2.2 Stroker DOHC by STW

[fredio54]

hopefully young STW does that too, then there will be 4 of us! So proud to be the first to put a big holset on an fe3 :-) shame I can't prove what they can do for another year or so :-( I did prove what they can do easily though, but stretching things will take more time and effort.

[STW]

Sorry for the lack of updates, Most what i've done has been modifying the plenum... I'll get some pics of thast too soonish Though it doesn't look all that spectacular.

The parts start finally dropping in at slow pace, here's what I picked up today:




That's one problem solved (I hope...) Next I'll just need to get pistons, valves, rods, head gasket, turbo, manufacture a new exhaust system, get new charge air piping and intercooler, and so on.... so pretty much still to go!

[fredio54]

Is that 225 or 240mm?

Looks a million dollars! :-)

EDIT : 225mm of course, but why not go for something small diameter and multiplate if you were going full custom?

[STW]

We'll see about drive line modding when the time is due

[chief tool]

Flywheel looks nice.....have to admit.

One question, why did they make a continuous raised section, the stock one has some gaps....I am not quite sure why the gaps are there, but I am sure there is a good reason....maybe its to let the dust out.....

maybe there is no issue...but its probably less likely to shatter if its made the way yours is...

if you dont mind me asking, what did it end up costing?

[fredio54]

good point re the dust.

also, the oem ones have a neat little drain to the back from the centre to clear oil from leaking seals too. has it been balanced yet? obviously not as the pressure plate isnt on it yet right.

you could drill and radius for dust and oil and then balance afterwards if you wanted.

Also keen to learn of the price.

[Dutch]

hey your flywheel looks different then mine indeed... i think this is whats talked about..
some pics

[STW]

The machinist didn't want to do notches on the ring on strength issues; the wheel's light enough as it is, I just hope the ventilation works okay

The cost was pretty high, but very much in line with what other brands cost here; about 500€. I've seen the results of an exploded alloy flywheel, I'll take the hefty bill rather than chances. Also, I have service just around the corner if I need repairs/modifications on it There shouldn't be any problems with this thing though; the wheel's made out of 7075-T6 alloy, comparable to medium tough steel, and the friction plate is cro-moly. All threads are helicoiled.

[STW]

Okay, progress has been slow...


here's a shot from the VICS shaping, nothing much happened except some shaping and opened the channel between runners 2 & 3. The one between 1&2, that's a tough one.



Here's a shot from the inside. The sharp edge at the top is a real nemesis, it must be gone when the plenum goes back together. It'll create serious turbulence.


Finally, some dressing up I managed to do this weekend at the summer cottage. The valve cover is painted with VHT wrinkle paint, similar to what BMW uses in their M series engines The paint will be tough as hell, but it takes several days to dry. The idea is then to buff the letters and ribs into bare metal and lacquer them.

[STW]

The DOHC's on a slower period again, waiting for parts (expecially the rods...) and stuff. The intake porting is progressing, but it's slow and tedious job, I'll post images when I'm done with it.

Instead, here's something related:



My new radiator! The old one is/was busted anyway and had tough time keeping up with just the mild boost. This, however, should by capable of more... much more. The big thermo switch is from a SAAB 9000, it switches on at 88 degrees instead of 96 of the Mazda unit.




Slightly thicker than stock

[bpt323]

what year saab 9000 & where exactly is it located on them.... i like the 8° drop

[STW]

It's in the radiator too.. but the thread is 22mm, it won't fit a mazda radiator

[fredio54]

Originally Posted by bpt323

what year saab 9000 & where exactly is it located on them.... i like the 8° drop

A real man would control that with his EMS anyway ;-)

[STW]

Hardwired temp switch, direct battery feed and convection for post-run cooling!

Here's a big reason why the new radiator is going in NOW and not with the 2.2 beast:



That's brine and age taking their toll. I might also tell the reason why the rest of the fins are still on is because they are too jammed up with dirt and crap to fall...


The new and the old fan side by side. You'll see the old one was at the end of it days too. I need to braze mounting bolts for the fan, I'll provide some pictures tomorrow.

Also, a bonus; the valve cover with additional touch-up:


I kinda like it myself!

[SixSick6]

If you're doing porting anyways and spending top dollar on parts anyways....send it off to Extrude Hone - Deburring and Surface Finishing and you'll be happy you did.