Starting a turbo build...Videos of it running :D

[theman53]

I was hoping to get away with it over winter. It was 25F here yesterday morning and really no change in EGT for the most part. I rotated the pin to least aggressive and 1,2 and sometimes 3rd I can hold it to the floor with it going to 1150 to at most 1,200F. 3rd sometimes will be too close to 1,000F after the shift and shoot right up to 1,200F by the time it boosts. For those temps I was hoping for it to run better than what it does. If I add the IC and temps come down 200F I still really won't be able to dump much more fuel in will I? Where Giles had it set it was great for power, but I couldn't get over 1/2 pedal before 1,200F in any gear...would an IC make that much difference? It was 85F when that was going on too, I figured with the 50+ cooler outside air temp it would help a lot,  but so far I haven't seen much.

[410]

An intercooler will make a big difference imo.  I still think that your static timing is a pinch on the retarded side.  If the timing was set to .85mm I would try .95-1.0mm.  I know Giles said no to the timing but just try it.  I think you will be pleasantly surprised at the effect it has on egts.

[theman53]

I was thinking the same.
What about this? I measured the incorrect core support I have and it seems between the headlights I have 31" and below the support lip about 8" so some modding required. I originally thought of the 28x7x2.5 size, but since the egt is so messy I am thinking of this http://cgi.ebay.com/ebaymotors/CXRacing-Universal-Front-Mount-BK-INTERCOOLER-29x11x3-_W0QQcmdZViewItemQQhashZitem3a5219c391QQitemZ250485523345QQptZMotorsQ5fCarQ5fTruckQ5fPartsQ5fAccessories

[410]

Any intercooler will do.  Look at the size of the factory tdi intercooler.  It's tiny!  My intercooler core is about 12x12 and 3" thick and works very well.  Get something that fits and you'll be happy.

[410]

I had a look at the link for the intercooler in your last post and that thing is huge!  I would go with something a little smaller that fits nicely instead.  Turbo lag might bother you with such a large intercooler.  I assume you received the boost pins I sent you?

[theman53]

Yeah I got them. I haven't tried the custom one.

I finally got it to a fun stage. The car has to be just about empty, but I can run it hard now. Most of the time it will only get to about 1150. I just don't think it runs as good as it should. It is fast, but not quick. It is hard to explain.

[AudiVWguy]

Think about running water injection. I went to the junk yard and found that the old toyota Cressida windshield washer pumps put out 40 psi. I mounted two of these into a subaru I think, windshield washer reservoir. McMaster Carr sells 40 psi misting nozzles in various sizes. Add a boost pressure switch to activate the pumps at whatever psi you want. I can watch the EGT's rise under boost until the sprayer kicks in, then they almost stop. I'm also steam cleaning the engine as I drive.
The point is every little bit helps.

--- Biggest down pipe you can fit
--- Intercooler
--- Water injection

[dankcorey22]

Check out my intercooler on my tdi its 3" thick but i dont really know the dimensions off the top of my head. it was a 1st gen eurojet kit for $400 and still had to cut and modify to fit  but oh well...lol

[theman53]

Think about running water injection. I went to the junk yard and found that the old toyota Cressida windshield washer pumps put out 40 psi. I mounted two of these into a subaru I think, windshield washer reservoir. McMaster Carr sells 40 psi misting nozzles in various sizes. Add a boost pressure switch to activate the pumps at whatever psi you want. I can watch the EGT's rise under boost until the sprayer kicks in, then they almost stop. I'm also steam cleaning the engine as I drive.
The point is every little bit helps.

--- Biggest down pipe you can fit
--- Intercooler
--- Water injection

Thanks. I could do the water injection, I had always just thought of water/meth and the expense is not what I want.
I have a 3" downpipe and 3" no muffler all the way back. I need an IC I guess. I think yesterday being in the 30'sF all day helped EGT finally.
Another thought...would coolant temps hurt combustion to the point of high EGT? My water temp gauge rarely gets over 160F, should I get the highest t stat? I have the lowest one now.

[theman53]

I changed the oil last night. Last time I put too much in as the first fill took almost 6 quarts, but the engine was fresh. The oil cooler and lines take a little more, but last time was too much. So I put 5 quarts in it last night and it was short what looked to be 1/2 quart. I adjusted the clutch and checked again. It was almost full I probably added 3 oz and it was perfect.
    On the way to church this morning the wife and I park and smell oil. I cleaned the VC off pretty good I had thought, so like almost every stop I pop the hood and look. Everything seems normal except I have 2 pea sized spots of oil on top the VC. I forgot to tighten the oil cap it was just sitting on there. Last night I took it off after starting it to feel for blowby, it didn't have much, and apparently I forgot about it. Now with 10 miles and it didn't move I would think at 7 or 10 thousand miles I will switch to synth.

[Smokey Eddy]

I like your alternator tensioner. With this colder weather + the occasional dusting of snow my belt is screaming. To the point of smelling like melting rubber...

[theman53]

I am finished with monkeying with the fuel. As soon as I get the chance I am going to reset my timing to 1.00mm against Giles wishes. He said no more than .95 as he builds the advance into the pump and to wait until it has miles more miles on it. It has around 5,000 now and really no change in EGT. I have turned down the fuel to the point the thing won't run until there is boost and it still wants to go over 1,200F under boost. Today it was around 50F outside and it really made me notice it again.
Anyone with tons of experience in TD tuning in the central Ohio area is welcome to come and help/offer suggestions. The sad thing is the less fuel the less power...even when really hot I don't think it runs as good as it should. I guess I can say I am dissappointed with Giles's pump and his lack of interest with my problem. It is my daily now so hopefully on the weekend I can get it done.

[theman53]

I bought a stock LDA pin and it is set to the least aggressive slop. The Giles pin is ground almost 3/8" at the top and was WAY too much. The max fuel is to the point I cannot gain any speed uphill starting in 1st gear. If I am rolling I can go up in 1st and gain speed if it gets into the boost. It seems no matter what I do it still will get high on the egt, it just takes it longer to get there with less main fuel. I don't have any black smoke either. I thought I had it a while back, but I must of just had some cool air or something that day. It was fun you could run it and only get to 1150, ever since it has been hairy.

It isn't overly rattley and when first started it takes a minute or so to go from white smoke to clear even with the advance lever pulled. I am at my wits end with it. I thank you for the response, but I think I have tried that many times.

[theman53]

Is there a point when your EGT gauge is too deep? There were no instructions on that that I saw. Maybe mine is too far in giving too much contact and taking more time to cool than it should? The other thing is I am only running 15-16psi tops.

Also my EGT when warm idling only will get down to 300F.

Andrew I wish you were in Ohio and could see this mess/help me.

[vanbcguy]

Do you have any extension wires or anything else funky on your EGT probe?