Home Forums KCW Completed Projects Dan’s boosted oval

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  • dan.mastro
    Participant
    Post count: 27

    Looking great Franz!  Work of art.

    Franz
    Moderator
    Post count: 5112

    Going to take her out and make some boost today.

    Thanks guys👊 I have been stressing about this exhaust for a while. The materials were something like $1300. Not much extra material or room for mistakes.

    Titanium is kind of hard to cut and grind…but it sure does weld nice. Probably the nicest welding material I have worked with.

    Franz
    Moderator
    Post count: 5112

    It’s still loud. The exhaust mods made it a little  quieter. Not much though! I can cut the can apart to add a baffle.

    More worried about getting it tuned and running crispy now. I re-set the max boost parameters and thought I had it figured out… but upon test drive it went lean with any boost.

    We need to make some more test passes. I want to put pump gas back in.

    Installed the chrome bits and made a license plate anti-shake bracket with red leather padding this morning.

    3E931227-A9D6-40D9-B1B6-DBC2FBEA19FBBD09AAC4-AE2B-406C-A6AC-A0A9A0100A91B7A39163-4716-4B0A-8799-A775A1B11AD7

    Franz
    Moderator
    Post count: 5112
    Franz
    Moderator
    Post count: 5112

    I’m getting her dialed in. The boost control target say 65 psi… but the 65 number does not relate to psi is more like duty cycle or something.

    Anyways we made 13.2psi of boost. You can see on the fuel map where it started to get lean on the top end. I’ve turned the pulse width up a little to compensate, and will give it a hair more boost.

    F4167AC1-6744-48DC-9CE1-60552C461A35FC056A79-6529-4853-AE3F-A614FD2A1F16

     

    John Jones
    Moderator
    Post count: 10431

    I’m ready for a ride😁😁😁😁😁😁😁😁

    The harder I work, the better I feel, sorta 😎

    Franz
    Moderator
    Post count: 5112

    I spent all day yesterday doing test drives and tuning the fuel map. I have it looking and running awesome.

    We are ready to schedule transport on this machine!👏

    There is nothing left to do except the final wash and shine.

    4B903EC1-CF88-4A27-BF0E-E5D651658958

    Top end air/fuel ratio looking good. A little rich on the low end….but I think that will look better when this car is at a lower altitude.
    3F231450-CB8F-4F1E-9D80-28BF74393E17

    Franz
    Moderator
    Post count: 5112

    The exhaust is better than it was for sure. You are able to have a conversation with the passenger while driving. I think the noise level is acceptable…The engine in general is noisey…Between the rockers ticking, and turbo whining, and oil cooler fans…  I don’t think it can get much quieter.

    I think you should try it Dan, I can always cut the muffler apart to add a baffle, but I am afraid it will hurt performance.

    The brand new 90amp alternator crapped-out too. We had a new one sitting here for another project. I swapped it in yesterday after I tested and checked everything else.

    The only way to change an alternator with the engine in the car is to remove the nut from the fan and leave the fan in the shroud.

    C00F95E2-5CCC-4E7D-B17C-4CE339BD0FCB

    Pete
    Participant
    Post count: 1102

    The only way to change an alternator with the engine in the car is to remove the nut from the fan and leave the fan in the shroud. C00F95E2-5CCC-4E7D-B17C-4CE339BD0FCB

    I saw this trick somewhere to make roadside alt/gen removal easier…..JB maybe?  Anyway, remove the pulley-side generator/alt stand studs and use bolts in their place when securing the stand.  On the fan side of the stand – notch the holes on the base so once the nuts are removed from the studs the stand slides rearward (since there are no longer studs at the rear in the way).  That way you can just remove the four screws from the alt backing plate from the shroud and slide the whole thing out, fan and all.

    Scott Sain
    Participant
    Post count: 387

    Sorry to see that had to be done. Definitely not a fun job with all the extra crap on this engine. I like Pete’s idea!

    VWs, food, music, and food
    VW Drag Night
    July 15-16, 2022
    www.vwdragnight.com
    Germanaire Drag Day and Social
    November 18-19, 2022
    www.germanaire.com

    John Jones
    Moderator
    Post count: 10431

    😁😁😁😁😁😁😁😁😁😁😁

    such a sweet looking car!!!!!!!!    Franz really dialed in the paint job on this, and now the engine is dialed… wow

    The harder I work, the better I feel, sorta 😎

    Scott Sain
    Participant
    Post count: 387

    FC056A79-6529-4853-AE3F-A614FD2A1F16

     

    Franz, I would think that means 6.5 pounds. When I set mine at 12 pounds it says 120. 16 is 160. Your overboost is set at 15 pounds. Should be a lot of fun.

    VWs, food, music, and food
    VW Drag Night
    July 15-16, 2022
    www.vwdragnight.com
    Germanaire Drag Day and Social
    November 18-19, 2022
    www.germanaire.com

    Franz
    Moderator
    Post count: 5112

    Hmmmm not sure Scott. I have it set at 50 and still making 14lbs. If I turn it down much more it goes into overboost fault and fully opens the waste gate.

    What do you have for your overboost settings?

    1856DB39-9DCD-42A9-85C9-FB73B67CC2C8

    John Jones
    Moderator
    Post count: 10431

    Scott you have both, carburetor and injected car?  Lucky man😁😁😁😁😁😁

    The harder I work, the better I feel, sorta 😎

    Pete
    Participant
    Post count: 1102

    Scott you have both, carburetor and injected car?

    🤐

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