2.5TDI + bi-vnt-turbo

[jayjay]

you nordic fellows! hahaha. it seems that every mind blowing ridiculous project comes from a back yard garage out of finland or norway!

[GoLfMan]

this project is just awesome

I also cant wait to see how it turns out!!!!

[shadowmaker]

Making the EvoIII head is taking time at the moment and I'm not sure that my van will be ready this summer at all, so I have decided to speed up some of my other projects: A Volvo S60 2.5T AWD AT -04 and Suzuki RG500 Gamma -86.

With Volvo there's just a matter to make gt40v (yes, a vnt) to fit under the bonnet. Goal is +500 streetable hp. Turbo needs to be located over the GB as it is volley ball size. Darton sleeves are also in progress, but almost everything else is already done (head with bigger valves, fuel system, IC, beefed up AT and turbine...)





Suzuki had some professional care and has ~150bhp with 142kg. It only needs few things and a good assembly.

Here's my pride and joy before I decided to tweak it some more .



Hopefully I get to test both these before our short summer is over...

We already know that vnts work with gas engines as my friend has been using gt17v with his previous ATV engines with succes. Here's my friends latest ATV with Aprilia V-2 1000cc and gt22v. Goal 240bhp.



Dual plenum intake is under construction. You can see it above IC, on the table.

And the other side.

[gldgti]

Goal 240bhp.

widow maker right there.

[shadowmaker]

It has been a while. I had my back surgered and got a baby girl, my third child. Now everything seems to be back to normal and I can focus on my projects.

Some ongoing aluminum work.






Here's my new dual airbox setup from Fiat Ducato under construction. Two 3" airducts will feed those from a roof scoop and boxes will be fitted into the trunk divider wall. This way I can use big paper filters instead of free-flow crap and have enough flow for far more than needed.







It's not going to look this spacy after I'm done. I'm going to need my trunk with second turbo, all the plumbing, heat shields, wastegates, WAIC, scavenge pumps...

[shadowmaker]

My friend's ATV got dynoed first time yesterday. At 0,6bar, 220bhp it started to slip clutch...

VNT seems to work and with mild setting it made 0,2bar @6000rpm in neutral. A lot is still to be made, but ice track racing is around the corner...

Here's a vid before dyno session. The owner says its too quiet now with the turbo on.
http://s50.photobucket.com/albums/f3...009011-001.flv

[shadowmaker]

Here's a dyno from my friend's ATV with 7psi which is the way they left it because slipping clutch. VNT stop screw is also in mild setting for now.



Here's a vid from the dynorun.
http://www.youtube.com/watch?v=0rrpn1SZmM4

My new WAIC between the stages. It will be big enough as LP boost will only be 1,6-1,8bar max. Sadly it's heavy.



Suspension parts for sandblasting and painting. New urethane bushings and adjustable coilovers to follow. I already have big 8 pot, 330mm front brakes and Brembo calipers for rear.

[GoLfMan]

awesome updates!!! keep them coming!

[shadowmaker]

DIY-drilled 300mm vented rotors from VW T5 + 4 pot Brembo calipers from Seat Cupra. Should be more than enough for the rear. Got also Wilwood hydraulic handbrake and Wilwood brake balance regulator.

Test fitting.



Some colour matching will be needed to go with D2 330mm front set.



I got also a promise from AVO to make me a custom coilover set (3-way adjustable). I'll just need to get them some measurements before they can start.

Transmission gets only dog engagement (and LSD if I can find suitable) and original gear ratios as we are not sure how much it will take. No point making expensive gears to a weak box. Maybe after testing it out first.

[gldgti]

wow, this is definately the most serious van build i've ever seen, apart from old air coolers

can you give me any maths on how you worked out the shape and area of the slot between the plenums on your intake manifold, and also the reducing cross section of the primary plenum? i have been attempting to make a 2 plenum manifold for my mk3 TD but i havnt found any real engineering data, just pictures.