PetenAli's WBX 2500 engine build

[PetenAli]

Love it!!

[silverbullet]

Just like the Oettingers

I have put an "H" on the other side, to avoid any confusion...

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PS I have now got some more "tin" to get the mk2 oil cooler ducting finished.
I scrounged some 16g which is a tad heavy for the job, but at least it will be less inclined to resonate or flap!
Neil has a multi-tapped plate for gauge senders etc, good as new so we will see if it can be built in, or if we have to drill and tap the fittings.
The JX aux pump switch for the fan needs to "see" the oil temp going into the engine post-cooler, so it may be easiest to tap the central boss on the take-off plate.
Oil pressure could be taken from the filter head.
I am in favour of adopting Chris Corkins' oil pump bypass mod, the PRV will then dump returned oil below the new baffle plate and the pickup will then have a "clean" feed with no risk of aerated oil being drawn in.
The baffle mk2 is pretty close to being ready too

[syncroandy]

Fantastic stuff, mostly a bit over my head, but the bit about the fan-assisted oil cooler just caught my attention as I may ditch the chargecooler on my next TDI build, for simplicity, and instead use an intercooler, which would need assistance with airflow. Anyway more later on that, probably much later..

On the oil plumbing, could you use steel lines instead of hose, they'd save space ? I used some ally pipe in the chargecooler plumbing on my current TDI and it worked well.

[lloydy]

my intercooler does fine Andy

[silverbullet]

Andy. I couldnt be bothered with making bends, having them swaged and oriented etc.
Yes it would make it that bit more finished but at under 3m of hose its a no-brainer.

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Oil temp/pressure tapping plate trial fitted. Engine tube still needs to be remade about 15mm shorter because the cap bottoms out long before it all pulls up. I can't just run a die up it because
1. The threads are rolled, so the plain bit in the middle is undersize
2. I dont have a 3/4" x 16 UNF die!!!


Easiest way is to buy some 3/4 UNF x 3" setscrews, cut the head off and drill them.
And these finally arrived too

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Now I can have oil delivery pipes at any length I need. Simply cut off, chamfer and drill

[Aidan]

Tidy
Mike might need a custom one for oil cooler plate on HIS new engine , Si will be in touch

[silverbullet]

Rumour machine is already in gear

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Oil cooler fan ducting MK2 trial fit before spot weld assembly, a lot closer this time.



Bottom oil cooler union hole will be a bit of a pig to drill & punch (right angle drill) but worth the effort imho

[bikermike87]

Tidy
Mike might need a custom one for oil cooler plate on HIS new engine , Si will be in touch

[silverbullet]

Going to start a new topic for the oil coolers in Modified

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Forgot to show you what was inside those blue boxes....

[Syncrobaz]

Ash tray ?????