~My 91 GLI to 1.6TD conversion build up~

[53 willys]

well turbonetics finally gave me my quote...they want $1,049.00 for the ceramic ball bearing turbo that will support 200hp..but still be usable in the lower RPM range...then I would still have to get a T3 exhaust manifold and a external wastegate...

so here is the break down
turbo=$1,049.00
manifold=$110.00
WG=$325.00
1,484.00 :x



so what are my options?? this would be a absolute KILLER set-up...but damn it's spendy!!
I'm real temped to get a journal bearing turbo..but I just can not seem to find one I want with good specs....I kinda want to try a K14..but they are expensive to buy..even used and I'm worried it is to small for my 170+hp goal?
I want the power...but I want usable power too.

VNT seems like waaaaaay to much hassle I would almost rather buy the high end turbo vs VNT...and I cant even locate a VNT17 or 20 anyways!


suggestions?

[88jetta350]

thats an odd valve cover all of mine have the oil fill on the normal passenger side where yours is opposite! and i have 3 of them!
wher you find that one at?
other wise looks good!
keep the pics. coming!
Duane

yeah I dont know whats up with that cover?? I bought it from a guy on Vortex... the ad had no pics...anyway I am glad it has the oil filler on the drivers side cause my intercooler piping would cover the oil fill cap if it did not come on the drivers side.......some one said it was a G40 polo cover??? but I have no clue??? :oops:

thanks for the kind words

If this isnt known Ive found where the VC is from. Its from a UK Mk3 8v GTI. Found a limey on the Vortex with one on his car and I asked.

Since nobody else knows what that valve cover came off of, allow the n00b. :lol:

Yours:


Euro Spec Golf 3 GTI 2.0 8v. Engine code AGG. (What Europe got instead of the ABA.)

Beat ya to it.....  :wink:

[Rabbit on Roids]

well turbonetics finally gave me my quote...they want $1,049.00 for the ceramic ball bearing turbo that will support 200hp..but still be usable in the lower RPM range...then I would still have to get a T3 exhaust manifold and a external wastegate...

so here is the break down
turbo=$1,049.00
manifold=$110.00
WG=$325.00
1,484.00 :x

ok, so instead of working the guts out of a single turbo on these motors.. and either having good spool off the line and none up top, or have no spool off the line but have it pull like a mother after about 3500.. why not take the best of both worlds? have a smaller turbo.. like a VNT 17, 20 or something for your first turbo, and have somethin quite a bit bigger for the 2nd turbo. im really fond of the compound turbo idea. 3/4 ton diesels sure like compounds. and if you had big enough turbos, and WG's set up good, drive pressure shouldnt be an issue should it? and pretty much im talking fabricate every aspect of this setup.. a custom fabbed manifold would probably be the best bet im thinking.. i havent seen a manifold for under 700 bucks that i thought would be any good at making power and keeping restriction down. i mean, maybe this is just a pipe dream of mine.. but popping the hood on my rabbit and seeing a turbo beside the engine would be cool. then look a little closer.. "holy crap, that thing has 2 turbos!"  :twisted:

[53 willys]

well turbonetics finally gave me my quote...they want $1,049.00 for the ceramic ball bearing turbo that will support 200hp..but still be usable in the lower RPM range...then I would still have to get a T3 exhaust manifold and a external wastegate...

so here is the break down
turbo=$1,049.00
manifold=$110.00
WG=$325.00
1,484.00 :x

ok, so instead of working the guts out of a single turbo on these motors.. and either having good spool off the line and none up top, or have no spool off the line but have it pull like a mother after about 3500.. why not take the best of both worlds? have a smaller turbo.. like a VNT 17, 20 or something for your first turbo, and have somethin quite a bit bigger for the 2nd turbo. im really fond of the compound turbo idea. 3/4 ton diesels sure like compounds. and if you had big enough turbos, and WG's set up good, drive pressure shouldnt be an issue should it? and pretty much im talking fabricate every aspect of this setup.. a custom fabbed manifold would probably be the best bet im thinking.. i havent seen a manifold for under 700 bucks that i thought would be any good at making power and keeping restriction down. i mean, maybe this is just a pipe dream of mine.. but popping the hood on my rabbit and seeing a turbo beside the engine would be cool. then look a little closer.. "holy crap, that thing has 2 turbos!"  :twisted:

hey man I am with you fully!! on the compounds...the ONE problem with compounds is they run lot's higher boost then a single...and that higher boost is gonna be murder on the head gasket!

I have been saying I want compounds from the get go!
but now that the headgasket is so hard to keep clamped down it worries me to run compounded turbos....
Shoot I could do compounds REALLY cheaply at this point...
I would just use my K26(with fresh rebuild) and snag one of the K14's in the classifieds....I just worry about the high boost that would come with this set-up..?

[Rabbit on Roids]

well, how much boost are we talking here? think we could build 40 or 50 psi? maybe more? cause i had a stock 1.5 with just a turbo on it, and it would hit 25psi and stay there all day. that was with a fiber gasket and stock head bolts. and the messed up thing.. the block failed before the head gasket did. im pretty sure the head gasket blew cause the block cracked, as i just cant see it happening the other way around. but i wont do a compound setup until im fairly certain i can get a bottom end to hold it. i wanna take a 1.6 TD block and put 1.5 internals in it. then cap it off with an AAZ head and metal gasket with ARP studs.

[53 willys]

rebuilt k14 turbo=$450-$500
rebuilt k26 turbo=$350+new compressor wheel=$450??? give or take?
ED 40mm External WG=$325
$1,275
this is bare bones estimate though...just like the one above.
I would still spend maybe another $200 on miscellaneous parts fittings etc??
I guess twins would not be that cheap at this point after all...

[53 willys]

well, how much boost are we talking here? think we could build 40 or 50 psi? maybe more? cause i had a stock 1.5 with just a turbo on it, and it would hit 25psi and stay there all day. that was with a fiber gasket and stock head bolts. and the messed up thing.. the block failed before the head gasket did. im pretty sure the head gasket blew cause the block cracked, as i just cant see it happening the other way around. but i wont do a compound setup until im fairly certain i can get a bottom end to hold it. i wanna take a 1.6 TD block and put 1.5 internals in it. then cap it off with an AAZ head and metal gasket with ARP studs.

i dont think the aluminum head can hold 40-50psi of boost...just ask andy2..he could not keep his head clamped with firerings and a copper gasket!
from what I have seen and read anything over 30psi is SUPER risky...?
you also bring up a good point on the bottom end...yes our bottom ends are pretty stout..but compounds make boost at really low rpm's so bent rods are more likely on a compounded set up too?

[Rabbit on Roids]

the VNT on my car builds boost super low. not huge boost, but its boost none the less. i can do an easy shift from first to second, roll on the throttle and start burning the tires. yesterday i was out driving around. and theres a hill by my house thats pretty steep, steep enough that i have to shift down in everything else that i own to climb it. i was going about 75 at the bottom and held her wide.. i was doing over 100 at the top and it was still gaining speed. if my turbo wasnt worn the f*ck out, it would probably boost even sooner. and bent rods dont really worry me that much. im not gonna run nitrous or propane. and im pretty sure somethings gonna give in the top end before we start seeing rods bend. those little bastards are some strong rods. and the crank, pfft. there bullet proof. the engine in my car now, i pulled it out and it had a bent rod. like really bent. looked more like a "C" than a rod. pretty much shattered the piston too. i was amazed how much destruction there was. took and honed the cylinders, got a used piston and rod from my grandpa, re ringed the whole setup, and threw it back together with the head off my old motor.

[53 willys]

sigh.....to many options!!! :?
I dont know what to do?!?!?
you kinda got me wanting compounds...but damn thats some big time fabing...and I just got this car rolling..be it not for long..lol
I could fab the twins my self..even do a exhaust manifold myself.
I guess I'm just being lazy...and kinda bitter at KKK turbos since my K26 took a dump..(my own fault I should have hooked the WG up :oops: )

[Rabbit on Roids]

well, since im in the situation im in now (no drivers lisence) i really have nothing but time. my car doesnt have to run every day. and honestly.. i could mock it up on my gasser parts rabbit. a tubular manifold with a real collector would be the cats meow. and i heard a pretty crazy idea that sounded crazy enough to make sense. the idea was to put an expansion chamber (something like you would see on a 2 cycle motorbike) after there turbo. i read somewhere that it straightens out the turbulent gasses from the turbo and makes them flow better.

[53 willys]

my wife has given me the ok to pull the trigger on the BB unit...the more I read the spec sheet the more I think I may try this BB unit.....it's perfect diesel match...nobody but a select few (like KKK) make diesel spec turbos off the shelf and the few that I am finding are almost the same price as my custom unit....and still non BB......

my mouse finger is getting itchy!! :lol:

[Rabbit on Roids]

that kinda turbo is it based from? or is it a completely custom job? i want either a set of compounds or one really good turbo for my next build.

[53 willys]

that kinda turbo is it based from? or is it a completely custom job? i want either a set of compounds or one really good turbo for my next build.

they suggested a custom T3 bb turbo
T3 45 Trim F1-54 .48 A/R

thats the specs on the turbo..dont know what it all means tho??

[TurboJ]

53 Willys, you got PM!


About boost, my friend Aki ran 41 PSI on his AAZ twin charged engine, and a stock three-layer head gasket held up very nicely.
He did mention something about head studs and the right torque though...

[UnderPSI]

A K14 and K26 would make a nice compound pair. You don't have to run extreme pressure to get a compound systems benefits. Could run 15psi.