2.5TDI + bi-vnt-turbo

**shadowmaker** · 24-03-2009, 09:35 AM

Sorry this a copy-paste of my build from another forum. Maybe this might interest some even down under...

The build up has started. Recepy:

-Evo3 head. It will be taken as far as it needs. Currently using Evo2 with bigger valves etc.

-New intake manifold.

-Performance cam. This will be something new and maybe it will need multiple takes to get it right.

-Twin turbo setup: I'm going to stick with the current one (gt23v-AMG) and add another vnt, gt37v to it. Luckily I have a big trunk... Things will be electronically controlled. This is the hardest part. I hope I get it right. For you that haven't ever seen a gt37v, this one is HUGE. Even HX50 is small compared to it.

-Additional A/W cooler.

-Fueling mods to get power up to 6000rpm, but I think I'll eventually need an additional pump to keep that bigger turbo happy. That's not going to happen with this build as this is too tricky as it is.

-New rods, lighter/modified pistons, knife edge crank.

-Lightweight SMF + twin carbon disc clutch. This is going to be the worst part for driveability.

-New gearbox with some exotic stuff in it: longer 1st, LSD from WRC Focus, dog engagement.

-330mm brakes in front + 8 pot calibers.

-Original rear discs + 4 pot calibers.

-Anti-lag system.

-Weight shaving up to 200kg, but that big turbo isn't going to make it easy (as it weights about 40kg).

-New angel-eye lights with custom look in the nose section. 6xHID.

I think I have almost every part ready, but it's not going to be a walk in the park...

Van:
http://i5.tinypic.com/455m13p.jpg

Old engine compartment with 350hp, 700Nm:
http://i16.tinypic.com/2laep0n.jpg

In action:
http://www.youtube.com/watch?v=hkSTslJf7Z4
http://www.youtube.com/watch?v=BDUgkusl6Uk

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Tearing it apart.

New Isotta chairs.

THE turbo.

**shadowmaker** · 24-03-2009, 09:36 AM

Intake will be looking something like this (left one). Long runners are going to be taken from D24 Volvo (6syl).

Here's some pics of the home made collector.

Small end.

Also decided to make a girdle to beef up the bottom end.

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Here's my new dual disc clutch. I'm a little afraid how it is going to behave...

Here's a donor for my dual plenum intake. Runners are 50cm long.

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We have a long winter here and nothing to do.

Some progres.

I think the old one served for some four years IRC.

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Now things are cooking. Exhaust is ready and intake is nearly ready.

It's time to take of the head and see what can be done to it.

Gearbox is long way from finished, but it seems that it can be done with the diff lock I have. Sadly it will require a lot of machining and special (=expensive) parts.

Custom made injectors are on their way and pump is under some serious construction.

**shadowmaker** · 24-03-2009, 09:38 AM

Manifolds were test fitted today for clearances. Both seemed ok.

It's time for sauna and refresments...

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Some ongoing electrical work.

Next one I don't recommend to anyone as lightening crankshaft is plain madness...

Original:

Under construction:

PLEASE DON'T DO THIS AT HOME!

**Greg Roles** · 24-03-2009, 02:35 PM

Freakin awesome. I SO get what you're up to, and why.

Quite the sleeper!

**shadowmaker** · 24-03-2009, 07:43 PM

Originally Posted by cogdoc

Freakin awesome. I SO get what you're up to, and why.

Quite the sleeper!

Well, my goal is to get road usable 450bhp out of it and with some weight reduction + traction upgrading maybe low 13´is doable on 1/4 mile. So it's not going to be THAT fast, but maybe will give a nice suprise to someone...

**Greg Roles** · 24-03-2009, 09:17 PM

One of the funnest cars I've ever driven was my Brothers modified Ford transit van with a Commodore (opel ) VN V6 in it ( the jap motor i think ).
That van weighed stuff all stripped out, and it was an absolute monster, burnouts everywhere, and it could drag anything the late 80's produced. Many a fun time had till it ripped the diff out of itself.

THAT sure surprised people!

Go the shadow hell bus!

**gldgti** · 24-03-2009, 10:10 PM

wow man, this is a serious build.

i'm impressed with your intake plenum design - like the idea of the large plenum to feed the runners and the feed plenum for the larger one to try to distribute the inlet air into the main plenum chamber evenly - and i guess a good idea for the street - given the amount of pressure you'll be putting on the internals, you want it all to be balanced nicely across the cylinders for engine longevity.... nice work.

that GT37 is HUGE. pointless remark i know, but mate, thats just plain BIG. i guess this kind of build could only really happen with a van, 'cos i reckon a turbo that big in a golf would just have to go somewhere inside the cabin - get lost passengers!

i watch with baited breath