 2018, 22:06
Nice video, your gearbox sounds like mine:D

haha, I WISH mine sounded that good :P Everyone who rides in my car asks if it's about to explode.

Wally
September 9th 2018, 15:49
Nice video, my wife would probably freak out on track going that fast!

She's awesome: wasn't even that impressed with our speed... :lmao:

We run the same gearbox obviously hey Steve ;)
It is indeed pretty loud on lift-off. Since its still in one piece after all these years and abuse, I'll leave it be :)

Steve C
September 10th 2018, 10:51
Love my G50 it still works after all hell I give it

H2OSB
September 10th 2018, 18:02
That sounds delicious!

H2OSB

Wally
April 7th 2019, 03:47
Well, not everything works out with my builds too as these pics prove:

https://live.staticflickr.com/856/43085859554_cdc7a95aaa_b.jpg

Torched a cylinder and head big time!
Root cause probably the one-off cast cylinders. No matter how thick the walls were...
Partly also my own fault as I didn't retorque the heads more often, which would have been more wise because the cast cylinders did need more 'seating' then I usually am customed to. I noticed this when disassembling the engine: head torque was too little on the other cylinders, so thats probably what started this.

Still, all other cylinders also showed a much larger bore up top then bottom of the cylinder (!), so they just didn;t stood up to the cylinder pressures I ran anyways. That also explained the excessive breathing I experienced: the rings just couldn't keep it sealed up top in the cylinders..

Anyways, for a 'quick' fix I bought a set of the AA 98mm birals so I could reuse at least my pistons.
Head is fixed at the moment already and I am reassembling the engine again :)

effvee
April 7th 2019, 04:29
Walter, what happen to your Ottinger Cylinder?

effvee
April 7th 2019, 04:31
Walter, what happen to your Ottinger Cylinder? The width of the sealing surface looked thick enough. :mad:

Wally
April 8th 2019, 02:48
Walter, what happen to your Ottinger Cylinder? The width of the sealing surface looked thick enough. :mad:

I sold that 66x103 engine about 7 years ago and started building this new 74x98 one, which is partly what this thread is about. Pay a little attention brother :rolleyes: ;) :D

Steve C
April 11th 2019, 20:33
Hi

Bad luck. A VW performance shop I worked in years ago used make seamless steel sleeves to fit over the top section of 92mm barrels to stop them from spreading, could something like that be used on your barrels?

Steve

Clatter
April 11th 2019, 22:48
Whooo!! Like a cutting torch!!:eek:

Wally
April 26th 2019, 18:21
Rebuild process started a while back, but I just had the long block back together with the 98mm AA birals.
Other small difference with the former set-up is that I could and have installed under cylinder tins again. They only needed a little shortening, but no biggie.

Oettinger crank, Pauter rods, Pauter cam and gear:
https://live.staticflickr.com/65535/33830459458_9b1759e2c6_b.jpg

https://live.staticflickr.com/65535/46791696125_beda74f1ce_b.jpg

https://live.staticflickr.com/65535/33830458988_9526180308_b.jpg

https://live.staticflickr.com/65535/33830458598_e23d0568a4_b.jpg

effvee
April 26th 2019, 20:50
Yessss,eye candy

dub_crazee
April 27th 2019, 05:39
Sorry to hear you’ve had issues wally, did you ever get back on the dyno and up to boost to 1 bar or did this happen before you had the chance?

Wally
April 27th 2019, 05:53
Sorry to hear youíve had issues wally, did you ever get back on the dyno and up to boost to 1 bar or did this happen before you had the chance?
The latter unfortunately. I was very hopefull though, as at just 0.7 bar it already was doubling the hp from the N/A dynorun on the same dyno.

Wally
April 28th 2019, 12:34
Thought to take a pic before the pulley and cooling parts cover it all:

https://live.staticflickr.com/65535/32780024827_4f3530b36a_b.jpg

Like this:
https://live.staticflickr.com/65535/47723402741_6b6da5cc8d_b.jpg

Wally
April 29th 2019, 12:30
Its ridicoulous: I posted one picture (the above one) of the engine in the flat4 racers section on FB and got 500 likes, 56 shares and 50 responses...

DORIGTT
April 30th 2019, 19:59
It's just tough because its hard to search on FB, and most want that instant gratification that it provides.

Wally
May 4th 2019, 11:58
Almost in again :)

https://live.staticflickr.com/65535/40806325243_5137dcd766_b.jpg

412STi
May 4th 2019, 18:24
:thumbup::thumbup:
:goodjob::

Wally
May 9th 2019, 14:38
Engine long block is back in. Hydraulic clutch feels good again.

Test mounted intake (picture) to mark the spot where to install the waterinjection nozzle.
Since my old controller had a short and no replacement parts were made for it anymore (...), the quick and dirty solution was to get the newest kit.
Unfortunately, I really could not reuse even some of the old installed waterlines (slightly different outer diameters), so had to removed all of the older wiring and waterlines... grr! Hate to do wiring, but had to.

https://live.staticflickr.com/65535/46873867035_4549a8077a_z.jpg

volkdent
May 22nd 2019, 18:14
This is going to be fun!!!

Jason

Bad bug
May 26th 2019, 08:43
Wally are you running your dry sump tank up front again.

Wally
May 26th 2019, 15:30
Wally are you running your dry sump tank up front again.

Yep, since ~forever. Some people still think thats a bad idea. Busted that myth long time ago. Its all about how you execute things.

Bad bug
May 26th 2019, 23:26
Ok great the suction line from the tank is what size AN fittings also where do you run your lines.

Wally
May 27th 2019, 03:30
AN12 iirc, inside tunnel

Bad bug
May 27th 2019, 18:34
Doesn't that create moisture spots in the chassis that could cause rusting to appear.

dub_crazee
June 13th 2019, 13:07
So close now Wally!!

Wally
June 14th 2019, 07:44
Indeed mate!
In fact, I had the car dynoíd already at 1.0 bar boost...😎

Wally
June 14th 2019, 08:39
https://live.staticflickr.com/65535/48060809836_0136ae3429_b.jpg

First run 0,95-0,97 bar: 404 hp
last run 1,05-ish bar yielded 414 hp, so anyways it proved that you can make 400 hp on 1 bar on 100% gasoline bought at the pump :mrgreen:

https://live.staticflickr.com/65535/48038740908_710c406c13_b.jpg
cold air/engineparts (first run) spools better ;-)

https://www.youtube.com/watch?v=sVJcey1cX5M

dub_crazee
June 14th 2019, 15:35
Thatís absolutely awesome Walter, congrats on another myth busted....or goal achieved. I canít even imagine what the feels like. How heavy is your car out of interest?

Wally
June 15th 2019, 07:08
It was weighed for inspection with the turbo engine and that was 960 kg about 12 years ago.
That was probably with half a tank and all seats in place.
Since then a few things are lighter, but added stuff too.
Hoping 930-950 kg on the street and 910-929 in dragrace mode..
But all educated guesses on my behalf ;-)

dub_crazee
June 15th 2019, 08:07
Is that with the g50? About 100kg over a stock bug then! Not bad at all! And around 450hp per tonne.....not many cars can boast that!

Wally
June 16th 2019, 17:16
https://www.youtube.com/watch?v=07wowurYL9M&feature=share

Simon
August 3rd 2019, 13:09
Hi Walter,

Long time no see! :)
More than 400 horses, pretty impressive :O

How are you liking the AA birals so far/how are they holding up?
I was wondering why you picked the birals instead of the plain iron cylinders, I'd expect the biral ones to be a bit weaker.
And did you do any machining/honing to them or are they stock?

Cheers,
Simon

Wally
August 4th 2019, 13:40
Hi Walter,

Long time no see! :)
More than 400 horses, pretty impressive :O

How are you liking the AA birals so far/how are they holding up?

I was wondering why you picked the birals instead of the plain iron cylinders, I'd expect the biral ones to be a bit weaker.
And did you do any machining/honing to them or are they stock?

Cheers,
Simon
Hey Simon,

Thanks! And very good to hear from you again! That has indeed been a looooong time!

I like the birals very much: in fact, I slao was a little worried about their thin-ish wall thickness, but they have withstand over 100hp per barrel without issue. So that is a true testiment to them imo.

The reason to fit those birals in the first place was because it was the ONLY stock 98mm cylinder on the market after I had burn a hole in my home-made cast all alu-nikasil cylinders...
This way I could re-use the JE pistons and could rebuild the engine relatively quickly.
After all, it seemed a little too quickly as I had accidently made a mistake (it happens :lmao: ) and switched pistons, which meant the valve pockets didn;t line up and the intakes finally did hit the pistons. The had less then 1mm clearence without the valve pockets lining up, so at 9000RPM it lived, which was surprising in itself, even more without reserve as it turned out.

Long story short, rebuilding the engine again as it did received quite a bit of damage on valves (bend) and pistons/cylinder and I am now gonna use 102mm Deutz cylinders and new pistons.
Will also use a JPM cam, which Johannes 'agreed upon' :D

So, no more meets for this year unfortunately. I did reach my goal of 400hp at 1 bar, but the 10-second run still has to be done. Only then will I sleep again ;)

I spilled my beans, but what are you working on yourself atm?
cheers, Walter

Simon
August 6th 2019, 10:01
Hey Simon,

Thanks! And very good to hear from you again! That has indeed been a looooong time!

I like the birals very much: in fact, I slao was a little worried about their thin-ish wall thickness, but they have withstand over 100hp per barrel without issue. So that is a true testiment to them imo.

The reason to fit those birals in the first place was because it was the ONLY stock 98mm cylinder on the market after I had burn a hole in my home-made cast all alu-nikasil cylinders...
This way I could re-use the JE pistons and could rebuild the engine relatively quickly.


OK, that's good to hear. I was/am considering some AA cylinders and pistons for the type4 engine (it's not running yet, had a lot of other stuff that distracted me, time flies apparently ;) ). Not sure if I'll pick the birals over the plain iron ones though.
And obviously you have (or had :( ) some nice pistons already, the AA ones are probably significantly less nice, but I'm not planning on running a turbo at the moment, so should be fine I guess :).


After all, it seemed a little too quickly as I had accidently made a mistake (it happens :lmao: ) and switched pistons, which meant the valve pockets didn;t line up and the intakes finally did hit the pistons. The had less then 1mm clearence without the valve pockets lining up, so at 9000RPM it lived, which was surprising in itself, even more without reserve as it turned out.

Long story short, rebuilding the engine again as it did received quite a bit of damage on valves (bend) and pistons/cylinder and I am now gonna use 102mm Deutz cylinders and new pistons.
Will also use a JPM cam, which Johannes 'agreed upon' :D

So, no more meets for this year unfortunately. I did reach my goal of 400hp at 1 bar, but the 10-second run still has to be done. Only then will I sleep again ;)

Ohw, really sucks to hear that, sounds like a painful learning experience :(
On the other good to hear you've already got new plans! (obviously! ;)).
Haven't seen these Deutz cylinders before. Are they for a type4 or for some other engine and repurposed?

If you want to share I'd be interested to know why you're going with 102mm vs the 98mm you had (or anything else for that matter).
I still have a bunch of these decisions to make as well (2056, 2270, etc)

And 9000 RPM is quiet a bit, do you make that regularly?


I spilled my beans, but what are you working on yourself atm?
cheers, Walter

Well, I have to move my car out of it's current home end of September and I'm trying to make it so that it can be driven out instead of towed or on an ambulance ;)
Quiet a bit of work to do, especially since I'd like to wrap up some of the suspension changes I was working on (do or don't do M030 suspension front, uniball or GWD torsion bar covers in the rear, do or don't do 944 bilstein cup coilovers in the rear, etc).
I'll be using the stock engine for this, simply because I won't have enough time to finish that as well, but this sudden call to action was a good reminder that I should finish the type4 conversion :)
That will probably be a project for this winter.
Also I received a bunch of "vrij rijden" gift cards which I'd like to use ;)
I'll create a topic here either this or next week to post some updates.

Wally
August 13th 2019, 04:35
Haven't seen these Deutz cylinders before. Are they for a type4 or for some other engine and repurposed?

If you want to share I'd be interested to know why you're going with 102mm vs the 98mm you had (or anything else for that matter).
I still have a bunch of these decisions to make as well (2056, 2270, etc)

And 9000 RPM is quiet a bit, do you make that regularly?


Deutz is a tractor manufactorer and is always a diesel engine...The older jugs are better to use, but harder to find and as the word seems to be out about these (old autocrossers used these 25 years ago already..), prices on ebay for used barrels are up. They used to be 'free' (tossed from old broken engines)

With Original head castings I would always keep as small a bore as possible as the heads warp originally already, even more so when fly-cut and even more so when 'openend up' for big bore. Everything you cut away is a weakening...

However, the Original 98mm bore idea had a long history from when friends made a set of custom made alu-'nikasil' cylinders and the were in 98mm, no choice there, but enough for a turbo engine ;)

However again..., with the billet heads I now use, warping is not an issue anymore, but I also want to keep the case openings as small as possible as opening that also weakens the case (spigot). The edges where the cylinders rest are extremely small on engines that run the standard 103mm bore cylinders. I don't like that for a (really) big hp engine.

As one doesn't always have free choice and everything is a bit of a comprimise, I got a very good 'deal' on the cylinders which were 102mm to begin with, so I'll have the bottom turned down a little to minimize wall (2mm) and keep case strength up a bit.
I'd rather had 100mm and keep that 1mm more in the case, but sometimes you also go with what you have and its probably not really that much of an issue and the extra cc's give a bit more bottom torque (spool), so that nice as well.

Long story, but considerations for decisions are never simple nor single :)