Franken motor!

[935racer]

Alright well I got it all sorted out, clutch tranny etc are all back in the car and working properly. I couldn't figure out what the heck the problem was so I welded a M6 nut to the pushrod plates' center to shim the pushrod. Works well at least. Hopefully tomorrow I'll get a good portion of the fab done, really need to get this thing on the road.

[935racer]

Got the FMIC all tacked up today, I'll get some pics tomorrow when I hav the rest of the fab work done. Tomorrow I plan on doing the turbo intake, downpipe, wastegate, and full 3" exhaust

Not too far now, hoping on the 27th I can get the rest of the stuff I need for gauges than I should be on the road.

[carrizog60]

and i am here to see it

some videos of the beast would be neat :idea:

[subsonic]

Who did you decide to go with for a maker on the FMIC?

What Dia. are you going to run for the IC pipes?  I am interested in the volume of flow vs. velocity of flow.

Bigger pipe allows more volume but at less velocity, smaller pipe has more velocity but less volume.  In Maximum Boost, I remember reading something about maximum velocity being 400( I cant remember if the 400 is CFM or what :? ).  Anything over that and you run into resistance be the air itself.  

So to allow the fastest movement of air, without restricting volume, I guess you/ us / we/ me  need to figure out a couple things.  How much air will be forced through the pipe at WOT.  What Dia. pipe will allow you to get closest to 400() without going over.

I know this was discussed on this forum a while ago. Someone posted some cool information that had all the maximum air volume/speed info
broken down by inside dia. of the pipe.  It had a long list of avail. diameters to work with.  I will try and find the post a little later today as time permits.

Hope all goes well with the fab work.  I won't be far behind you. :twisted:  :wink:

[TedV]

Bigger pipe allows more volume but at less velocity, smaller pipe has more velocity but less volume.  In Maximum Boost, I remember reading something about maximum velocity being 400( I cant remember if the 400 is CFM or what :? ).  Anything over that and you run into resistance be the air itself.  

So to allow the fastest movement of air, without restricting volume, I guess you/ us / we/ me  need to figure out a couple things.  How much air will be forced through the pipe at WOT.  What Dia. pipe will allow you to get closest to 400() without going over.

Corky Bell listed it as maximum feet per second.  I use his formula then round up to next size or so. I don't have my notes handy but I crunched the numbers for a 1.6 at 24psi ignoring volumetric efficiency just a pure air pump any by memory was about 1 11/16" inside diam minimum. The larger the pipe the more lag you get, so it's up to you to balance lag and flow, keepin in mind length of pipe too. My air/water IC has 2.25" OD pipe and is right over the trans, so my pipe will end up around 2 to 2.25" OD, .065 wall, but with what I am doing I need a broad power band and will give up a lil top end for less lag and better mid range.  Takes time to fill up cubic yards of pipe :wink:

[subsonic]

I found the information.  This link has a good discussion on the volume vs flow topic.  Pipe dia. listed as well as max cfm and mph.

http://www.vwdiesel.net/phpBB/viewtopic.php?t=8959&postdays=0&postorder=asc&highlight=intercooler+diameter&start=15

So I guess part of the information needed to solve the equation is CFM that the Franken will put out at max RPM.  I am iterested  in this as well as my Franken is nearing completion.

[935racer]

Damn forgot to get pics, tomorrow I promise.

Ok so all the charge piping is done, seam welded and installed, same with turbo inlet, downpipe, and wastegate dumptube. Gauges are half wired, still need to relocate the battery, finish the gauges, and build the exhaust. Tomorrow should be rippin up the streets. :twisted:

Oh and the charge piping is all 2.5", downpipe, exhaust and turbo inlet are 3".

[dillenger1]

Is all that shiny metal painted?Looks awesome..I could only hope my build comes out this good..

[subsonic]

For the wastegate dump tube, is that a seperate pipe?  If so, how did you plumb it in?  Does it rejoin the exhaust sys. or terminate on it's own?

[935racer]

All the SS piping is being left raw, its actually polished the way we buy it, but we decided to dull the finish by cross graining it, I like the look.

The wastegate is currently dumping into the atmosphere, and we made a megaphone out of it. Haven't stopped laughing it looks so funny.

[carrizog60]

is possible to make a k24 WG to dump to atmosfere?
what is involved?

[jimfoo]

is possible to make a k24 WG to dump to atmosfere?
what is involved?

No, you need an external WG to do that.

[935racer]

The car is more or less done, gauges are wired, battery relocated, all the fab work with the exception of the exhaust system. Haven't been able to go drive it though because all the snow  :cry:  Tomorrow the snow should be melted enough to get it out on the road.

Here are some pictures:







Anyone remember this jetta? Its been sitting for 2.5 years!

[rabbid79]

Dave, your welds are amazing!  Can't wait to see how it runs.

[MJF]

Anyone remember this jetta? Its been sitting for 2.5 years!

Malones old Jetta?