Sam's build thread

[Sydneykid]

A few random comments/suggestions;
If you are running say a 20 psi radiator cap that will raise the boiling point to around 120 degrees, so there's headroom.
I'd wire in an override switch so you can turn the fans on anytime you want.
Oil generally heats up faster than water and doesn't fluctuate as much in temperature, so an oil/water heat exchanger acts as a dampener.
I recall a test on NASCAR engine where it produced it's best power at 85 degrees, we find similar, one of the reasons why we run E85.
Regular leak down tests (both wet and dry) are must on turbo engines, catch problems early before they get big.
Do they have a PCV valve, if so try cleaning it, a quick soak in petrol does the trick.


Cheers
Gary

[sambb]

Just tested the fan control module through the radiator fan switch plug. The low speed is coming on for the fans but not the high speed. So probably a shagged high speed relay. I've dug out the one I took off the old car and will throw that in. Once I get that sorted i'll have to re access whats going on with water temps cos if high speed fan control wasnt working in traffic that'd have been having a big effect.

I was chatting with SimonKK the other day and when throwing ideas around we thought that you could put the heat exchanger back in yet run it with an oil cooler too. In the water line that feeds the exchanger its hot water, you could run an in line tap. So on the street have the tap open so it works like OE but for the track close the tap so that water temp cant influence the oil temps and the oil then runs solely off the oil cooler effect independent of what the coolant temp is doing. A switchable way of having best of both worlds - Sound do able?
Yeah I threw in a spare (2nd hand) PCV which tested ok. I will ditch the plastic membrane ones for something a bit more solid when I get around to it, but yep the PCV valve did look ok and the PRV tested ok too.

[sambb]

Yay. Just picked up the new (second hand) K03 TFSI turbo. The exhaust Mani is ssooooooo much better than the OE one. There is zero free play in any direction in the wheels and it came with all the water/oil lines attached which is a mega bonus. The comp housing is much bigger than the K03s one ie it actually looks like a turbo rather than a little water pump. Having come off a 2.0L TFSI with its extra capacity, VVT and VVL, super high comp and direct injection to get it spooling I'm now hoping the turbo is not going to be too big for our 1781cc, but turbo tech has come a long way since our 1990's turbos and everything I've read says they spool beautifully so hopefully its on the money.

[simon k]

nice...

[metalhead]

Turbo sounds good!

Just heard from Graham Orr re Kempsey. He won his class under 2L in the CRX. He said that Daryl Small you know the VL commodore maroon and silver sport sedan thats always at Bathurst flipped his car end over end and landed on his wheels on the finish line and then got straight out of the car! He said it was pretty heavy to see.

Yeh, not good. Bill uploaded these, the first shot is a second before disaster...

[sambb]

Ah man. Thats nasty. Wouldve been a big hit for a 70year old body. There's always carnage at Kempsey. Graham said the road was really rough and broken up to the point of being sketchy.

[sambb]

Ok so I was wrong. The fan control module is fine. When you are testing the low speed of the fans with the low speed bridging you obviously need to leave the low speed bridge in when you put the high speed bridge in place. Bridging the pins in the plug for high speed wont work by itself. So yeah my fans are fine and the high temps are basically because of the combination of the way the thermostat (190 farenheit) and the fan switch work together.
I think i'll try a cooler fan switch in the radiator as cruising temps are fine, its just the traffic jam/startline temps that get too high, and if that doesn't stabilise the temps across all street driving then a cooler thermostat might go in too. One of them has been on the shelf for a while.

[sambb]

Standard BW/KKK K03's':

COMPRESSOR WHEEL
Inducer: 38mm
Exducer: 51mm
Tip height: 4.4mm

TURBINE WHEEL
Inducer: 45mm
Exducer: 38mm
Tip height: 6.8mm
Blades: 11

MK6 Golf GTI 2.0T EA888 Gen 1
IHI
6/6 Blade Cast Compressor Wheel & 8 Blade Turbine Wheel
40.2 mm Inducer / 52.5 mm Exducer - Compressor
45.0 mm Inducer / 41.0 mm Exducer - Turbine

[metalhead]

You're not coming up to Ringwood this weekend Sam?

[sambb]

**** whats on? not the state round??

edit: just dug out the calender. A club one I'm guessing. No I'm working all weekend on day shift. I'll use it to try and get a duct built for the oil cooler but that's about as racey as I'll be getting.