I did some testing on my local dyno when she made 160 (this graph reads 159,5 chp) with the small turbo on max 1,335 bar boost (see graph).
For the Challenge I threw on a really big turbo and turned the boost up a tiny bit even further and she made the 174 hp that won the Challenge, but the dyno was different there and due to the really BIG turbo, was extremely peaky. On the road, it wasn;t even so bad, but that dyno loaded pretty fast too. It didn't have rpm on the graph either (let alone a boost plot!), so little to see from that one
The 160 hp graph from the early testing was pretty neat for a 1200 I thought though (purple line is boost plot, how cool is that!):
http://i174.photobucket.com/albums/w...8.jpg~original

It was a lot of fun in Tornesch! I think 180 hp (corrected) would have easily been possible if you didn´t have those little hesitations.That litle 1200 sounded pretty pissed off though! Really aggressive on boost! Even 200 may be possible on a more aggressive tune.But since it was a long trip home,no sense in unnecessary risks! It is really astonishing just how much stock 1200 components can take! Remember these are 34hp engines!!

That is absolutely incredible - great work again walter! What remained 'stock' internal wise on the motor out of interest?

AWESOME!! :D

What do you define as stock? Stock 1200 ('40hp') rods, but shotpeened and ARP bolts from a Ford engine as they were the same (searched long time).
Lots or all is basically stock, but most stock parts we tried to make a little better/stronger. Upgraded, but basically stock parts therefore.
I used sort-of the same tactic as with my 2,2 ltr ;)
Likewise the 64mm non-stroker crank, (cast Mahle, but said to be made for oettinger) pistons and original VW twin port (1300) heads.
So, lots of TLC :-)

Good work Wally, thanks for posting the curve!

Wally just mentioned the key...TLC and quality workmanship.I started the 1200 Challenge in 2009 and the turbocharged engines were all pretty similar as the rules dictated a stock bottom end and the 77mm bore.Armin Klein held the crown since then with a 130hp turbo 1200.A more aggressive cam and better tuning brought Wally these results.Personally I believe that Wally´s ability to tune and dial in an engine is gets him these great results,just like with his 2.2 T4.Especially if you compare to how the other competitors´engines run and how they act under a load.There´s no cooincedence or luck involved ;)

Thanks for the flowers Mark ;-)

by stock i mean the same parts as vw would have used even if re-worked. i think its amazing what abuse those parts are taking. you must have put a lot of attention into many if the parts - i dread to imagine the housrs you have put into it! :cool: great work

Anyways, 1200 is out of the car and the type 4 is being worked on to get it reassembled and slightly upgraded.
Long block together again. Always a major point to reach :)

http://i174.photobucket.com/albums/w...7.jpg~original

Yes it is a major point. Good to see it going back together.

Looking good Wally!

whats the slight upgrades? i'm guessing some rods that are not banana shape!

Yeah, that part for sure: a set of slightly used Pauters (taken over from Jake Raby) will take their place.
Also a new cam with a little more lift and duration, lighter clutch/flywheel and the new cooling system.
Maybe a smaller turbo for track (the corner type) events.

Thats about it.

Don't know if you've seen this.
0:51
http://www.youtube.com/watch?v=Mz9OA...eature=related

Yeah, its in my favorites album. It was a damp track that day with a few slides here and there.
Cheers for that mate!

Have cut the (new) fan housing to shorten it as my engine is still extremely short:
http://i174.photobucket.com/albums/w...2.jpg~original