Jetta project 200

[TurboJ]

Thanks mate!
I'll see if I can use a tank off my friend's Vento...

As for updates - yes I have been working on the car and progress is nice, but still no pictures as I still don't have a new computer.
I will update this topic once and for all when I get all my pictures on one hard drive.

[RabbitJockey]

i am still very excited even tho its been going on for a long time...

[Alleslowbuged]

Hello TurboJ,

i hope everthing is going on, like you wand. Something new in scandinavian?

Best Regards

[Tiago PSS]

TurboJ You are unsing an 1.9 aaz pump or 1.6 pump??
I´m very Impressed with your project! it´s an inspiration!.

Best Regards

[TurboJ]

OK...
Finally back on here!
It's been a really challenging time for me, the past couple of months, but things are moving on, and hopefully I will soon have something new to report!

Everybody: If there have been particularly interesting developments since august, I'd be more than happy to hear about them 

Tiago, it's not a VW pump at all  I may post some more specific info when the pump is ready.

As for now, I need just a couple more parts, then it's assembly time!
I'm going to be extra busy during the christmas holidays...

[carrizog60]

iveco turbo daily pump?

[TurboJ]

Yep, that's the base pump ( how did you know? )
But it's undergoing some extensive modifications to suit the VW engine and to combine high flow with acceptable idle and low-speed response.

Last weekend we finally settled on the turbo system for my engine.
During the past couple of months, several different turbos and exhaust manifolds have been tried on highly tuned AAZs around here, and
there is more experience accumulating as I speak. It seems that when you go well past the 200 hp mark, and do the associated improvements
to your pump, head and camshaft, the engines become quite picky with their turbos. It's quite difficult to build a turbo that has enough flow
on both sides, enough pressure potential, strong enough internals and acceptable spool-up, on a high-performance AAZ.

But once you have worked your cylinder head so that is really flows, and have a suitably hot cam, a well-optimized pump, and a correctly built
exhaust manifold, you can run stupidly large turbos with little trouble. With those big Holsets and Schwitzers off industrial engines etc, you have
potential for safe 2.5 bar boost all day, and yet they spool up nice if you have the right work done on your engine.
As for the right work and correct parts, good old Aki has fabricated me a really nice stainless steel tubular exhaust manifold that will allow a
Schwitzer S2B to fit the tight spot between the inlet mani and the firewall. We'll be looking at 45-47 mm compressor inlet and 54-57 mm turbine
outlet sizes. The bigger Schwitzer also comes without an integral wastegate, so there's a good reason to fit a more reliable and efficient external
wastegate. Now I'm really looking for H-profile rods too...

I'll post up some pictures of the new development as I get something done in a couple of days!

[Alleslowbuged]

Dear TurboJ,

i was thinking, that you an AKI has stopted to work with our stupid old diesel engines, because i have not seen something during the sommer, so welcome back in the www. Honestly, i am glad to see me wrong, becuase this is one of my all time favorite builts and i like your way to handle this engines.

What you say regarding the switzer S2B is very interessting, i had follow the same idea (without testing something) for a long while, in regard to my one build. Up to now, i have a S2B turbo (with your specs) and a additionally a Nissan ballbearing turbo (ebay offer, were i cant say no) and did not know, which one is the best to use. So please speed up your work and give me hint.

Best Regards Alleslowbuged,
who just get his ported and polished cylinderhead back.
   

[TurboJ]

I'll try to work as quickly as possible

We haven't been active on forums since summer for a number of reasons, but I believe I will have a good deal of progress to report, at least after the christmas holidays! There are also two twin-charged engines being built at Aki's workshop as I speak, and one of them should possibly be ready for the summer, so expect to see some crazy diesels in the following months!

Good luck with your project too!

[clarkrep]

I'm lookin forward to updates also, been followin this build from the beginning just haven't anything constructive to add. At some point I'd like to have the math you guys use to design the dual plenum intakes if it's not too much trouble. I assume it's different for the 1.9 than your 1.6 because of the amount of air each engine flows regardless of whether they use the same(aaz) head. Is this true?
Thanks,
Aaron 

[carrizog60]

it was a guess that iveco pump.
in portugal it was tried on a Mtdi and worked good so on a power build i knew that was an option...

many greetings to you and good luck with the build.

[TurboJ]

On Monday I will be working on the car, and there will be updates afterwards!
Things are going pretty well as far as the engine is concerned too, I really think I can get the car running before summer!
Although I probably shouldn't say that aloud, what with mr. Murphy and all...

[RadoTD]

Awesome build! I just finished reading through all 19 pages of it and can't wait for more!

One question though, did you ever end up tracking down a CAD file for that main bearing girdle? It would be awesome if we could get some of those made over here!

[cyrus #1]

One question though, did you ever end up tracking down a CAD file for that main bearing girdle? It would be awesome if we could get some of those made over here!

PM truckinwagen (aka owen) He organized a group buy of main bearing girdles.  He might have one left...

[TurboJ]

That's a good bet.

As for me, I don't have any CAD files, but I can source a girdle if someone really, really needs one.