Project tdi...

[martin_r_smith]

Looking good mate, reckon your ready for the strip now

Maybe but going to run it for a while to see how the DMF handles 360+ ft/lb at 2500 rpm!

[Jamest5r]

Maybe but going to run it for a while to see how the DMF handles 360+ ft/lb at 2500 rpm!

That's going to be interesting

[stribo]

Looking forward to seeing it smoking it's way up the strip.

[martin_r_smith]

Looking forward to seeing it smoking it's way up the strip.

If the mapping goes well it shouldn't really be smoking at all! I'm trying to keep it as clean as I can to be honest, I'm not into this 'rollin coal' malarkey.

[Jamest5r]

If the mapping goes well it shouldn't really be smoking at all! I'm trying to keep it as clean as I can to be honest, I'm not into this 'rollin coal' malarkey.

You will be once you start chasing times trust me

[Doingitsideways]

There good engines really, very strong. I have a plug in box for one of these that gave me 170bhp and 270lb/lb on its own, 190bhp with an mbc and decat. Id sell it to you if your interested.

Yeah, I have/selling a 960 that I dropped a D24 in, the D5252's 6cyl daddy.
That responded really well to a massive hike in boost (from 8 to 22psi) and some fiddling with the fuel pump.

I'd be very interested in the tuning box. What's involved with it?
Just it just turn it into a smoking machine and make it drink like a fish, 'cos I have the T5 for that! Lol
Have to collect it yet and assess it as it stands yet anyway. It's done a fair few trips to the moon and back.

Let me know how much you'd want for it though

[klunk]

You still on your standard main bearing bolts martin?

[martin_r_smith]

No I've got newer vag tdi 12.9 grade.

[Doingitsideways]

I've heard about the crank bolts being weak.

Any idea what sort of power they become suspect?

[martin_r_smith]

Not really, they can go on standard cars just as easy as tuned ones. Shadowmaker ran his 280+hp one with standard bolts with no issues. I don't know of many that have actually snapped but whilst I had the sump off to replace the gasket I thought why not!

Probably best to worry about it when it happens I reckon.

[MaxTS]

Cool project. I had a Peugeot 205 with a 1.9 XUD CG paddle un-sprung clutch, KKK K04 turbo, FMIC and 11mm hybrid Bosch pump from a Transit van. I had it dynoed at 190BHP and in a 800kg stripped shell it was great fun!
I do still have a GT2052s sat in my garage ready to fit an XUD.
I was looking into VNT turbo's and a few guys from the French side use those with inverted boost cans (standard VNT's run off vac so the need the spring swapped over to go the other way as you probably know anyway) and they oven up the vanes with boost, it's crude but it works. The trouble with that is they can surge because of the mechanical pumps being hard to control so you have to control them with your right foot. But with ECU controlled DI they are very very good.

[klunk]

D24 the D5252's 6cyl daddy.

Hardly mate, The D24's a dog in comparison!

[martin_r_smith]

I've been having a few boost problems but pinpointed the issue, the mbc! As it had to be wound in so far to hold 24-26psi the tension in the spring was so great that after it had opened it would release pressure and snap shut agai, thus causing my pulsating boost.

I've turned it down a fair bit now but I'm on the look out for a better mbc, any ideas or recommendations? I would use an electronic controller but they are pretty pricey.

I should be getting my updated tune in the post next week ready for a bit of dyno testing!

[Henk]

I was looking into VNT turbo's and a few guys from the French side use those with inverted boost cans (standard VNT's run off vac so the need the spring swapped over to go the other way as you probably know anyway) and they oven up the vanes with boost, it's crude but it works. The trouble with that is they can surge because of the mechanical pumps being hard to control so you have to control them with your right foot. But with ECU controlled DI they are very very good.

I'm looking at putting a VNT on mine (GT2256v), but controlling it is a bugger. A simple standalone ECU would be best, to be able to modulate boost better, as driveability should be better. Have a solution using boost and throttle position, have seen engine vacuum used also but not sure what that means exactly (load, speed?)

For the hassle though a standard wastegate turbo is probably much easier!

[martin_r_smith]

The joys of modifying cars...... Or not!!

On the rollers testing out the latest remap, 3-4 power runs in we noticed the coolant level rising and the pipes getting very hard. The conclusion is the head lifting under full boost, b0ll0cks!!

Need to source some stronger head bolts now and as usual there is nothing of the shelf for this. If anyone knows of a M12x1.75x115mm head bolt that's high tensile (12.9 grade) could you please enlighten me.

[martin_r_smith]

Right new head bolts in, try her out up the road, come back for a check and the expansion tank is full to the brim. Cooling fan on (first time I've seen it on) and monumental pressure in the coolant pipe, but the bottom hose is still stone cold?? So out comes the brand new thermostat in a pan of water, low and behold 100 degrees and still not opening. Just goes to show even new stuff can be defunct . Fitted another new one but tried it first! All is good again!

Had a cheeky blast on the dyno and got 237bhp 364ft/lb. Pretty happy but still needs some tweaking, not so much for power but to tone down the delivery a little!

[Doingitsideways]

Awesome!

Bet it comes on boost with a bang!!

[t5 pete]

Right new head bolts in, try her out up the road, come back for a check and the expansion tank is full to the brim. Calling fan on (first time I've seen it on) and monumental pressure in the coolant pipe, but the bottom hose is still stone cold?? So out comes the brand new thermostat in a pan of water, low and behold 100 degrees and still not opening. Just goes to show even new stuff can be defunct . Fitted another new one but tried it first! All is good again!

Had a cheeky blast on the dyno and got 237bhp 364ft/lb. Pretty happy but still needs some tweaking, not so much for power but to tone down the delivery a little!

Good news

[martin_r_smith]

Awesome!

Bet it comes on boost with a bang!!

It does! But the poor 16t isn't man enough for the job so I'm on the hunt for a suitable replacement, either garret gt3067 or if I'm very lucky to find one a holset he221w. The later is preferred really.

Bad news though, on fuelly I've dropped to 40.3 mpg sure I'll get over it though

[Doingitsideways]

Pmsl!!

Nice turbo choice there.
How much boost are you running?
Not surprised the 16t's shatting itself!