The Superboxer, a new heart for the Silver Bullet

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Re: The Superboxer, a new heart for the Silver Bullet

Postby silverbullet » 20 Dec 2017, 20:27

More lightening. A bit of cheeky 4th axis milling and then more manual work.ImageImage

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Re: The Superboxer, a new heart for the Silver Bullet

Postby silverbullet » 24 Dec 2017, 09:36

The last bit of contouring/lightening around the starter boss etc.
Still a bit hefty between the top two engine bolts but very difficult to lose any metal from there, unless I put some deep curved slots in there, which is still an option.
The daft thing is that if I had known how bulky the clutch cover was going to turn out, I would have designed for a modern reduction gear starter in the first place and that tapered bowl wouldn't have been required...
Hey ho.

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Re: The Superboxer, a new heart for the Silver Bullet

Postby silverbullet » 28 Dec 2017, 19:39

Lightening is a sickness...ImageImage

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Re: The Superboxer, a new heart for the Silver Bullet

Postby silverbullet » 30 Dec 2017, 10:11

All done, bar the tapping to secure the clutch fork bearing.
Close enough to target weight for me!
New year means new induction heater, so I can finally get the pinion bearing renewed and reassemble the UN1 and get back to the engine build, which will be getting dowelled main bearings (aka "shuffle pins" in the US)ImageImageImageImageImage

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Re: The Superboxer, a new heart for the Silver Bullet

Postby silverbullet » 31 Dec 2017, 16:02

Final details, more by luck than design!
Just managed to squeeze in the clutch shaft bearing retaining bolt (although I will have to make my own bearing, no biggie) Image

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Re: The Superboxer, a new heart for the Silver Bullet

Postby PeteandNikki » 31 Dec 2017, 19:13

Wow! That is a thing of beauty. No wonder we are still waiting for that shifter!
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Re: The Superboxer, a new heart for the Silver Bullet

Postby silverbullet » 05 Jan 2018, 21:07

Thanks! I am quite pleased with it but if I were to do it again, I would have started from having the clutch made first and then the housing would have been 5mm longer and avoided some of the later headaches!

Tbh the shifters have been delayed by production value engineering matters, getting access to the relevant machines at the right time, outsourced processes etc etc

I should now be able to move on to the supercharger mounting and getting the inlet system made up.

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Re: The Superboxer, a new heart for the Silver Bullet

Postby silverbullet » 08 Jan 2018, 18:09

Ok...so now the clutch housing is all done (bar the shouting) I can return once again to the compressor mounting and inlet system.
A slab of perspex on tapered wood blocks on top of the engine case gets you a working plane that is parallel to the crankshaft.
Cramming in the vacuum bypass valve (essential for off-boost cruising economy) is still going to be a challenge, if only because of the very tight hose bends needed (I have wasted a good few quid on silicone so far)
At least VW knew that a kink in the coolant return hose would give me vital clearance!
Its looking like I will have to remake the inlet plenum too, its pretty well masked by the rh chargecooler...ImageImageImageImage

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Re: The Superboxer, a new heart for the Silver Bullet

Postby silverbullet » 12 Jan 2018, 20:10

Well our local platers made things nice and shiny again and then I got my thinking hat on again to try and get this damn bypass valve fitted.
Reckon I have cracked the problem with some lateral thinking but these 30mm bends are now over-trimmed, so Derby Performance Hose will get my money once more...ImageImage

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Re: The Superboxer, a new heart for the Silver Bullet

Postby Dutchman » 08 May 2018, 17:07

Very nice pice of enginering.
I'm will follow this threath.
Dutchman Robin, 1Z TDI + Audi gearbox.
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Re: The Superboxer, a new heart for the Silver Bullet

Postby silverbullet » 10 May 2018, 18:20

Thanks! Progress has stalled after the winter, I think that making the bellhousing burned me out for a while. If I can get the UN1 reassembled (I still need to replace the pinion bearing, but two gears are shrunk onto the shaft) then I will get some more enthusiasm for the project.

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Re: The Superboxer, a new heart for the Silver Bullet

Postby silverbullet » 25 May 2018, 11:11

The pics are back! But I wont be using photophucket ever again.

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Re: The Superboxer, a new heart for the Silver Bullet

Postby silverbullet » 18 Jul 2018, 17:38

Haven't posted for ages, but recent events could mean a slight change in direction for the project...
Another rare VW engine has come onto my radar recently, so I am considering using the box-fresh 2.5 as a base for supercharging. The NOS Mahle pistons are up to it, lower boost psi figures will result, but that will work nicely with the 9.5:1 true SCR making for a more fuel-efficient engine when cruising off-boost.
More later ;)

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Re: The Superboxer, a new heart for the Silver Bullet

Postby silverbullet » 20 Jul 2018, 21:43

I aquired a hardly-used WOSP hi-torque starter this week, so I've had a little tinker to find the best mounting orientation.
Settled on hard over to the offside, which minimizes contact with the coolant hose (removed a little redundant metal off one boss on the starter too)
Loads of clearance off the UN1 so no worries about the battery cable terminal getting too close and shorting out.
Life and work are busier than ever, but I am findi g some enthusiasm for this project again. Sometimes taking a long break is just what's needed to make progress!ImageImageImage

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