Let the tinkering continue.....

[Greg Roles]

OK, we're at phase two. My first thread was a lot of rather trivial messing around and testing / learning, now it's time to start getting serious.

I had the hose for my intercooler spray made up today at Enzed, at a measly $25 for a 300psi hose. The plan is to put this in and set it up with the smart spray controller made from a modified mixture meter from Jaycar. I've built the modded kit, and just need to mount it all and set it up. Having monitored the intercooler temps for several weeks now, I'm convinced of two things:

1) the stock intercooler does a tremendous job of handling normal driving temp spikes, with turbo outputs around 120 degrees only giving a several degree post intercooler rise at speed. It's a great heatsink for normal road use.

2) The time you REALLY need an intercooler spray is after a minute or two idling at the lights or in heavy traffic. The pre intercooler drops down towards 40-50 degrees on idle, whilst the output which is normally a few degrees above "ambient" starts to heat up towards this figure. After 2-3 minutes they are almost the same, and the intercooler output remains well over 40 degrees for several minutes of driving afterwards! Heatsoak at the lights is by far the biggest issue for the TDI, hence my spray is going to be geared towards this area. My smart controller is adjustable to turn the spray on at a certain intercooler temp, and I'm going to co trigger the radiator fans in conjunction with a pressure switch, so the fans only run when I'm not moving / moving slow.

This way the forward shooting mist will be drawn into the cooler at idle, and do it's best to help when it's most needed. There's links in my old thread for the coffee pump intercooler spray, and the smart controller, both from Autospeed.

My next area to attack is the inlet, and apart from keeping the stock MAF for now, which is a obvious restriction but necessary till a custom tune can be added, the entire lot is going to be replaced. Will take a few weeks to get right, but I've amassed all the bits and had my handy old man lathe a few bits up as well. He's an electronics engineer with a hot rod affliction to boot, which is about to start coming in very handy. Go Pa!

Then it's onto the exhaust, and the DPF bypass dump pipe is the go, and I'm at the stage of working out how to fool the O2 sensor, but it's looking very possible. Keep my mostly stock pipe and DPF for 95% normal driving, and have a secret weapon for the fanging.

Meantime I'm saving my butt off for a normal clutch to replace the dual mass, and a Peloquin or Quaife "LSD" to help the poor thing launch right.

Going to be a good "next" thread.

[Greg Roles]

And just so you know it's not *just* the golf, I decided to give the old mower a bit of a pep up as well. Been fun porting it. Will be slightly overchoked...

[Transporter]

And just so you know it's not *just* the golf, I decided to give the old mower a bit of a pep up as well. Been fun porting it. Will be slightly overchoked...

Keep playing with that lawnmover and leave GT TDI alone.

[Greg Roles]

You of all people are gonna FREAK when you see what I have planned for it...

[Mischa]

sounds serious. a word of advice though; sort your suspension out before you start playing with the thought of LSD's and the like. with a better suspension setup you'll probably find that traction isnt an issue except fanging it around a corner in 2nd gear (or in the wet obviously). with more stable cornering your inside tyre will have more weight on it and be less prone to run wild.

[Buller_Scott]

hey cog, alot of people on the club seem to be upgrading maf to r32/pd150 etc, but i havent read too many that are doing maf delete.

what would be the advantage of a maf delete?

[Greg Roles]

A bigger MAF is the way to go, but the sensor is designed to give a reading proportional to the cross section, so there's no guarantee a diesel would be fuelling right with a bigger version. It would be worth testing though, and may be on the cards.

Deleting the MAf wouldn't be a great idea, as the car uses this to get the fuel mix right, and you need that sort of fine tune controll to get the max power out of the thing.

Suspension on the cards too Misch, but good point all the same, it's all a matter of the cash!

[swingn]

I'm new, so you'll have to forgive my ignorance

Very interested in seeing the results you get & by the sounds of thing you have truely done the research

But what is it you are trying to achieve? Better drivability & longevity? Uber power & nm?

Like I said, I'm new here...

[Greg Roles]

"For those 13 seconds or less, I'm free"

[Buller_Scott]

I'm new, so you'll have to forgive my ignorance

Very interested in seeing the results you get & by the sounds of thing you have truely done the research

But what is it you are trying to achieve? Better drivability & longevity? Uber power & nm?

Like I said, I'm new here...

hey swingn

the best thing to do would be to read cogdoc's thread entitled "let the tinkering begin..."

that has lots of pics and good comprehensive explanations by not only cogdoc, but other members.

i've learned alot from these guys.

but in a nutshell, basically, cog is putting systems in place that not only improve on the stock systems for ease of maintenance and facilitation of longevity (for example, his provent which reduces sludge buildup in the intake manifold; and his intercooler water spray which reduces intake temps without having to spend the money for an upgraded fmic setup for normal driving conditions), but these systems will also allow his car to run more healthily when he DOES start to do power upgrades.

see, he's patient. many people (including myself) would chip it before having the gumption to complete the mods that he has BEFORE power upgrades.

hope this helps