Twin - tech design stuff

[onesixv@juno.com (Eric L Ellis)]

I hope that radiator core support was trashed before you cut it.

Eric
"Good, bad...I'm the guy with the gun!"
http://www.geocities.com/blitzkrieg16v
AOL IM:  OneSixV
http://www.geocities.com/onesixv

On Fri, 29 Mar 2002 09:33:10 -0500 Allyn <amalventano1@comcast.net>
writes:
> tberk recommended i repost this without the flywheel thing in the 
> topic (as others may have just
> skipped it). It has also been modified slightly based on responses 
> so far.
> 
> current plans: each engine will have water pump and alternator. goal 
> is to be able to drive on
> either engine (like if i fry one at waterfest, so i can still make 
> it home, redundancy is good).
> front engine will have power steering pump (needed for other 
> (ah-hem) hydraulic 'improvements').
> 
> each engine will also have:
> port+polish + balance + VERY lightened flywheel + arp head bolts
> stock 16v (1.8) c/r, stock cams
> water injection (pulsed injectors, ecu controlled) at turbine 
> exhaust (increase charge
> density), base of intake runners (in cylinder cooling), and external 
> chargecooler-radiator and
> engine radiator spray (increase efficiency).
> water injection will be controlled by feedback from rtd's installed 
> in strategic spots.
> exhaust thermocouples (4), providing feedback to intake runner water 
> injection control for that
> cylinder (also to ecu for fuel dumping and/or boost/timing retard as 
> needed).
> wide band o2 sensor (driver circuit is already built into the ecu 
> design).
> fuel rail/bosch injectors/boost corrected regulators
> turbo (for said boost) + computer controlled wastegate + bov + 
> chargecooler
> engine mgmt by yours truly, one brain per engine with crosstalk for 
> synchronization (design approx
> 50% completed/tested).
> 
> (this engine stuff may sound extreme, but realize that most parts 
> are already in hand, partially
> designed, or just havent been ordered yet).
> 
> body wise:
> - all under-carpet insulation removed, (will dynamat front/rear 
> firewall area)
> - tube-steel cage tied to front/rear subframes (surrounding each 
> engine, supporting all
> engine/suspension mounting points
> - MUCH internal unibody will be gone (except for fender mount points, 
> etc). goal is to end up with a
> stiffer overall frame with enough weight removed to more than 
> compensate for the rear engine weight.
> i've learned alot cutting the donor up into pieces, and have a 
> pretty good idea of what can go and
> where subframe will go. got some more stress calcs to work on but 
> getting there.
> - rear seat gone, rear firewall may possibly be kevlar/carbon mix 
> (save weight).
> - rear portion of stock gas tank will go byebye, will be shaped to 
> allow for front part of rear
> engine.
> - all glass except for windshield/door roll-downs replaced with 
> plexi (if i can find some that will
> not interfere with attempt at stock euro gtx external appearance).
> - fiberglass/cf (painted) hood
> - air conditioning - already gone (its a non-ac rocco), but i will 
> have to install a condenser ahead
> of the front radiator to act as the chargecooler heatsink.
> 
> dare i say... brake wise(ouch):
> 10.1 ate power discs up front, 9.4 ate power discs in rear, 
> proportioning valves removed, 16v
> mc/booster
> s/s lines, stock 16v calipers (front), 8v (front) calipers (in 
> rear)
> 
> *note, those are current plans, may do 11.0/10.1 front/rear
> 
> tranny wise:
> 2 ff trannies, possible factory lsd's (with shim kit) transferred 
> over from agb's. bolt kits.
> shifting/clutch will probably be a semi-automatic servo driven 
> system. interface with ecu for
> throttle cutout during upshift/throttle blip during downshift. 
> Possibility of a full automatic mode
> with staggered front/rear shifts when driving 'normal'. (keep in 
> mind that once servos are in place,
> system characteristics are changed by reprogramming only).
> remotely possible that i can get down to the shop at lower base (the 
> one that makes sub parts) with
> a cnc vector map and some steel i can get a couple of quaife 
> replicas pumped out.
> other possibility is some sort of electrically locking diff 
> (tinkering with some designs, hard to
> make one that wont self destruct if engaged during slip condition).
> 
> electrical:
>     intend to run a +12v and gnd bus throughout, with a 
> bidirectional rs-422 (yes, 422, not
> 232) serial line going to all switched devices. serial line will be 
> ground/fault protected. any
> simple switched device (windshield wipers, dome light, headlights, 
> etc), will consist of a digitally
> keyed microcontroller driving an igbt to power its respective 
> component from the +12v bus. Overload
> will be handled by each individual microcontroller. Each item will 
> have an address to perform its
> function. +12v power distribution will use ckt breakers in a 
> selective tripping configuration.
>     Goal of all of this: it will save about 15 pounds in wire, do 
> away with the fuse/relay panel
> block as well as the spaghetti behind it/all over the car.
> 
> ok, well, enough of that, off to bed for me, gotta chop the rest of 
> the rocco tomorrow, throw it in
> the back of a van and bring it to the dump. I should have a couple 
> of interesting pics of various
> other cross sections (a-pillars, lower rad support, firewall 
> bulkhead, etc)... as i'm cutting the
> front section in half to get it into the van.
> 
> *this is already done:
> http://scirocco.dhs.org/vw/pics/0-allyn/project/index3.htm
> http://scirocco.dhs.org/vw/pics/0-allyn/project/index4.htm
> 
> 
> later
> Al
> 
> Allyn Malventano, ETC(SS), USN
> 87 Rieger GTO Scirocco 16v (daily driver, 170k, rocco #6)
> 86 Kamei Twin 16V Turbo Scirocco GTX ('it has begun', rocco #7)
> 88 rocco 16v (on receiving end of a sawzall and 7 sciroccos worth of 
> agression)
> 87 Jetta 8v Wolfsburg 2dr (daily driver, 260k, 0 rattles, original 
> clutch, driveshafts, wheels :)
> 
> 
> 
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> Scirocco-l@scirocco.org
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> 

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