G-Teched my 1.6TD - Part 2

[zagarus]

edit: I'd also like to note that during some hard (est. 170-190bhp) runs,

is that what your 1.6td is running?!! :shock:

[malone]

Those are estimated numbers, I didn't have the chance to go on a dyno, but I'm confident in these numbers after being compared against a MK3 Golf VR6 (by racing & comparing consistent Gtech results). Anyway, it was real fast.. enough for me to want to keep the engine I'm selling my 3 diesel vehicles, this black MK3 Golf, the red 1991 Jetta 1.6TD, and the light blue 1984 Rabbit.

There will be no room to store these cars other than the TDI I'll be getting, but after I'm settled in a while after moving, I'll find a clean chassis to put the IDI engine back in. Maybe a MK1 or MK2 instead of another MK3.

[malone]

Great to get an update and hear about the job and plans you have for the future.  Bummer about the cooling issue.  Good luck on house-hunting, a garage was more important than square footage when I was searching!  Probably similar for you...

Thanks.. $250,000 ($223,000 USD) will get me a 900 to 1,200 sqft condo or apartment in Langley, BC, which is a 1 hour 15 minute drive away from my work in Vancouver. Detached homes with decent garages are at LEAST $310,000 USD ea. in Langley. Homes in Vancouver are not cheaper.

I can find a townhome with a garage for $223k USD, but it's a very narrow 1-car garage. No elbow room. Lower mainland BC likely has the highest housing costs in Canada :roll: I have a few months to do house-hounting, though.

I could consider renting a small warehouse with a few people to store full-time project cars in, but even that may be expensive.. we'll have to see.

On the crankshaft, I am leaning towards polishing, shot-peening, and cryoing, in that order.  What experiences do people have with custom rods on high output VW Diesels?  I have only talked to VW Gas guys and those rods hold up with just minor modding to a lot of power, but I imagine the BMEPs are much lower.  Dunno, just wondering.

Keep us informed, you are a real inspiration.  Any more information on the compound setup?  I am leaning heavily towards that myself.

Other than what I've posted before, I have no further information on the compound setup. The turbos I mentioned may not be finalized... finding the best sized compound turbos on paper is tricky.

Your order of crankshaft prepping sounds good. I'm curious as to know how custom rods affect BMEP.

Simon Cooper "tdi rs" used custom rods in his ~220whp mechanical TDI after bending stock rods. He did not mention any adverse effects from switching to custom rods.

[zagarus]

okay so 170-190 hp, do i even want to know where the torque is at?! :idea:

[malone]

okay so 170-190 hp, do i even want to know where the torque is at?! :idea:

Not much, around 190-210 ft-lbs to be conservative. My TD's torque peaked at approx. 4,000 RPM unlike a typical TDI at 2,100 to 2,500 RPM. Estimated 140hp at 4,000 RPM, climbing higher until the fuel cut-off point at 5,250 RPM.

I like the closer torque : HP ratio because it means I do not need to make impractical amounts of torque just to have adequate HP. My next TD setup may have torque peak during higher RPM. It'd be interesting to see if I can hold 250lb-ft at around 5,252 RPM for 250hp, but I'll still push the engine as far as it can go.

If my ~200 ft-lbs torque peaks at 2,500 RPM instead of 4,000 RPM and then quickly drops off (just like a TDI), I'd likely only have roughly 120hp. Depends on the rest of the torque curve.

[zagarus]

how much time and money has been put in to get these numbers?  what do you think i could achieve as a semi serious diesel tuner?  110hp a possibility?

[malone]

Major components are as follows.. prices are in CAD:

Fuel pump upgrade: $950

GT20 turbo and exhaust manifold, both cermachromed: Roughly $1,000

Air/water intercooler conversion based on brand new OEM TDI intercooler: Approx. $500 total

Autometer gauge set (including oil temp, oil pressure, volts that I already bought years ago): $500 after discount.

Damaged 1.9L AAZ head: $300.

4-puck clutch, pressure plate, and lightened flywheel: Roughly $300 combined.

The PD130 intake manifold is valued at approx. $175

That's $3,725 total

Starting with a wrecked 1.6TD engine and including upgrades, including complete 1.9TD head rebuild, the costs were probably $4,000. Includes $265 USD for Raceware head studs, custom camshaft, etc.

Throw in $200 in misc. stuff, like headgasket, new timing belt, oil, fuel filter, etc.

That's a grand total of $7,925 CAD. Still a rough estimate. Seems like a hefty price tag. Also I was nowhere near the maximum power potential due to lack of intercooling, lack of fuel during high RPM, etc. I haven't bent my shot-peened OEM rods yet. Building on the stock block may suck in another $2,500 mainly due to AAZ pistons, coating, custom rods and crank work (not cheap). 2 new turbochargers for compound turbocharging is not going to be cheap either. I'm fortunate enough to receive sponsorship by Superior Fuel Injection for upgrading my fuel pump to a Stage 5 or so next time. I've only put 10,000km on my stage 4 fuel pump and I still need more fuel!

$8k CAD so far seems like a lot, but including the value of the vehicle shell it's not more than $12,000 CAD... which is still half the price of a typical low km 90HP MKIV TDI vehicle.

The MKV Jetta TDI will cost me around $30,000 CAD after taxes and I'm back to square one with 100HP :roll: but it's intended to be a warranteed daily driver (and my chip demo vehicle) so my IDI will be an evening or weekend racer/driver.

[malone]

how much time and money has been put in to get these numbers?  what do you think i could achieve as a semi serious diesel tuner?  110hp a possibility?

To answer your second question, start by:

1) installing an intercooler.

2) installing a boost gauge and a pyrometer (tap in thermocouple pre-turbine).

3) upping your boost to 24 PSI or so if you have a T3 or K24.

4) upgrading your fuel pump and setting its timing to 1.05mm. Doing the fuel governor mod and turning up fuel IQ is decent, but there's still more than that.. i.e. upgrading camplate to 1.9. That should be enough for 110HP.

[zagarus]

sweet!  i plan on getting intercooler and exhaust done next month, the intercooler is 21.75x6.5x2.5 and is 300cad from kinetic motorsport.  The exhaust i plan on getting done at passenger performance.  So thats a good start. Plus ill be getting a manual boost controller and uping the boost.  Just need to figure out when to do the egt gauge install.

[malone]

Good idea on the exhaust upgrade, I forgot about that. Maybe PP can install the EGT thermocouple pre-turbo when you go in for a downpipe...

[zagarus]

thats what im hoping will happen, heck maybe ill even get them to install my intercooler while im at it...Intercooler, 2.5 exhaust, egt gauge!! Damn i'd be set then!

[935racer]

Yep I can definately do the whole works for you, aftercooler installs and plumbing are my favorite.

[zagarus]

so whats that gonna cost me   ?

[935racer]

Downpipe, full mandrel bent exhaust, aftercooler piping, silcone adapters and  boost clamps, egt install... Probably want to make a custom air intake and put a cone filter on there at the same time, Gonna be around $1200.

[zagarus]

thats it!!!! *** son you have a customer...next month that is, gotta make the money first     Ya i know which exhaust ill probably be getting, i know the intercooler, so ya sweet.