Project tdi...

[t5 pete]

You could gain some pennys tho by sending piccys lol

[martin_r_smith]

You could gain some pennys tho by sending piccys lol

I've not been back over to the lock up yet but hopefully this weekend, although they may go well on a new project in the pipe line.

[Casual Alien]

There's no pointing doing anything with the inlet manifold, the turbo is far more of a restriction to be honest. You could always cut it in two and smooth everything out, you won't gain anything with a standard turbo but it you plan on changing it may be worth while.

Ok fettling session postponed.

What turbo do you recommend?

[martin_r_smith]

Not sure yet, I'm working on it myself. Important thing is though to get the fueling sorted first, as it doesn't matter how much air you've got going in if you have no fuel to burn!

[Casual Alien]

Not sure yet, I'm working on it myself. Important thing is though to get the fueling sorted first, as it doesn't matter how much air you've got going in if you have no fuel to burn!

Got ya....I'm just collecting recommendations for my pipe dream!

[Henk]

would have thought the stock manifold would give a fairly imbalanced flow, it would be interesting to compare across there.
Might be a consideration if the target was seriously high hp
Modifying the inlet to be a dual plenum would be a solution

but for 200hp... wouldn't have thought so

[martin_r_smith]

I've had enough of the juddering so having the clutch changed again next week, not bad 2 clutches in 10 days lol. This time a stage 2 kevlar clutch from CG motorsports. They kindly offered to swap it for the dual friction one i have now as I was quite disappointed with how it behaved at slow speeds.

Hopefully the kevlar one should be a lot more like a standard clutch for everyday use, anyone used one before?

[t5 pete]

That's really decent of them to swap it now its your turn do do a good deed and get my pictures lol

[martin_r_smith]

Well after I gave them an ear bending about how it wasn't still "daily driver feel" like the quote on the website, I think there doing it just to shut me up! In all seriousness I couldn't fault the clutches performance when driven hard but you can't drive like that all the time and for me the slow speed drivability was far to compromised to be acceptable.

About the wheels, I think I'm going to keep them for now for a little project, ford based lol. But... there is a 940 up the road with a set on for sale so I'll keep an eye it.

[martin_r_smith]

16t arrived today, hopefully I'll get it fitted before the dyno day. Just need to figure out where to root everything and plumb in some water lines.

[martin_r_smith]

Hit a small hurdle, I thought my turbo shared the same inlet flange as a 16t, but no. So progress has been halted currently until I can get a 850/70 manifold and cut the flange off to weld on my manifold.

On a good note however the second new clutch is in and I'm very pleased to report it is judder free! Happy motoring again.

[martin_r_smith]

Small update.

16t now mounted to a spare manifold, lots of cutting and welding was needed in the end and the use of various flanges. New map is on the way from Dirty Torque in Shrewsbury, I gave up myself simply because I just didn't have the knowledge to do a good job. DT have been very helpful and I should have the first map tomorrow ready for a dyno sesh on Tuesday.

I'm hoping with the new turbo, bigger injectors, 3" intercooler with 2.5" pipework, map to suit and a couple of fuel pump tweeks I should (fingers crossed) be making around 240bhp and somewhere in the region of 340-360 lb/ft. I'll put some pics up soon too.

Does anyone know of another high power 850/v70 tdi in the UK?

[Henk]

Hmm, I'm in Shrewsbury, may have to get into contact with them.
have you had to do anything to the ECU to have it remapped, Thought they were 'fixed' like the TDi VWs are.
Care to share what parts you're using? Still got the air-con condenser too?
Have been looking at DSS or HFLO-X injector nozzles, have a GT2256v turbo but will get an adapter instead of cutting and welding.

Respect for breaking new ground with these engines, only yourself and Shadowmaker that I know of that have done anything to them.

[martin_r_smith]

Hmm, I'm in Shrewsbury, may have to get into contact with them.
have you had to do anything to the ECU to have it remapped, Thought they were 'fixed' like the TDi VWs are.
Care to share what parts you're using? Still got the air-con condenser too?
Have been looking at DSS or HFLO-X injector nozzles, have a GT2256v turbo but will get an adapter instead of cutting and welding.

Respect for breaking new ground with these engines, only yourself and Shadowmaker that I know of that have done anything to them.

Yeah the ecu is socketed to accept reprogrammed eproms. I do still have air con yes but it might not stay yet as it doesn't currently work anyway! I use DSSR nozzles from United diesel, also in Shrewsbury. Keith there has been very helpful and I can't recommend them highly enough. The intercooler is a little unknown, I bought it off cherry on here but not sure on its history. Interesting you choosing a vnt turbo, I did think about it and I'm sure DT could utilise the egr map to control the actuator. A GT2256v should bolt straight on as the tdi has a T2 flange, but if not an adapter should be ok as long as it's not to long as it pushes the turbo right up against the master cylinder. My exhaust is a 3" downpipe to a decat 2.5" with only one small silencer.

I know of Shadowmakers crazy beast, but i wont be going to those levels, 240/350 will be fine for me.

[martin_r_smith]

Thought I would put a few build pics up.

All the front end removed ready for the big intercooler. It seems I have even less space than a T5 to wedge a 3" one in but it is going to be possible.


Manifolds removed to make way for the 16t.

After some swear words the 16t fits a treat. A custom bracket for the actuator had to be made due to the turbo being rotated.



The oil feed and return lines needed modifying and I was quite surprised how much smaller the diameter of the c70 return line is compared to the tdi one. Going to see how I get on without water lines to start with, I have read up on it and asked several experts their opinion and they think it will be fine as a diesel runs a lot cooler.

[martin_r_smith]

Found some more pics..

The modified manifold ready to take a td04 16t, next to old k14 housing.


It is surprising how restrictive the standard one is really. With the poorly designed wastegate setup of the standard k14 too its not surprising 200+bhp isn't really possible, believe me I tried!! Exhaust manifold pressure is huge due to the restrictions, so much so the exhaust valves cannot seat properly due to the back pressure.

Modified 16t flange to mate up to standard t3 flange.


This is the manifold with the 16t on.


I have used the old egr port to place a fitting for monitoring emp.

[Jamest5r]

Looking good mate, reckon your ready for the strip now

[Doingitsideways]

Excellent build. Following this with great interest.

I've just bought myself an 850TDi for work.
Will never be modded to the level of yours, but I'm sure some of your experiences will be transferable.

Just need to find someone around Manchester to map the bloody thing first!

[martin_r_smith]

The big intercooler was a tight fit but managed to go in with minimal trimming to the front panel. I know people will wonder why I haven't relocated the horns or trimmed the centre piece out for 'increased' air flow, but i wanted a completely standard look so they are staying where they are.


Nice shot of the turbo all plumbed in. The copper coil is to disapate heat from the exhaust gas before it gets to the guage to monitor emp.

General overview of the engine bay now it's all back together. I'm going to paint the shiny pipe black as it's not 'factory' enough for me.






The pipe work from the turbo to intercooler had to be changed due to the outlet on the intercooler coming out of the side not the front/back where the original one is. The hardest part was replacing the stupid twisty factory bottom pipe, what a crap design that is! Anyway all 2.5" now and nicely routed. Couldn't get great pics of it but you'll get the idea.





Can you spot what's missing here??

Give you a clue it weighs about 15kgs and is the size of a suit case lol.

[martin_r_smith]

Excellent build. Following this with great interest.

I've just bought myself an 850TDi for work.
Will never be modded to the level of yours, but I'm sure some of your experiences will be transferable.

Just need to find someone around Manchester to map the bloody thing first!

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.