some 1.6 td caddy makes 163hp

[Natedogg]

unless i'm missing something that graph shows bugger all go to 3500rpm and then everything over a 5000rpm - that can't be nice to drive daily can it?

[rabbid79]

MJF, could you let us know some of the things they are doing to make this kind of HP?  Besides the usual HP building things such as large exhausts, large turbos, large intercoolers, I'm particularly interested in things like compression ratios, thermal coatings, machining, etc.  Are they using stock pistons?  How do they keep the swirl chambers from melting?  What kind of reliability do they have?  Is this stuff just good for 12 seconds at a time, or could they sustain this kind of power for a couple of minutes?  I'd really like to know because I'm going to be doing a performance build in my 2.0 TD 5-cyl and I'm looking for ideas.  Thanks.

[MJF]

MJF, could you let us know some of the things they are doing to make this kind of HP?  Besides the usual HP building things such as large exhausts, large turbos, large intercoolers, I'm particularly interested in things like compression ratios, thermal coatings, machining, etc.  Are they using stock pistons?  How do they keep the swirl chambers from melting?  What kind of reliability do they have?  Is this stuff just good for 12 seconds at a time, or could they sustain this kind of power for a couple of minutes?  I'd really like to know because I'm going to be doing a performance build in my 2.0 TD 5-cyl and I'm looking for ideas.  Thanks.

For 150-180hp, theres nothing unusual. Good pump is must, thatīs where the power comes. I drove ~40kkm with my 180hp Audi. Cracked head a couple times, but it had strange overheating problem that had nothing to do with high hpīs. Other than that, no problems. After that, body rusted away and it was scrapped. Engine moved to my Scirocco and was built again. Scirocco had zero overheating problems (220hp) from earlier Audi-build, could be floored as long as needed. Heat is your enemy, watch coolant temperature, exhaust temperature and exhaust manifold pressures closely.
That 270hp Golf have stock pistons, h-profile rods, main girdle, ported 1,9 head and HX35. Nothing too special in there that I know. 
Aki-76 knows better of thermal coatings, I havenīt tried those.

[RabbitJockey]

what do you know about their pump?

[rabbid79]

For 150-180hp, theres nothing unusual. Good pump is must, thatīs where the power comes. I drove ~40kkm with my 180hp Audi. Cracked head a couple times, but it had strange overheating problem that had nothing to do with high hpīs. Other than that, no problems. After that, body rusted away and it was scrapped. Engine moved to my Scirocco and was built again. Scirocco had zero overheating problems (220hp) from earlier Audi-build, could be floored as long as needed. Heat is your enemy, watch coolant temperature, exhaust temperature and exhaust manifold pressures closely.
That 270hp Golf have stock pistons, h-profile rods, main girdle, ported 1,9 head and HX35. Nothing too special in there that I know. 
Aki-76 knows better of thermal coatings, I havenīt tried those.

Excellent, thanks for the info.

[TurboJ]

what do you know about their pump?

Talked to the owner of the 270-hp 1.6, he has a 1.6 pump with a 11 mm head, modified governor and LDA.
The turbo is huge, and it makes the power possible along with a well-built pump and cyl. head, but it's basically only good for drag racing ( so he says ) because the power band is so narrow.

About credibility - it can be difficult to believe these numbers - but it's all 100% true, and the dynos that have been used are conservative even. Why, 1.9 TDIs have been made to produce 400 hp, and they don't rev as high. 270 hp on a 1.6 diesel isn't really all that revolutionary, remember that turbo F1 cars used to have 5 times that much on their similarily-sized gas engines. Five times!
You can make huge power on any engine if you know what you're doing, but that's just numbers.
Ideally you want an engine that has a good power and torque curve, even if the top end suffers a little - unless you're on a drag strip every time you drive the car, that is.

In my humble opinion though, anything over 240 hp or so on a 1.6 will not be very street-diveable.
That kind of power will require such turbos that will spool up very late and slowly, and that's why these are racing-only machines mostly. But turbo technology is again going forwards these days...

[RabbitJockey]

yeah it makes sense really, thinking back on daves car he was out of fuel at 195hp or so on a 9mm pump, and he had a very ported head, if he had a bigger pump i really wonder what he could have done, especially with a giles built and tuned pump.  not to mention he did 195hp at a very high rpm (nearly 6k)and these other guys are doing it much lower

[jtanguay]

In my humble opinion though, anything over 240 hp or so on a 1.6 will not be very street-diveable.
That kind of power will require such turbos that will spool up very late and slowly, and that's why these are racing-only machines mostly. But turbo technology is again going forwards these days...

drive it like you stole it

[Aki-76]

this is TurboJ ceramic coated sylinderhead

http://s434.photobucket.com/albums/qq68/Aki-76/asiakas%20osia%20ja%20muuta/?action=view&current=13042009353.jpg

My own twin turbo piston

http://s434.photobucket.com/albums/qq68/Aki-76/moottorin%20osia/?action=view&current=12042009344.jpg
( not polished yet )
and intake valve

http://s434.photobucket.com/albums/qq68/Aki-76/moottorin%20osia/?action=view&current=13042009348.jpg

Right is polished.

Now i drive my new daily car test drive,and itīs ceramic coated head,valves,precombust chamber and exhaust port,exhaust is 3 layer cermic and turbo is also 3 layer coated.Fuel economy is fantastic.horsepower is also good  

[RabbitJockey]

can we get numbers for your fuel economy?

[TurboJ]

We'll have to wait a while to get a full average on a 1000 km distance, but:

When Aki still had the stock 9mm pump, he drove a 400 km trip and the fuel gauge only went down 1/4....

Yes I know that's not really scientific, but it does show that economy improved noticeably compared to the stock engine. Aki also reports that even at highway speeds, you barely have to touch the gas pedal because of how willingly the engine pulls...  Good flowing head and the ceramic coating, and a good turbo - that has to count, and if efficiency didn't go up with those mods then that'd be a surprise anyway!

[jtanguay]

We'll have to wait a while to get a full average on a 1000 km distance, but:

When Aki still had the stock 9mm pump, he drove a 400 km trip and the fuel gauge only went down 1/4....

Yes I know that's not really scientific, but it does show that economy improved noticeably compared to the stock engine. Aki also reports that even at highway speeds, you barely have to touch the gas pedal because of how willingly the engine pulls...  Good flowing head and the ceramic coating, and a good turbo - that has to count, and if efficiency didn't go up with those mods then that'd be a surprise anyway!

so were the swirl chambers coated??? i recall reading that it negatively affected performance.

[TurboJ]

Yes they were.

How would that negatively affect anything?
It should be better if more of the energy was kept inside of the chamber and not let escape by transferring heat onto the casting around. Of course, I'm no expert, but controlling that heat transfer should only be good, right?

[gigaz2]

yes and no, its that transfer that "lights up" the mixture of turbulent air and diesel
but if the prechambers get too hot, the aluminum in the head might not like it

that's why I thought on using Renault prechambers on my 1.9 head frankenengine

[Aki-76]

Yeah,my daily car is fully coated precombust chamber
http://s434.photobucket.com/albums/qq68/Aki-76/moottorin%20osia/?action=view&current=13042009349.jpg
This photo is my twin turbo engine head but daily car head is similar.Engine cold star is fantastic,sound is little rude,but few second itīs smooth softly.I donīt see any problem this.
heat transfer is quite interesting,because almost all heat come in air which crush precombust camber.

Now i use "big core" pump with 12mm head,and fuel economy is about 4.5-4.6l / 100km,
orginal 9mm pump economy is 4-4.1l/100km.

Engine produce about 140hv,with orginal intake,orginal exhaust,NO intercooler,boost is 1.4 bar.Next week i install intercooler and,well,maybe we see resultīs in here.

This dyno sheet is orginal parts,just head/turbo modification
http://i434.photobucket.com/albums/qq68/Aki-76/asiakas%20osia%20ja%20muuta/kyttiksendynolappu001.jpg