VW Lupo 3L --> 2L

[California98Civic]

A specimen of bold awesome:

Originally Posted by Vekke

Nice chopping!

[AndrzejM]

Crazy project but I love it! Good luck with 2l testing. I'll keep my fingers crossed.

[Vekke]

Did the FE test today. Weather was nice +22 celsius but really windy.

http://www.youtube.com/watch?v=Wjv5E...ature=youtu.be

Drived 105-90 km/h speed and tried to keep instant gauge at 2 liters.

Total leg was 350.1 km and used 8.17 liters. Cars own gauge showed again pretty correct and calculated result was 2.33 liters.

There is clear difference to last test tanks.

Now the bad news. I think I broke my gearbox. I am not able to get 4 th gear in and gearbox makes bad voices :/.

[euromodder]

Originally Posted by Vekke

I did also some fuel consumption testing and current setup gives 2.3 l/100km @ 100 km/h average speed easily if cars own meter is still accurate. So there is clear improvement to last september.

That's pretty close to the 2L already.

Are you already running tyres that are A-rated for fuel efficiency ?
[unlikely, as they aren't available ...]

First attempt to reach 2 liters will happen on propably on Tuesday when weather should be plus 21 celsius.

Bummer about the gearbox though

[Vekke]

I knew it will brake sooner or later and it decided to broke sooner.

02M 6-speed FSM/FJW gearbox has taller gear ratios and can handle the torgue. Needs lots of fitting but I believe thats the only way to go. Now need to find some money tree...

[Fionn]

Sorry to hear about the gearbox, the same thing happened my first one - you might remember me mentioning it further back in the thread.
Unfortunately if 4th gear is gone then it won't be possible to repair it as 4th is part of the shaft.
As you say the 6 speed box will be a much better long term option. You will need new mounts and also have to cut away a bit from the left chassis leg to get it fit but it has been done.
Congratulations on the excellent results so far anyway, a real inspiration!

[Kriesel]

subscribed, looks like a very great build!

Wish we could get the Lupo in the states.

[ausias]

Maybe it is a lot easier to fit a JDD gearbox (Dif Ratio = 3.157, 5th = 0.658) and swap fifth gear from 0.658 to 0.625. this gearbox was standard in the seat ibiza ecomotive with the 1.4 PD TDI 80cv (polo BM, etc) and the proposed fifth gear that uses the same spring plate is also from a SEAT Ecomotive (but Leon, Altea, etc and recent Bm, Greenlines, Ecomotives, etc.).
The serial numbers are:
02Z 311 361 B
02A 311 158 AQ
Also yo can fit 0.622 and 0.588 5th gears that are very close to mad taller gearing on FJW/FSM i'm not sure but i think that D.R(V-VI)=2.407, VIth=0.756)
JDD is a kind of JXY gearbox (D.R = 3.157, 5th = 0.700) but with taller 3rd to 5th gear.

I think It will be easier to find parts from (unknown ¿ecoboring?) cars produced in the 2008-2010 and nowadays, than a 6v from 2001 to 2004 (FJW, FSM) that much people wants to pimp their rides when they add lots of BHP to their TDI of the most sold VAG platform because VAG mounts short 6v gearboxes from 2004 to now, losing lots of top speed.

It seems that the longest gear ratios will match exactly the ECO torque curve at 100 kph, but i think that the load of your engine now it is not so diferent. But i d'on't think that the lose of your engine tranny between 1800 to 1600 rpm will reduce fuel consumption a 0.33L/100km (you will need a freewhell and a downhill slope to maintain speed and saving almost the idle fuel consumptiom of you engine). maybe non linearities of the BSFC versus engine load will help also and improve efficiency with taller gearing, but i think you are very close with your actual gear or tires.
You said that your 5th actual gear has a freewheels on it. Will the manual gearbox add engine drag fuel consumption?
I think you will need to change you engine and downsize it to a smart 0.9 cdi to lower the fuel consumption at low speeds. or lower your cd more. or maybe chopping a cilynder
You have reduced several L/100kms the fuel consumption at top speed, i'm sure. but 100 kmhs seems low speed in a very light, aerodynamic, low rolling, good power to weight car. Good lock on finding the right gearing to save the needed fuel.

[Vekke]

Car is back to life. I took my silver 3L gearbox and put it in the red beast. Reason is that the second target of this summer is to faster than Golf GTI VI. This summer standing mile drag race is 6.7.2013 at Joensuu airport and that is where I need show is my lupo goes faster than 220+ hp cars.

Öljypiste SpeedParty 2013 ilmoittautuneet

Target cars to beat with 120 hp and 250 nm on that list are:
Skoda Octavia RS TDI 170 hp and 350 Nm
Honda accord 2.2 i-DTEC 150 hp 350 nm
Audi A4 avant 1.8T quattro 163 hp 225 Nm
Seat Ibiza 1.8T Cupra 180 hp 245 Nm
VW Polo GTI 1.4 180 hp 250 Nm
Skoda Octavia vRS 2.0TFSI 200 hp and 280 Nm
Audi 2.7 S4 B5 Avant 250 hp

On wish list

Renault Megane RS which is 264 hp 360 Nm stock
Subaru impreza WRX STI 280 hp 373 Nm
BMW 335i Cabrio 306 hp and 400 Nm

Target end speed is 208 km/h which was end speed of that Golf GTI VI. During this week I will try to make sure that the car goes 60-120 acceleration under 6 seconds which means after that car should be faster than that GTI.

That gearbox swap is only temporary as I was not able to get 02 type gearbox 228mm flywheel balanced on time.

[Vekke]

Ausias you havent seen all the tricks that the car will have. Also the ECU is not optimised yet for efficiency so that first test I was not able to do any P/G as its planned on that 2 liter record run.

And gearing is the biggest key to success I am afraid if I want to reach that two liters with steady throttle.