Golf II GTD with 1.9 AAZ engine --- EVO II

[Mark(The Miser)UK]

Hi BlauMaulesel,

and have had no idea how to make a consistence simulation, without time transient calculation. Best Regards
Alleslowbuged   

What if you repeated the simulation 4 times, each one with only one port open?Then you can compare, and even superimpose to some extent revealing dead spots and contraflows.

At first glance, there seems to be too many zero movement regions. They look more naturally like maelstroms, but that's  the  Poe in me

[Alleslowbuged]

Hi,

spooling seems not as bad as i thought yesterday, perhaps the turbo need a few revs for " wake up" or i was to confused yesterday.
Today i have notice spooling started a bit below 2000 rpm, results in 0.2 bar (3 psi) boost at 2000 rpm in third gear and 1/3 throttle.

@ Mark
agree, i will do the four simlulations later, after i find my prefered intake variant.


Best Regards
Alleslowbuged      

[rallydiesel]

I'm surprised at how shallow that water passage is. Makes me hesitant to even gasket match ports. Maybe I'll just stick to just shaping the seat areas.

[RabbitJockey]

I'm surprised at how shallow that water passage is. Makes me hesitant to even gasket match ports. Maybe I'll just stick to just shaping the seat areas.

yeah it scares me too, but atleast now i'd know how to fix it haha.  the most to gain is in the valve seat area anyway tho.

i'm surprised with such a big exhaust housing how well that turbo seems to be spooling for you.  it would be interesting to see how it does with more fuel.  as i'm sure you know every thing is a trade off, and you're not going to make crazy torque at 2k if you want to actually make big power unless you have a compound setup.  if you can maintain an efficient 30psi with proper fueling over 5k you're going to move a lot of air and make some very serious power.    awesome build

[carrizog60]

alles,can you make that calculations for a 1.9d intake with flow coming from the driver side?
i have one of those(looks like a gasser one),i heard that they were good,why didnt you tryed one of those?

[Alleslowbuged]

Hi,

i have one of these and have had scheduled to use it on my rabbit project, but this was cancelled because of the D-port-shape of the na intake.
I have not found a pipe -  td-intake arangement, which convinced me really, so i allready have considered to make a simulation with the na intake.
Problem is, first that i am not sure were i have it and second that i do not remember if that the na intake will make collision with the turbo.

Yesterday i have ordered a new stock engine bearing and a additional PU inlet:
http://www.clausvonessen.de/pi22/pd49.html

I have also odered a few Ø80x2 alu pipes and a few Ø120x5x500 alu flat sheets to make the tapered intake pipe from (either for td or na intake part).

This is what seems to be best, but is to much for for manufacturing (for me)


This is what i end up with:




But as i wrote, if the na intake will fit i will take it.

Best Regards  

[Alleslowbuged]

Hi,

here i am again, with now nearly 300 km  on the speedo since the (second) restart.
I have driven daily to work and back and today i have looked a bid more detailed on
the bosst gauge.

Here is what i have seen (you have to expect a working wastegate):


after that i have again trimed the matchbot calculation and print it again in the S2a compressor map:


I think without a wastegate i have a surge problem between 4200 rpm and 4600 rpm, assumed boost pressure will be ~3 bar (45 psi), which
would suit with the s2a compressor plot. When i go for it actual, the power increase very rapidly from 3300 rpm to 4200 rpm, then the power
increasing stops (nearly decreasing) until ~4600 rpm, than it goes forward again.

The engine bearing comes today and tomorrow i will visit the garage of a friend, were i will install it. I will find enough time i will also install the
wastegate and if everything goes on well, pherhaps i can go on a dyno on saturday.

Best Regards

P.S. here is the link to the updated Matchbot calculation:
http://www.turbodriven.com///performanceturbos/matchbot/index.html#version=1.2&displacement=1.9&CID=115.938&altitude=500&baro=14.456&aat=75&turboconfig=1&compressor=62k80&pt1_rpm=1500&pt1_ve=85&pt1_boost=2&pt1_ie=95&pt1_filres=0.08&pt1_ipd=0.2&pt1_mbp=0.5&pt1_ce=58&pt1_te=75&pt1_egt=900&pt1_ter=1.14&pt1_pw=5.41&pt1_bsfc=0.36&pt1_afr=16&pt1_wts=300&pt1_wd=83&pt1_wd2=74&pt1_wrsin=69033&pt2_rpm=2000&pt2_ve=92&pt2_boost=3.5&pt2_ie=92&pt2_filres=0.1&pt2_ipd=0.2&pt2_mbp=1&pt2_ce=62&pt2_te=73&pt2_egt=1100&pt2_ter=1.19&pt2_pw=2.14&pt2_bsfc=0.36&pt2_afr=16&pt2_wts=320&pt2_wd=83&pt2_wd2=74&pt2_wrsin=73635&pt3_rpm=2500&pt3_ve=92&pt3_boost=7&pt3_ie=92&pt3_filres=0.12&pt3_ipd=0.4&pt3_mbp=1.3&pt3_ce=65&pt3_te=72&pt3_egt=1400&pt3_ter=1.3&pt3_pw=0.78&pt3_bsfc=0.36&pt3_afr=16&pt3_wts=340&pt3_wd=83&pt3_wd2=74&pt3_wrsin=78238&pt4_rpm=3000&pt4_ve=92&pt4_boost=15&pt4_ie=90&pt4_filres=0.15&pt4_ipd=0.5&pt4_mbp=1.5&pt4_ce=69&pt4_te=71&pt4_egt=1600&pt4_ter=1.53&pt4_pw=0.47&pt4_bsfc=0.36&pt4_afr=16&pt4_wts=368&pt4_wd=83&pt4_wd2=74&pt4_wrsin=84681&pt5_rpm=3300&pt5_ve=90&pt5_boost=30&pt5_ie=88&pt5_filres=0.18&pt5_ipd=0.7&pt5_mbp=1.8&pt5_ce=65&pt5_te=70&pt5_egt=1800&pt5_ter=2.06&pt5_pw=0.89&pt5_bsfc=0.38&pt5_afr=16&pt5_wts=400&pt5_wd=83&pt5_wd2=74&pt5_wrsin=92044&pt6_rpm=5500&pt6_ve=88&pt6_boost=30&pt6_ie=85&pt6_filres=0.2&pt6_ipd=1&pt6_mbp=2&pt6_ce=62&pt6_te=70&pt6_egt=1800&pt6_ter=2.62&pt6_pw=18.27&pt6_bsfc=0.38&pt6_afr=18&pt6_wts=400&pt6_wd=83&pt6_wd2=74&pt6_wrsin=92044&
     

[RabbitJockey]

Hi,

here i am again, with now nearly 300 km  on the speedo since the (second) restart.
I have driven daily to work and back and today i have looked a bid more detailed on
the bosst gauge.

I think without a wastegate i have a surge problem between 4200 rpm and 4600 rpm, assumed boost pressure will be ~3 bar (45 psi), which
would suit with the s2a compressor plot. When i go for it actual, the power increase very rapidly from 3300 rpm to 4200 rpm, then the power
increasing stops (nearly decreasing) until ~4600 rpm, than it goes forward again.

The engine bearing comes today and tomorrow i will visit the garage of a friend, were i will install it. I will find enough time i will also install the
wastegate and if everything goes on well, pherhaps i can go on a dyno on saturday.

Best Regards
     

so your boost vs rpm graph is based on what you have seen while driving?  Also i must ask, when you say 3 bar and 45 psi, you mean absolute pressure, correct?  as in 2 bar of boost and 30psi like your first graph shows?  also maybe with your new intake the surge problem could be solved, especially since it is occuring at only a few hundred rpms.

[Alleslowbuged]

Hi Trev0rbr,

no i mean 3 barg or 4 bara, the pressure was that high because i was driving without wastegate. My pressure gauge has only a display range from -1,0 bar to +2,0 bar, so i did not really know what was the actual pressure.

As promised i wand to drive to my friend today, but on the way to my garage (to pick up some tools) i have had a leakage on the cooling system, at the outlet from the thermostat casing. It seems as i have not put in the splint pin correctly in place, so the o-ring connector could open freelance. So my cylinderhead has had his first serious thermic topic to go on with. As i reconize that something is not as it should be, the heating fault directly, which means there was no water left. But because i was nearly on my garage i could roll to it.

During waiting for cool down of the engine, i change the engine bearing to a stock one with a pu inlet. In fact it is a bit better than my motorsport bearing, but when the engine pulls hard, it vibrates also highly.

I also installed the wastegate and fabricated a temporary wastegate pipe, which end up parallel to the downpipe under the car. I also bring my boost controller in operation, so that i now can run with 2,0 bar boost pressure constantly.

Before i come home (a few minutes ago) i was on the autobahn and make some "full pulls" in third, fourth and fifth gear. What i can say is, that the turbo has no problem to keep the boost pressure at 2,0 bar (30 psi) over the full speed range up to the red line (~5500 rpm).

Whats about power?
In fact i dont know, yes there is power but it feels not as spectacular as want. I would suspect ~150 hp from 3500 rpm to 4500 rpm, but ww will see.
I do not know deatiled pump timing, as did not check it after reinstall the cylinderhead (the pump was not loose since last timing check) and i also did not have checked internal pump pressure. I hope to got both solved tomorrow.

Best Regards 

 

[carrizog60]

whats the problem with the D shaped ports on the intake?
fitting would be a pain but it would be less fabrication if it flowed good.

glad to see things moving,hope you can get your power goals

[Alleslowbuged]

Hi,

i meant that the na intake is not capable for my golf mk1 project (http://www.vwdiesel.net/forum/index.php?topic=12547.30), because i use there a portet mechanical head with O schape ports and i will make a manifold with a shorted 2.4 na intake (6 cylinder engine) for that engine. So in fact the 1.9 na intake would be fine for the aaz, if it suit with the turbo.

Best Regards

P.S. I wand to make a dyno run this morning, but the don't have time for me.
   

[carrizog60]

well,best to not having time than not having money 

will be here to see your dyno

[Alleslowbuged]

Hi,

status update:

There are good news and there are bad news, good is that the cylinder head really seems to work under all conditions without any issues.
Bad is the the f...cking adapter is broke again today. I had 500 km gone yesterday (i achieve 30 mpg) in the evening, and have visit a friend,
so iwas on the autobahn again, but did no further full load runs. Today on the way back, the complete wastegate brokes out @ 140 km/h and
0,5 bar, so without many stress.



Best Regards
Alleslowbuged

[RabbitJockey]

Are you going to switch to the eBay 8v manifold

[carrizog60]

is that made of tuna cans?