Aircooled VW South Africa

Look, the brand of turbo does make a difference. I have had brand new fong kong crap leak on the first startup. It had nothing to do with the oil return... it was simply a piece of junk to start off.

With your turbo mounted up so high there should not be any draining issues.

What oil pressure do you see on the engine when hot? Idling and max oil pressure?

Thanks for the advice and sorry for the hi-jack oil press has never been lower than 2.0 bar and i am pretty confident everything else is "right" the turbo as you said is the main suspect , im gonna try this one again as it has now been rebuild again , if there are any issues im changing it for a brand turbo right away.
Again thanks for the advice I will keep you guys updated

No problem.

What is the max oil pressure? Too high oil pressure might also be an issue if there is no restrictor in the oil supply line. I have used a Nitrous jet before, drilled to 1mm to restrict oil on a chinese turbo that solved that same kind of issue.

VW boost control valve installed and plumbed up. The waste gate pressure is set to 7psi and the ecu will control the higher boost levels
Vacuum accumulator (old combi fuel rail) installed and plumbed to the manifolds, fuel pressure regulator and dump valve.
Fuel lines done, feed from tank to surge tank, from surge tank to the fuel filter / pump, from pump to t section that feeds the fuel rails and then ends off at the fuel pressure regulator before going back to the surge tank. The idea was to use a stock beetle fuel tank, so I sent a perfectly good tank to "XYZ company" to get cleaned and coated to handle methanol. I was told it should cost around R1k to do but they will phone with a quote. So they phoned last week with a price of R2800.... to which I declined. Got the tank back and some one decided to hack the thing into 2 pieces. So there goes a perfectly good tank down the drain and an aluminium tank is now in progress.

Good work ! You must be itching to get this going after all the graft ! What fuel pump are you running (what press) I am thinking of changing my pump as you can only get to it with the engine out and i think the old pump might not have had enough oomph when its boosting . I have found a merc pump thats rated 7.5 bar which is maybe a overkill any thoughts ?

I'm using a Aeromotive A1000 fuel pump kit which is methanol compatible. For the open track days I want to run methanol to help with reliability.

The fuel pump that you use depends on the fuel flow required. The guys advertise these fuel pumps as 3 bar or 6 bar which means absolutely nothing. Look at the fuel delivery. Also the fuel delivery will change with pressure and voltage. See below example.

eg, a VW Golf Cti pump is 160lt/hr. Now to work out the fuel required, change that to cc/min. 160 x 1000 % 60 = 2666cc. Rule of thumb is that you need 1000cc to make 100kw on the wheels. So that pump is capable of 266kw on the wheels if all conditions are right.

For a turbo application I would at least look at a Walbro 255lt/hr pump to be safe. It's a good quality pump with more than enough volume.

Fuel delivery vs pressure:

for what its worth your return line from turbo can never be to big lol, I learnt to always use the largest possible line I could fit, currently im on 19.5mm id, 14mm worked but I had to drop my feed line restrictor from 4mm to 1.5 with the 14mm return, when I fitted the 19.5mm line I drilled out my restrictor to 2.5mm never had any issue, I use a garrett turbo, cheapy turbos just blow seals in like 200km if your lucky,

very nice build man, love the work your doing, I would love to see it in action

Ignition coil pack fitted and plug leads routed. I decided against the four individual coils mainly due to space constraints.
Front end almost done, new brake pads, bearings packed, brake lines routed... just need some tie rod boots.

Aluminium for fuel tank ordered.
Rear braided brake hoses ordered
Fittings for fuel filterers ordered.

Getting there slowly.

There is an event end of May that I would like to attend. If the #170 bug behaves next weekend it might be possible to be ready on time.

good luck Louis.
Work to the deadline, but dont rush to finish, be happy to finish a week late.

Looking good so far

Thanks Tony
I'm not happy with the car, I'll rather miss the event and go another time... but hold thumbs, maybe all goes according to plan

holding...

Dry sump tank cleaned and installed
Oil filter housing installed, oil lines almost done.

Got the fuel tank material yesterday, made some fittings and then welded it. Note, I am not an expert welder... so it does not look so hot, but I'll get there one day

Finished the fuel tank last night. Found a couple of pin sized holes in the welding.

Water spray tank fitted as well