building a sportquattro

[Acidburn]

Looking good, what sort of power you aiming for?

[Jeffer]

just fitted all the stuff on a mockup cranckcase, and it fits perfectly. Really pleased with the results. Now the fabricating starts on the sump and the intake manifold. The throttleody is a 3" wilson manifold one.

[G60Rallye]

Just utterly amazing!!!!

This car is going to be such a spectacle when its finished!

[newsh]

Beautiful work Jeffry!

[Jeffer]

[Jeffer]

Today I've been in the workshop with a dutch Audiforum member (Arlo). We machined the bits for the drysump system and inlet that I have designed previous in Solidworks.
We also made everything from aluminium. Als the bearing girdle, thats 15 mm thick alloy. We also Anodised it on the spot. The finish is excellent. Thickness of the anodisation is 15 Mu and really hard. The rest of the parts need welding and will be anodised later on.

[quattro84]

I'm helping Jeffer out with the drawingparts.. especially the FloWorks calculations.
Like said the current design is based on buyable standard 90 degree bends.. I did some flow calculations on them and the seem te be almost perfect within 1,5% difference in massflow per cilinder. But unfortunately my design had an extra bend directly after the throttlebody. This makes that the flow is almost even.

With Jeffer's setup the extra bend isn't possible, so most likely i have to add an internal air divider to steer the massflow of air. I'll post up some results when i have the entire intake routing ready for flowtesting.

Same goes for the watercooling routing for the CC.. FloWorks can figure out losses in speed & flow, aswell the heat dissipation. I'd like to try an other coolant than water to make it more effective.

[gnutz2]

I see what you mean, i,m using -12 lines it would be intresting running a flow meter on one of the lines to see the actual flow with all the losses taken into account.

I think coolant lines for the CC the same size my engine coolant (32mm) would not be over kill.

Look at the CC lines on this renault F1 engine and its running IC's aswell.

[Jeffer]

Hmm, thats one big radiator. Much bigger then I had in mind.... Have you tried with some extra liters of coolant?

- 7 liter tank
- 20 liters per minute pump

SO that means when you are WOT throttle for 15 seconds (with the current limited flow in the lines) there is actually passing 5 liters of water through the core. Thats not a lot..... Thats still 2 liters of unused water. So you should increase the lines and the bigger pump again to gain effeciency,

76 liters per minute pump (1,25 liters per second)
15 liters water
15 secs WOT (wich is long with a GT42R )

That results in 18,75 liters of water that will pass through the CC. Only if the lines will flow enough ofcourse..

So you use -12 fittings for you plumbing?

[gnutz2]

This is my CC radiator with -12 fittings, i was suprised to see high inlet temps.

[gnutz2]

What are the spec of you CC setup? liters of water, size of core, size of cooler? Interesting to know. I'm planning on putting the tank in the boot, with 15 liters of water in it. It'll have a Meziere 20 gallon waterpump attached to it. So with all the lines I think it'll be close to 18 liters of water for the charge cooler. The core itself is a Garret core wich they rate to a 1000HP..... Concidering the rest is up to the task aswell

My CC is 280mm x 120mm x 120mm, i did run a 17.5 gallon a minute pump but found inlet air temps were high so i changed the pump to a more conventional 20 l/m (4.4 gallons and hour) pump and the temps were about the same so i assumed the 3/4" ID pipes i'm using were limiting the flow of water.

I think my coolant volume is about 7 litres so your system will have a big advantage over mine with that volume of water as it will take longer for your system to be saturated with heat.

I'm sure some good field tests will proove your system

[G60Rallye]

18 litres of water! Can it give that much power advantage over an air to air intercooler to warrant all that extra weight?

[Jeffer]

What are the spec of you CC setup? liters of water, size of core, size of cooler? Interesting to know. I'm planning on putting the tank in the boot, with 15 liters of water in it. It'll have a Meziere 20 gallon waterpump attached to it. So with all the lines I think it'll be close to 18 liters of water for the charge cooler. The core itself is a Garret core wich they rate to a 1000HP..... Concidering the rest is up to the task aswell

[gnutz2]

Once again great work

That looks like a charge cooler core you have there, i found on my CC that inlet temps get a little high but you have about twice the core size of mine.

With the size of that turbo this project looks like a drag racing machine so maybe you could run the CC coolant through a tank with ice in

[Jeffer]

the inlet manifold is flowed to some extend in Solidworks.... The plenum design can still vary. I've now used commercially available alloy weld-els to see what can be made with that. The drysump system is going to be like in the drawing. All components are in for the drysump system, except the drive pully. I now found a drive pully wich has enough "flesh" to machine fit it in between the plate and the timing belt cog. The sump pan will be a machined flange, and a alloy sheetmetal cover. So it'll be fairly easy to construct.