Jetta project 200

[53 willys]

dang you have some sweet tools!!
that girdle is PIMP!!! somebody get a CAD for that PLEASE!!
good work!

[TurboJ]

Thanks man!
I'll try to get a CAD drawing at least, but there MIGHT be a possibility we could get some made. I'll look into that and let you guys know  

[nokivasara]

This is an awesome build  :shock: two thumbs up!

[Smokey Eddy]

Oooo Girdle Interesting.
I made some progress too!
http://www.vwdiesel.net/phpBB/viewtopic.php?t=16482&start=105

[TurboJ]

Yeah, I saw that earlier! Nice stuff. Let's see who gets it finished first, eh?  

[Smokey Eddy]

GRrrrrrrrrrrrrr
I'm waiting on 4 valves and a ring set
ring set has another ... 12 days or so just on shipping then i start to put everything back together.
my aim is for the first week after Christmas i want to start it up.

[theman53]

quote"  Building of the twin-plenum intake manifold.
The log than connects to the original manifold's plenum needs to have an opening of exactly right dimensions to provide equal air flow for each inlet port. The twin plenum design works really well when done right, which is why race and rally cars have used them extensively since the '80s.
The fomidable Group B Audi S1, for example, has a very similar inlet manifold design.
I only hope that I'll be able to squeeze the front upper strut brace in there with the new inlet manifold.

More will follow soon as I will have to speed things up to get the car finished before february.
Again, comments and questions are all welcome!"

Sorry but I need to know and see your design. I just posted something on here asking the question on what the insid of these manifolds should look like...please let me know.

[TurboJ]

No problem!

Here's my intake manifold. It's still some way of finishing, but you can see the basic idea here. The OE manifold on which it is based is that of the 1.9 N/A D engine (type 1Y) which is somewhat similar to a G60 inlet. It's one of the best OE manifolds in terms of flow. And it has the correct port shape for the AAZ head...


The diameter of the primary tube has to be correct for the equivalent secondary plenum (that of the original manifold) And then the two chambers are connected by a thin longitudinal opening which, again, has to have the right width. All respective to the volumes of the two chambers.


Here you can see an almost-finished manifold based on the VW LT 6-cylinder diesel inlet. The opening between the two chambers is visible here. In addition to dividing the flow equally to each inlet port, this design also prevents much of the unwanted flow-back from the cylinders.
Unfortunately I don't have the measurements at this time, but really that wouldn't help much - you need to calculate the volumes, diameters and opening widths accurately and then there's more math and flow theory involved - all staring from which manifold you use as a starting point.

Anyway, in practice these manifolds have been tested and tests show they really do the job of equal air flow. Also there's a noticeable increase in power, while smoking is greatly reduced as all cylinders have the same AFR.

[theman53]

OK. I understand R-ith-mathtics somewhat, let me know what the formulas are and I will get to work. That manifold you started with is different than mine. I have the 1.6td for transverse engines, but I am sure that it will work. I was also thinking of a design before I posted earlier... what if you plumbed the turbo piping into a T and then into the top of the log on BOTH sides. Of course there is more piping, but I am thinking it might equal itself without the second plane. Just a thought though.

[TurboJ]

I know one tuned VW 1.9 diesel engine that has a twin-inlet manifold that you described. Apparently works OK as the car makes 250 hp.

I will PM you the math stuff when I get in touch with the guy (I don't have the right formulas myself).

[Fridge]

Hello!

This is my first post on here!!!

Firstly, i just want to say that i don't have a VW (Boooo) I have a vauxhall Nova with a 1.7 isuzu td and i also want to say that i'm amazed at what you guys have been doing with your dubs. Theres some really insperational stuff on here!
Mine currently has the fueling turned up and boost at about 22psi putting out around 110-120 bhp.

I was wondering, what is an 'aaz' head?. Also, TurboJ where could i find out more about how my head should be ported? Could you give me some pointers or recomend a book?
What is the speacial pump you talked of, how is it different from standard?

I'm new here and i hope you guys don't mind me asking questions. I'v made my way through the FAQ's so i'll try not to ask anything too tedious/stupid.

[jtanguay]

Hello!

This is my first post on here!!!

Firstly, i just want to say that i don't have a VW (Boooo) I have a vauxhall Nova with a 1.7 isuzu td and i also want to say that i'm amazed at what you guys have been doing with your dubs. Theres some really insperational stuff on here!
Mine currently has the fueling turned up and boost at about 22psi putting out around 110-120 bhp.

I was wondering, what is an 'aaz' head?. Also, TurboJ where could i find out more about how my head should be ported? Could you give me some pointers or recomend a book?
What is the speacial pump you talked of, how is it different from standard?

I'm new here and i hope you guys don't mind me asking questions. I'v made my way through the FAQ's so i'll try not to ask anything too tedious/stupid.

welcome! there's no problem with asking questions people here aren't ***s  :wink:

[TurboJ]

1. I was wondering, what is an 'aaz' head?.

2. Also, TurboJ where could i find out more about how my head should be ported? Could you give me some pointers or recomend a book?

3. What is the speacial pump you talked of, how is it different from standard?

Let's see...

1. AAZ head refers to the AAZ 1.9 TD engine that was used by VAG (VW-Audi Corporation) between '92 and '98 approximately. The AAZ head is a common upgrade on a 1.6 TD as it has much better flow capability.

2. As far as porting itself goes, any head shop with a good reputation can help you, but if you wan't to do it yourself, it's basically just to remove some material everywhere around the inlet / outlet canals, and smoothing out the valve guides. Smoothing out the combustion chamber and pre-cup edges is a more specialized job - you have to know a diesel tuning specialist really if you want good results. This is why I'm also resorting to a friend to do this job for me, one who has a lot of experience in tuning VW diesel engines.

3. I have just sent you some PM !

Feel free to ask if you have more questions! Someone will always answer, this is a very friendly bunch of people on here!

[Smokey Eddy]

i just ported my new aaz head
waiting for parts
We'll see what the difference is when it's back together!

[truckinwagen]

you mentioned earlier about a motor with a supercharger and a turbo.
how were they plumbed? I just bought a G60 and want to do the same(I was going to do a compound turbo, but $100 for a G60 will change plans fast)

my thought is to have the turbo feed the G60, but I am interested in how your friend did his.