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| L110CDL Member Since: 31 Oct 2015 Location: Devon Posts: 10782  
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Sorry to but in, but i'm following this thread with great interest as its great what you are doing with the engines and you know what your talking about, really great
 1996 Golf Blue 300Tdi 110 Pick up.
Keeper. Clayton. |
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11th Dec 2016 9:21pm |
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| Boost Member Since: 17 Oct 2014 Location: Gloucestershire Posts: 203  
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As promised, some more photos!
Collection of cr@p  Click image to enlarge Click image to enlarge Click image to enlarge Click image to enlarge Click image to enlarge  |
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12th Dec 2016 9:08pm |
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| Boost Member Since: 17 Oct 2014 Location: Gloucestershire Posts: 203
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Oops double post
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12th Dec 2016 9:11pm |
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| jst Member Since: 14 Jan 2008 Location: Taunton Posts: 8051  
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have you checked the required air flow that turbo would need and matched it to the filter pipework, only that, and its probably the photo, that looks kinda small.
the tgv needs a min 3" for the c/s area to match required flow. Cheers James 110 2012 XS Utility 130 2011 M57 bespoke Camper 90 2010 Hardtop 90 M57 1988 Hardtop |
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12th Dec 2016 9:24pm |
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| Boost Member Since: 17 Oct 2014 Location: Gloucestershire Posts: 203
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Hi jst do you mean the diameter of the compressor inlet (or whatever it's called)? or the actual pipework diameter leading to the turbo?
Cheers |
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12th Dec 2016 9:34pm |
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| Boost Member Since: 17 Oct 2014 Location: Gloucestershire Posts: 203
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The purple pipe in that photo is 3" with a comically large K&N if that's what you mean?
Cheers Fred Edit: Just guessed c/s stands for cross-sectional area |
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12th Dec 2016 10:07pm |
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| Defendermatt Member Since: 15 Sep 2016 Location: Derbyshire Posts: 313 
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Glad to see you're making progress with this! At a much faster rate than what I am
Yes jst is talking about the c/s of the pipe from the filter. I agree on the picture it does look a bit small maybe because of the length of it. But 3" should be sufficient. Will you be using 3" from the turbo to intercooler and intake or the standard 2" ones? Also you might want to think about where the intake will be getting a cold air feed from, having the filter just lingering in the engine bay would not be as good as it being a real cold air feed not warmed by the engine. |
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13th Dec 2016 6:15am |
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| Boost Member Since: 17 Oct 2014 Location: Gloucestershire Posts: 203
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Hi, yeah it's coming along
I'm sticking with the 2" intercooler pipe diameter as not sure if there's anything to gain going bigger, correct me if I'm wrong though! I was thinking of routing the intake into the inner wing behind the headlight for a cold air feed, maybe drilling some holes under the plastic light surround for the full Mad Max effect .
Matt are you going with a kit for your Variable Geometry setup? (sorry if you've mentioned it earlier) Pic: Clearance with the stock oil return line - with the new turbo, its return is lower than the fitting on the block. Click image to enlarge |
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13th Dec 2016 6:03pm |
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| Defendermatt Member Since: 15 Sep 2016 Location: Derbyshire Posts: 313
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Ideally I would like to open the pipe work up a bit to 2.5 inch maybe. But going from 2.5 or 3 inches then closing down to 2 inches at the intake and IC ports will not be good for flow.
Like the sound of taking a hole saw to the front of the wing! 
Yes I will be having a kit. Not sure which yet and I'm a way off making the decision of what route to take yet. |
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13th Dec 2016 9:56pm |
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| Boost Member Since: 17 Oct 2014 Location: Gloucestershire Posts: 203
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I think you're right
 , the cooler in/outlets are 3" and i'll be using 2" piping. Plus a load of it's just turned up in the post today, Cock!
I had a harebrained idea to cut the front of the intake manifold (where a coupler slides on to accept the boost pipe) thus enlarging the intake to 2.5"... Along with a 2"-2.5" coupler on the compressor outlet... Damn it |
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13th Dec 2016 10:18pm |
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| Boost Member Since: 17 Oct 2014 Location: Gloucestershire Posts: 203
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On second thoughts, surely the difference in lag between 2" and 2.5" intercooler piping is negligible, especially as the compressor outlet on the turbo is 2"?
Also I've got a GReddy boost controller I've used with the stock turbo that can be used to switch between low boost (10-14psi) and high-boost (15-30psi???  )
Jokes aside what do people reckon a realistic safe boost is, for a burst of power for example? 20psi? All good fun in a 30 year old crate! |
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13th Dec 2016 11:31pm |
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| Defendermatt Member Since: 15 Sep 2016 Location: Derbyshire Posts: 313
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Yes any bigger pipes would not suit the fact that the IC and inlets are 2" still.
what intercooler are you going to use? I have run 20psi (1.5bar) on a challenge truck all day long. I have spoken with an Italian guy about a bi-turbo system he has built for the tdi and he said that runs 28psi on stock internals |
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14th Dec 2016 6:54am |
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| Boost Member Since: 17 Oct 2014 Location: Gloucestershire Posts: 203
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The intercooler I'm using is a big universal one with 3" in/outlets
Click image to enlarge |
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14th Dec 2016 12:11pm |
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| Defendermatt Member Since: 15 Sep 2016 Location: Derbyshire Posts: 313
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Looking good.
Are the outlets on the same side? |
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14th Dec 2016 12:22pm |
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