Author Topic: The GTD RETURNS! (Read 117886 times)

RabbitGTDguy · « **Reply #105 on:** June 12, 2007, 09:06:33 am »

I appreciate the comments...

On the AWIC heat exchanger. The picture is deceiving as to the size of the VR6 auxilary radiator that I am using. Also, when looking at a properly designed AWIC setup, there is alot more than the "size of the exchanger" to consider. I've never read the rule of thumb where the exchanger needs to be twice the size of the intercooler itself.
Corky Bell in Maximum Boost also states that the front cooler is the least important part of the system.
If you think about it, the exchanger does most of its work when the car is sitting at idle, not under boost helping to dissipate any heat soaking that may occur at idle.
The amount of time that water spends in the front cooler vs. the amount of heat there doesn't present a big enough trade off to install a larger front exchanger (especially when I start running out of room to put stuff in an MK1). Also there is to consider the size of my res. (2.5gal or so), the capacity that the hose will carry from the trunk of the car to the front, plus the capacity of the intercooler and the front cooler itself.
The res. actually is the most important part of the AWIC system besides the core/intercooler itself. Bell's book also states that for a 15 second "heavy" boost run that a pump capable of 10gal/min will move 2.5 gal of water in 15 sec.
Great mass of water = greater the thermal inertia
All total...I should have close to 5gal of water or so that I'll be moving around between the 2.5 gal res. and the rest of the system capacity.

(And if I want to ice it...i can throw the keg on ice...and Wa la!)

I've put alot of work into the AWIC setup in the last year. Changing through a few different pumps, had a series of heater cores i was going to run at one point, etc. and have wanted to have this installed for quite some time. It'll be exciting to get it in.

You friends 16vT will run hotter than the mTDI i imagine and what was your friend using for a res, where is it mounted? What was the total amount of water capacity in his system, and what was he using for an exchanger. There are so many variables to consider, but I'm happy with the design and will see via intake monitoring just how efficient it is once hooked up...

I'd be interested in the whole picture with the thought that you discussed and more info on where it came from to weigh in the future but I've never heard of making the cooler that much larger unless your res. is under the hood and/or the total h20 capacity of the system is low/contained under the hood.

Joe

A2TD · « **Reply #106 on:** June 12, 2007, 09:57:54 am »

His res was located in the hatch, and his pump is 15gal/min, and a 3 gallon res, but my point was reagardless of sump capcity, if the rad is too small, it won't be able to cool the fluid fast enough, therefore resulting in a static temp increase across the board. Now another key factor to consider is turbo charger efficiency. My friends 16vT is running a gt3037R @20psi, @20 psi this turbo is making alot of heat. The original rad wasn't heat soaking but the overall static temp was too high for his liking.

Now if you ran a gt20 or a gt22, where the efficiencys are stellar, your cooling requirment is reduced. I run a GT20 @22lbs on my MK3 with the stock intercooler, and I haven't had any heatsoake problems. I did 4 consecutive hard runs with my car, on a warm day, while logging intake temps through VAG-COM, and at the end I only saw a 5 degree temp increase.

Which turbo are you running again??

RabbitGTDguy · « **Reply #107 on:** June 12, 2007, 02:02:23 pm »

Well, I guess we'll see. If I'm proven otherwise, I'll run two in a series

My turbo is a standard T3 unit, nothing fancy...can't afford a GT series at this moment and probably will go to a Holset this winter. I find that interesting...makes you wonder what...if any good one of those PWR cannon AWIC do anything at all...

Hmm...

Joe

RabbitGTDguy · « **Reply #108 on:** June 15, 2007, 07:49:12 pm »

FINALLY... no more trips to the welding shop...

Added this to the arsenal today thanks to Todd (Fuslit) and I poking around on Craigslist. Couldn't pass it up for the price, so I drove up to Rochester this afternoon to make sure it could be mine!

After that...found he also is selling a TIG machine (500.00) as well as a pretty nice portable plasma cutter too (800.00) and he only sold this because he upgraded to a 220v MIG unit.

Now just have to get some gas bottles and get to it.

Joe

RabbitGTDguy · « **Reply #109 on:** June 17, 2007, 08:44:42 pm »

Did some more work today on the car.
Namely... I was able to mount the AWIC finally, the "keg" res. and the pump in the back of the car. I'm pretty happy with the mounting of the intercooler and how I ended up doing it just in case I ever wanted to return the car to stock and/or run a battery up front again.

A few pics...

Tomorrow...may remount my aux. oil cooler slightly to make some more room up front for the AWIC radiator and the fuel cooler (though, may run that lower in the car, or up in the wheel well...haven't decided yet. Finding room in the MK1 body is getting harder to do.

Decided to cut costs and save a bit this summer by not going for full aluminum intercooler pipes at this moment. Plus, I have quite a few full mandrel aluminized steel piping downstairs that is just sitting and could be used...not to mention, good first practice for the welder as well. Have a variety of angles to use as well (one 135, several 90's and 45's). Going to order what silicone adaptors I need tomorrow online probably and if all goes well...maybe have this up, in and going sooner than I thought!

Going to work on the wiring/relay setup for the system tomorrow as well I think...

Anyone know "the best place" to buy the silicone couplers and elbows? I was looking at summit... and Ebay.

Joe

Audi80 · « **Reply #110 on:** June 21, 2007, 01:44:08 am »

Joe, I got something for you

RabbitGTDguy · « **Reply #111 on:** June 21, 2007, 06:01:20 am »

WAHOO!!!!

:lol: Kudos man!!! Thats Awesome!!! :lol:

RabbitGTDguy · « **Reply #112 on:** June 28, 2007, 07:37:37 pm »

Well...more updates... A few of the pics are about a week old now as I went about installing the fuel cooler, relocating the oil cooler slightly and installing a few of the AWIC components...

The fuel cooler I'm using...

Also...the AWIC heat exchanger...

Some of the biggest good stuff came tonight though... my mocked up intercooler tubing/routing with the silicone connectors (that finally came today...after being a week late!)

Deburred, cleaned and flushed everything out of the intercooler system tonight. Drying now and I'll permenently install the intercooler tubes, etc. tomorrow. My autotech strut bar I believe is going to have issue clearing the tubing. Have to slightly "re route" the vac. pump line from the booster as well, but thats not a big deal at all. I'm very happy with the routing of the piping and its length.
The bay also doesn't look too cluttered in my opinion either. Can't wait to see how nice it is once the paint/bodywork is done this fall/winter.

Good news on the drivetrain end as well. Will be getting a CTN trans this weekend for sure in trade for another 02a that I sourced for someone.

Very exciting

Joe

Holeshot · « **Reply #113 on:** June 29, 2007, 02:47:59 pm »

Dang - NICE ride, man.

Beers,

Matt
\x/ hillfolk!

RabbitGTDguy · « **Reply #114 on:** June 30, 2007, 08:30:10 pm »

Some more progress...

boost tubes fully installed after some tight work, etc. No rubs, etc from what I can see and I really took it for a run today and it was holding 30psi without issue...could have gone more...but, no water system yet..

Going to work on that setup here tomorrow afternoon and Monday...electrical setup, etc. and maybe have the water all set up for Weds.

Only thing that didn't work was I was hoping to use a stock overflow tank for the "fill" point in the system...since the keg is in the trunk and the pump which are the lowest points... Having it up high would make filling and bleeding easy...so, think I might get a nice small aluminum overflow tank and call it a day. Doesn't have to be huge.
The system is going to be really efficient though...so far I'm calculating 5 gal of water or so..., very nicely sized res., good line and heat exchanger flow, etc.

Now...if only R520s were in the budget...

Will have another goodie to post tomorrow I'm sure, but for now...

Intercooler plumbing in and installed and I did it JUST right as the autotech strut bar I've been waiting to put in just clears things!!!!

Big reason for the fit is having moved place where I am pulling the boost reading from, which was the inlet source on the intake manifold...but now is on the intercooler since I had it there ready to use!

going to get a nice stainless one down the road...hate the vinyl tubing, but want to be "happy" with "where" things are located before I invest money in more expensive "odds and ends".

By the way...if anyone wants a phantom series vac/boost gauge (reads 30Hg/30PSI split), let me know. I have no use for the vac. side and would love to get just a boost gauge instead of the split...don't know what I was thinking in the first place...

Thats the update for today!

Joe

ezekiel · « **Reply #115 on:** July 01, 2007, 12:07:14 pm »

beautifull. You have no idea how much this build has helped me with getting my build rolling.

RabbitGTDguy · « **Reply #116 on:** July 01, 2007, 07:10:29 pm »

Thanx

Another goodie for the MK1 as of today which will be going in this fall/winter.

02a TDI tranny... Code "CTN"

and these goodies on the way from Finland...

The "white" ATS caps were hard to find but are the correct ones for the "White Editions" that are on the rabbit.

Traded this 129k 16v 02a trans that I bought and pulled last week for the trade...as well as a shift box

working on cleaning up the CTN trans now to hopefully make it look close to as nice. However, depending on $$$ I may do an LSD this winter for it, so I'd be taking the case apart...maybe powder coat. Def. will 'blast the case though and do some other work! Going to be great gearing for my particular setup though...

CTN
1st 3.778
2nd 2.118
3rd 1.360
4th 1.029
5th 0.755
R&P 3.157

Right now with the FN in there, its really interesting with the R&P. Can't wait to have this stuff in!!!

Joe

lord_verminaard · « **Reply #117 on:** July 02, 2007, 07:54:17 am »

Hmm, does Matti have more of those clutch cable kits?

This is looking great! The tubing is top notch, not cluttered or cobbled in any way.

30 PSI? You're using a T3 from a 1.6 right now? Damn! I also have a T3 and was planning on using it as my "Shakedown" turbo until I get my final setup worked out, but maybe not!

Plus, I've started pulling apart the T3 for a quick rebuild, but I snapped three bolts on the turbine side and I cannot get the turbine side separated from the center section. My wastegate valve is also bent and hopefully a machine shop can straighten it as it seems finding a replacement is near impossible.

Looks great Joe, very inspiring.

Brendan

RabbitGTDguy · « **Reply #118 on:** July 02, 2007, 08:38:42 am »

LOL , I don't think so...but it could be asked.

On the turbo. I'm not running a stock t3 from a 1.6 TD. Its larger on the exhaust side, a .48A/R at the moment with a .42 50 trim compressor. Its not what I ideally "want" on the car...but we're working on that for this winter as well.

Joe

A2TD · « **Reply #119 on:** July 03, 2007, 01:08:01 pm »

Nice job on the install

Quick question for you, your breather hose off the valve cover, where(or what) did you run it into??? mines sorta sitting behind the engine and i get that horrible oil vapour smell that makes its way into the car(I'm an mk3 fwiw) at times.

PS that CTN tranny is gonna make that little bunny fly

Author Topic: The GTD RETURNS! (Read 117886 times)

A2TD

Audi80

A2TD