Twin - tech design stuff

[amalventano1@comcast.net (Allyn)]

quite trashed. not split, but bent all to hell on the pass. side. had a front impact so hard that it
accordianed the whole pass. side frame.
you know i wouldnt cut a perfectally good lower rad support in half.. heh
Al

----- Original Message -----
From: "Eric L Ellis" <onesixv@juno.com>
To: <amalventano1@comcast.net>
Cc: <scirocco-l@scirocco.org>
Sent: Friday, March 29, 2002 9:56 AM
Subject: Re: Twin - tech design stuff


> 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
> > http://neubayern.net/mailman/listinfo/scirocco-l
> >
>
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