My bug - ANGRRR - the ongoing project

[Thumper]

Very very nice Tony!

Looks fantastic!

[Tony Z]

As and when time has allowed, I have been making plans to mount a small carbon fibre spoiler which I bought during a recent visit to Remmele in Germany. It is quite convenient that they are about 100km from my brothers place.

There isnt much of a story to this, other than the fact that you only get one chance to mount it. So you have to get it perfect 1st time.

The spoiler itself, which is to be mounted onto the roof.




After sanding the spoiler straight and neat, it was time to measure, remeasure, measure again and then mark.
As you can see, I used plenty masking tape (blue) and did my measurements numerous times to ensure I got it all right first time.
I also taped up all around the wing and the wing itself to prevent the adhesive from getting to places I didnt want it to get. Also, the markings showed me exactly where to put the wing once I had applied the adhesive.






Then after applying the adhesive it was time to mount the spoiler and tape it into place to it doesnt move anywhere.
Then I needed to add weight to it to get it to properly follow the contour of the roof and to keep pressure on it for the 24 hours it takes for the glue to fully set.


And then the final product, after washing the car and removing all the tape






And to the keen observers, you will see that I removed the bulldog sticker which was mounted on the car in 1996

[vader]

Very sex Tony...

Turned out fanF@ckingTastic!!!!

[retrovan]

Looks good on a photo, can not wait to see it in real life.

After all that effort, just to think you now have to pour Fiber Glass all over the Bug, to get an Mold of the scoop.

What some friends would do to help some friends.......

Herman

[riaanj]

Like the way you kept pressure on it, bags of screws, buckets, amplifiers!
Looking good, is there a specific place you need to mount for it to be at it's most effective? (a certain distance from the back window perhaps?)

[MarshallGTi]

those seats are super hot

[Tony Z]

Had the dyno session today. It was interesting to say the least...

the car has always suffered from a flat spot that I have not been able to do anything about. This has resulted in numerous timing adjustments with little luck. It turns out that the car is going massively rich from 3000 to 4200rpm, with plenty black smoke and popping.
All the jets in the IDFs were changed for different ones, including the emulsion tubes. F11 tubes worked out the best of the lot, we tried F2, F15 and F16. They didnt have any more and luckily I brought along a set of 40IDFs which I bought a while back which had the F11s in them. The emulsions cost R400 each so the dyno center doesnt carry a full stock of all the options...

The flat spot was ironed out as best as possible over 5 hours worth of dyno sessions including 14 runs for jet changes and 6 runs for timing changes. The flat spot looks horrible on paper but in the car it is pretty alright.
ANGRRR drives smoothly at lower rpm, with me even shifting into 4th at 1200rpm and when I put my foot down she runs up through the rev range smoothly. You would never say there is a 310 deg cam in there..... and the dyno guys couldnt believe it is that smooth with that much cam.

Needless to say, the results are as follows:
the car was only run up to a max of 6000rpm
Torque: 235Nm at 4558rpm and remaining flat and dropping to 225Nm at 6000rpm
Power: still climbing at the highest reading... 135Kw at 5764rpm
So yea, thats 181hp and still climbing.

The car a damn quick and sounds crazy. Easy to drive and best of all... FUN

[arnocill]

Congrats! Thats very impressive figures.
Keep going, only 19hp to reach the magical 200hp mark

[Bugger]

Congrat that is nice that power in a Beetle is really fun to play with

[vader]

So what is the comparison between the two builds? If I remember the power was 132kw but can remember what he torque fig was. Is there an estimate of total rating and why did you only run it to 6000rpm? Is it cause the motor is still new and not run in? I was thinking there would be an increase in the power fig but you did say it was still climbing when it max test revs. did you keep the old test read out to compare with this dyno run? Lets see it dude.

Good work Tony

[Tony Z]

The engine is the same as the last build exceept the cam was upgraded from 300deg to 310deg, with the same lift.
I should have increased CR a little with the new cam but didnt.

Old build never ran properly as I always had oil pressure problems due to faults in the casting of the aluminium case. The cam gear scraper port was tiny which I suspect lead to too much oil being foamed and then this foam would get sucked up causing oil pressure loss.
Previously power was 170hp, now its 181hp. It could have been more but in reality, the exhaust is sized for the smaller cam... but this is why I have such a flat torque curve now.

The main focus of the dyno test was to make the car streetable since it is a street car, so ultimate power isnt such an issue. The jets are fine to run up higher in the rev range.
Have a look at the video below. This is a 4th gear run, from 60km/h up to 205km/h. It was the second run of the day. No I didnt get to film another run.
From 0:08 to 0:17 you can see the extremely rich flat spot which I had from 3000rpm to 4000rpm. After that the throttle is lifted at 6000rpm.
Even though the flat spot is still there, you can hardly feel it while in the car. The aim of the dyno session was to get the flat spot sorted and do as best we can.
To be honest, I dont intent driving above 6000rpm in 3rd anyway... (6000rpm = 145km/h in 3rd and 205km/h in 4th)


Old dyno chart


new dyno chart


I'll prob try to get more out of it in time, but for now, at least I can enjoy the car without stressing too much about things or trying to figure things out that I dont have the equipment to test...

[vader]

Whats your oil pressure like now?

[Tony Z]

Whats your oil pressure like now?

Stable but too low. I need to put in my bigger pump sometime (again).

[4agedub]

What is low? 80'c oil temp 1 bar at idling? or does the light come on

[vader]

I heard the flatspot but after it runs sweetly.. Sounds amazing at 200kph what could be the cause of the flat spot? A/F ratio, blockage in the idle curcuit or maybe a problem switching between idle, mid and full throttle curcuits?