Twin - tech design stuff

[amalventano1@comcast.net (Allyn)]

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 :)