Let the tinkering get serious!!....

[sabloke]

Oh man, the wait is just killing me... Can't wait to see what torque figures she'll be pulling! Keep up the great work!

I was thinking to get a NOS kit form UK for mine but to be honest there must be more useful ways to shred the gearbox to pieces. Poor thing is pretty stretched as it is, no need for extra 50 horses there... 150+ kW at the wheels would be a lot of fun though

[Greg Roles]

Hang in there man, I'm two years in now, and to be honest these final stages will take a few months just in the fabrication alone!

Spent aster Friday on the car, and pulled the turbo to intercooler plumbing totally out. For the record the GT turbo is a Garrett GT1749VC, which by all accounts flows a lot more in the top end over the former VB model ( which i believe is on the 103kw ) and the even prior VA model which seems to be what the boys in the USofA have to play with.

The inlet of the turbo is 46mm outer and 41-38mm inner tapering. The vw elbow is part number 3CO129635 VCDR446019601. I'd like to find a straight version of that, for my paln is to make the inlet a straighter one. The turbo compressor outlet is 32mm, and those e-bay adaptors I bought that are for the GTI fit with a bit of dremel work. Suprising they are almost identical!

Also removed the oil pressure sender unit I drilled into the side of the oil filter housing, and liquid metaled a curved plate onto the inside of the housing. It's been oil tight thus far, and will put it in conjunction with the OEM pressure switch as suggested by Transporter. MUCH better solution!

[Greg Roles]

Had a good easter! Snow pump and plumbing is now in right up to the solenoid just past the intercooler outlet. Snow recommend putting the spray just past the intercooler to avoid pooling. Controller wiring is through the firewall and ready to hook up. QTP shutdown flap to replace the EGR mechanism is getting the o-ring necessary cut this week, and I'll be into the inlet plumbing in the next few weeks. The autobahn88 GTI adaptors all click in ( after a bit of lathe work ), and it's all down to a bit of inlet pipework now.



Tons of wires to hook up, but good to have them all in one spot finally! Made an alloy shelf to hold all the electronic boxes.



Starting to come together, bit of custom inlet plumbing and the engine bay is largely done!

[Greg Roles]

OK been busy, even though my thread has been quiet...

Turbo timer in the drivers pocket....and no it's not for the turbo...




I have to say hooking up all these electronics in one go is quite a mission. I'm about halfway through my "rough" install, once it's all working I'll tidy up all the wires, but for now it's all about just getting things functional. At this stage the water meth kit is up and ready to run, and I'm down to the last few things for each system. Anzac weekend will have it sorted!!



Basically I'll have the turbo timer to run my shut down flap, for the stock system uses the EGR flap to stop the airflow and thus engine without juddering and I think it's a wise thing should you ever lose a turbo bearing etc and get runaway. The timer can also run the air blower, and help move some air under the bonnet on shutdown to try and lower heatsoak on returning to the car after a short stop. I'll test it and see if it does help at all.

The Intercooler spray is run by the MAF signal and the temp probe in the intercooler fins themselves. The air blower is also run by a temp switch in series with a pressure switch, so if it's both hot and there's no airflow, on goes the blower, mainly for the lights. The final small kit is for the water level in the windscreen washer bottle, from which my intercooler spray is drawn.


Sounds simple, but there's been quite a few pages of nutting it out involved!!

[gldgti]

Nice work cog. Your finished system will have all the conveniences of a factory type setup (you do nothing, all automatically controlled) which is tops for a daily driver. I suppose all you'll really have to do is fill up the washer bottle when it says low

[Preen59]

Nice work, Greg.

I've been tempted to buy one of those boost referenced snow kits, but haven't worried about it just yet. Would rather get the other money pit going.

I'm extremely interested to see how your kit goes.

[Greg Roles]

OK, electroncs are all but hooked up, much neater, and I'm down to fine tuning this weekend. Onto the inlet now, and my Pa has lathed up the QTP, so the next phase is the inlet plumbing. I'll be sure to do a before and after dyno run on the stock ECU with the snow gear so we can see how it performs.

On that note I've just chatted tonight with the third person who is interested in going the DPF delete and water meth route, and I'd just like to say that there's NO WAY I'd be doing that on a DSG, and adding meth over the top of an already massive tune without a lot of monitoring, safety, heat etc mods, well I'd not be putting any cash on your engine / trans longevity. Remember the 2.0 TDI has a massive torque spike at 2000rpm, and it's THAT which is the problem, not the final NM handling fgure. I'm worried people will just take the power adding ideas I've listed without any of the cooling, monitoring and safety mods I've done, and there's a lot more than I've been bothered to list on my threads. An EGT gauge is the bare, bare minimum!!

Think it through people, the stock tune is showing dangerous temp spikes, water meth at 50/50 is still only "neutral", meth adds heat, water drops it. Hence all my other work to allow for that!

In the end it's your call, but I'm worried with the plans people have out there!

[h100vw]

Maybe 20% meth would be a safer mixture to inject Greg, at least it would pull some heat out. That top Snow kit has EGT monitoring doesn't it? Agreed it all needs logging to make sure it's doing it's job. That could be time consuming job, having read that thread I sent you.

Gavin

[Buller_Scott]

In the end it's your call, but I'm worried with the plans people have out there!

awww damn because i was gonna run a chip express plug in module on top of my track map, like some guys are doing with their GM diesels.....

lol j/k.

this thread is inspirational. you've got mega balls and A LOT of gumption. rad work, greg. most rad.

[ml16]

This is awesome mate, a great read.

Be interesting to see how the DPF and tune go. I am looking to do just a cat-back and CAI with a tune to mine and then focus on handling.

You are a diesel pioneer!