Manual Boost Controllers

[SteveH]

All,
  After installing my Boost and EGT gauges, Im ready to step the boost up abit.  However, my engine (1V) has a K14 turbo with solid lines.  Anyone fab up some soft lines ?  Im going to wander down to the local hydraulic shop and see if I can find the proper banjo fittings that I would need.

-Steve

[jtanguay]

couldn't you just solder on a T and go from there?

[mk1vdub]

if you do find the proper banjo fitting please post it here as I'll be looking to do this too at some point  

I did wander if you could just cut the line then maybe use a brake pipe flaring kit and just push on some ruber hose and jubilee clip it?

[chris-pl]

guys go to scrap yard and get banjo fittings from fuel lines from golf or jetta

[fspGTD]

Know what kind of threads are in the wastegate banjo?

The diesel fuel banjos are I'm pretty sure 12mm and/or 14mm diameter bolt threads.  That might be a little big for a manifold pressure signal application.

I have a source on some M10 x 1.0mm banjos... they are replacements for a Tial blow-off valve.  Beautiful aluminum banjo bolt with a 6mm / .25" size hose nipple paired with a special small-head/flanged stainless steel bolt, and aluminum crush washers:


They are generally only sold by the pair though, and for that they would generally run about $20 plus shipping.  I just picked up an extra pair, even though I only need one extra at the most, just 'cause I thought they are such neat pieces of hardware.

Then again, quickest/easiest/cheapest solution would probably be as mk1vdub suggested - re-use the stock banjos, using a tubing cutter on the stock hardline and slipping a rubber hose over the cut end, securing with hose clamp.

[SteveH]

All,
  Here's the parts in question:




Im sure that you can cut the hardline, flair it, and clamp some rubber line over it.  However, Im going to see if I can find some barb fittings down at the local shop.
My question now is this.  Once I install an intercooler, how good of an idea would it be to install the wastegate intake line in the actual intake manifold, instead of on the turbo (In other words, post-intercooler, rather than pre-intercooler) ?

Thanks,
 Steve

[shox75]

can u please show me a schematic of ur install, and what kind of manual boost controller is it (manufactoror?)?
I would really appreciate it, i also installed a manual controller but it does not function right. I have now control over boost.

[fspGTD]

shox75: I have been reading on old threads here lately myself covering adjustable pneumatic boost controllers.  
I would recommend reading these two threads:
http://www.vwdiesel.net/phpBB/viewtopic.php?t=105
http://www.vwdiesel.net/phpBB/viewtopic.php?t=139

-----------------

SteveH: close as I can tell, the OD of that bolt is 8mm (or is it 7mm?)

There is a small banjo fitting on 1.6 liter turbo-diesels where the boost pressure hose connects to the LDA device.  I checked it out in ETKA, and it looks like the banjo bolt is 8mm.  I recall it has a pretty small hose nipple though... ETKA says it is to go with 3.5mm hose.  That is only about 1/8"ID... and since the nipple has thickness, the hole through it would be even smaller.  This seems too small and restrictive to me for your wastegate application.  But in case you want to give these parts a try, they are available from VW and they also are surprisingly reasonable in price.  The part numbers are:

N 901 836 03 - 8mm banjo bolt
063 133 662 B - 8mm banjo fitting (barb for 3.5mm ID hose)
N 013 830 2 - 8mm sealing washer

[SteveH]

SteveH: close as I can tell, the OD of that bolt is 8mm (or is it 7mm?)

There is a small banjo fitting on 1.6 liter turbo-diesels where the boost pressure hose connects to the LDA device.  I checked it out in ETKA, and it looks like the banjo bolt is 8mm.  I recall it has a pretty small hose nipple though... ETKA says it is to go with 3.5mm hose.  That is only about 1/8"ID... and since the nipple has thickness, the hole through it would be even smaller.  This seems too small and restrictive to me for your wastegate application.  But in case you want to give these parts a try, they are available from VW and they also are surprisingly reasonable in price.  The part numbers are:

N 901 836 03 - 8mm banjo bolt
063 133 662 B - 8mm banjo fitting (barb for 3.5mm ID hose)
N 013 830 2 - 8mm sealing washer

Wow, thanks for the research.  However, I believe that you are correct in stating that a 3.5mm barb would be too small.  I need something 1/4" or so.  Also, you are correct in the assumption that the banjo bolts are 8mm.  I wanted to go to the hydro shop yesterday, but they were closed for inventory...So perhaps tomorrow I'll get down there.  If they have what we need, I'll pick up a couple of sets for you all.

-Steve

[larry104]

Know what kind of threads are in the wastegate banjo?

The diesel fuel banjos are I'm pretty sure 12mm and/or 14mm diameter bolt threads.  That might be a little big for a manifold pressure signal application.

I have a source on some M10 x 1.0mm banjos... they are replacements for a Tial blow-off valve.  Beautiful aluminum banjo bolt with a 6mm / .25" size hose nipple paired with a special small-head/flanged stainless steel bolt, and aluminum crush washers:


They are generally only sold by the pair though, and for that they would generally run about $20 plus shipping.  I just picked up an extra pair, even though I only need one extra at the most, just 'cause I thought they are such neat pieces of hardware.

Then again, quickest/easiest/cheapest solution would probably be as mk1vdub suggested - re-use the stock banjos, using a tubing cutter on the stock hardline and slipping a rubber hose over the cut end, securing with hose clamp.

Where do you get the barb banjo fittings?