05/21/2026
20 Years of RAT Legacy: The Epic 2006 Type 4 Torquer Cross-Country Test – May 2006!
Two decades ago, beginning 21 May 2006, Jake Raby and Bill Kanz loaded up the legendary Bluebonic Plague — a battle-hardened 1966 Type 1 VW Beetle restored in 1997 and used as the primary test mule for Aircooled Technology’s engine program — and embarked on one of the most demanding real-world durability tests in aircooled history. This wasn’t a casual cruise. It was a full-scale rolling laboratory designed to validate the RAT Type 4 Torquer (a 2270cc package) under every conceivable condition.
The engine, built entirely from off-the-shelf Torquer kit components with no special “trick” parts or assembly shortcuts, was installed exactly as it had been completed for its magazine feature. It had already been dyno’d at 170 HP at 5,500 RPM and 180 lb-ft of torque at 3,500 RPM. The trip would prove its reliability, power delivery, thermal management, drivability, and efficiency across America’s harshest roads.
Before the Trip: Engine Build & Magazine Feature
The Torquer engine was constructed specifically for a major in-depth build-up story in Hot VWs magazine. Hot VWs Technical Editor Dean Kirsten visited the Aircooled Technology facility to document the entire process — from case preparation and component selection to final assembly and dyno testing. This resulted in a detailed multi-page article (later expanded into the book “All About VW Performance Engines #3”, which featured an 18-page deep dive on the Type 4 Torquer). The engine was assembled, broken in on the dyno using Raby’s proven multi-stage procedure, and then installed in the Plague with zero changes for the cross-country adventure. The goal was clear: demonstrate that a properly engineered, off-the-shelf Type 4 package could deliver massive performance and bulletproof reliability in real-world abuse.
The Journey: 3,450 Miles of Proof by Fire
They departed Cleveland, Georgia, on May 21, 2006, with Jake handling all driving and Bill managing telemetry, data logging, weather monitoring, and two laptops from the back seat. No map, no radio, no chase vehicle — just raw endurance and science.
Trip Specs & Highlights:
• Total Distance: 3,450 miles across 11 states
• Vehicle: 1966 Beetle (Bluebonic Plague), curb weight 2,480 lbs with two occupants, fuel, and gear
• Drivers: Jake Raby (46 hours seat time) & Bill Kanz (data/telemetry)
• Departure: May 21, 2006
• Overall Fuel Economy: ~21 MPG (target 25 MPG; impacted by heavy testing, elevation swings, jetting experiments, and constant high-speed running)
• Average Cruise Speed: Mid-70s MPH sustained (peaks well into the 80s; multiple 50-mile stretches at over 90 MPH with rock-solid temperatures)
• Crankshaft Revolutions: 9,660,000
• Data Logged: Over 1,628 spreadsheet entries; 90%+ of the trip; 1.4+ GB of data
• Sleep: Only 16 hours total for both
• Other Stats: 160 gallons of fuel, 5 gallons of Gatorade, 8 meals, 46 roadkills, one traffic stop (Colorado Highway Patrol — resolved amicably after Jake showed off the engine), two wrong turns, and countless experiments
Terrain & Challenges Endured:
• Southeastern humidity and heat (Georgia/Alabama)
• Rolling hills and temperature swings (Kentucky, Indiana, Illinois)
• Brutal crosswinds on the Nebraska plains
• High plains leading into the Rockies
• Loveland Pass, Colorado (~12,000 ft summit): They attacked the steep ~6-mile grade at an average of 71 MPH in 4th gear, passing slower vehicles with strong, usable torque. Jake was driving so aggressively that Bill had to yell, “STOP — We are passing the Continental Divide!” They slammed on the brakes for a quick photo in the middle of the road. At the summit, they encountered Chrysler field engineers performing their own high-altitude testing, who were stunned by the Beetle’s performance.
• Desolate high-speed desert runs across Utah and Nevada (sustained 90+ MPH cruising)
• Highest CHT recorded: Just 393°F on the climb into Reno. Most amazingly was the cylinder head temperature delta which saw a peak of only 18 degrees F across all 4 cylinders over the entire data logged test period!
• One epic 23-hour, 1,000+ mile push; hail storms; a tornado, tire rub fixed with an on-the-spot grinder job in a Walmart parking lot
Constant real-time experiments included swapping 5 different test oils (with samples taken for analysis), jetting tweaks (e.g., dropping the #4 main to 140 to balance EGTs), propping the deck lid for inlet temperature comparisons, and dual fan drive ratio testing. Temperatures stayed textbook throughout.
After the Trip: Drag Strip Validation in Sacramento
Upon arriving in Sacramento at ~1 AM after the final brutal push, the Plague went straight to the drag strip for Bug-O-Rama. Fresh off 3,450 hard miles with zero mechanical issues and no engine changes, it still ripped off a strong 14.3-second quarter-mile pass at 94 MPH trap speed — undeniable proof that the Torquer’s power and durability were intact.
Legacy & Impact
This run wasn’t just a road trip — it was exhaustive proof by fire: sleep deprivation, mechanical improvisation, weather extremes, altitude, high loads, and relentless data collection. The validation from this adventure, combined with the Hot VWs magazine exposure, helped cement Raby’s Aircooled Technology engines as among the most reliable and powerful aircooled packages ever built. The Bluebonic Plague remains the original RAT test vehicle to this day.
Twenty years later, that same spirit of relentless real-world testing, American craftsmanship, uncompromising performance, and Type 4 mastery lives on in every engine that ships from the shop. The Torquer proved it could handle anything — and two decades on, the legend continues stronger than ever.
Here are some incredible photos from that unforgettable journey.
Follow this link for hundreds of pages of data, photos and results.
https://aircooledtechnology.com/aircooled-technology-cross-country-engine-test/
