Author Topic: Compound pics (Read 112703 times)

foxracer1 · « **Reply #240 on:** December 30, 2007, 02:43:02 pm »

So what compressor are you using? K24 or K26. I'm guessing the K24 comp.

andy2 · « **Reply #241 on:** December 31, 2007, 12:13:34 am »

k26 compressor

foxracer1 · « **Reply #242 on:** December 31, 2007, 01:44:00 am »

oh okay smaller 24 turbine housing spooling larger 26 turbine/compressor. Sounds like a good set up. Very interested in hearing the results.

zaprzal · « **Reply #243 on:** December 31, 2007, 06:11:12 am »

isn't k24 exhaust housing a/r too small?

andy2 · « **Reply #244 on:** December 31, 2007, 12:16:02 pm »

Quote from: "zaprzal"

isn't k24 exhaust housing a/r too small?

Not when using it in a compound application.The wastegate has been enlarged to bypass the needed flow to the big turbo.The wastegates on the T3's,k24's are double the size that they need to be (old school turbo) :lol: .The wastegates on the smaller turbos like k14,T2 and k03 have much smaller wastegates along with smaller wheels and turbine housings!

Helliouse · « **Reply #245 on:** January 14, 2008, 12:28:48 pm »

Andy, thank for all the updates.
Have you looked at how Ford, and Cummins do their compound setups?
Big turbo first, then the small, with a separate waste gate before the small turbo. I am not sure if you would have the room but this would allow for the larger turbo to spool properly, and let enough exhaust gas pass through to spool the small.

On a second note, did you have a post in here with Dyno results, as I can't seem to find it, if not can you post some, even if they are old?

andy2 · « **Reply #246 on:** February 28, 2008, 07:31:32 pm »

I'm still slowly plugging away at my project Its a bit too cold for me to get excited about working on the engine.I've installed The H-beam rods that I bought from Kerma TDI.Very nice rod and I like having the tangs on the rod bearings which the PD rods did not have.I have a new turbo/manifold ready to be fabricated into my compound setup.Its a 50 trim T3 and I'll be using an internal wastegate with it.

Taking hints from 935racer,Dvst8r and zaprzal about the k24 being too small fineally got throught to me :wink: .Its all Ebay made in China stuff so we'll see how it holds up :twisted:.I'm using permatex 300 sealant to glue that head and block together.

Also every time I've pulled my pistons out I've noticed that the total seal rings are moving around :? .The middle ring is the gapless ring and the two ring gaps are positioned 180 deg from eachother.However the two gaps meet up with eachother after only a couple of 200 hp runs.They probaly should have pinned the rings to keep them from rotating.Once the gaps line up the compression is allowed to bypass the ring like stock ring almost.

DVST8R · « **Reply #247 on:** February 29, 2008, 11:11:05 am »

Glad to hear you haven't given up on it, you are so close to having a monster!

andy2 · « **Reply #248 on:** March 26, 2008, 09:01:52 pm »

A pic of the latest turbo setup before its all covered up.

We had to cut into the rain tray above the fire wall to get the big turbo to fit better this time around.We have added a thin sheet of aluminum between the firewall and the turbo's as its all very close to the melting hot exaust.Some custom wastegate work was done to get it all fitted in.A heavier accuator for the small t3 was robbed off an hy35 as we need the small turbo to make approx 25 psi.

We lowered the front motor mount to get clearance for the turbo's as well.I have an oil cooler thermostat to add to the cooler plumbing this time around as the oil temps were too low before causing oil to not flow properly and cause damage.

Mike and I just got the inj pump issue's all sorted out it now has a different governor setup and some other modifications that it was lacking before.

hillfolk'r · « **Reply #249 on:** March 26, 2008, 11:16:35 pm »

Quote from: "andy2"

A pic of the latest turbo setup before its all covered up.

We had to cut into the rain tray above the fire wall to get the big turbo to fit better this time around.We have added a thin sheet of aluminum between the firewall and the turbo's as its all very close to the melting hot exaust.Some custom wastegate work was done to get it all fitted in.A heavier accuator for the small t3 was robbed off an hy35 as we need the small turbo to make approx 25 psi.

We lowered the front motor mount to get clearance for the turbo's as well.I have an oil cooler thermostat to add to the cooler plumbing this time around as the oil temps were too low before causing oil to not flow properly and cause damage.

Mike and I just got the inj pump issue's all sorted out it now has a different governor setup and some other modifications that it was lacking before.

cut raintray??lol

andy2 · « **Reply #250 on:** May 11, 2008, 05:20:40 pm »

Click here to watch cold-start-50

A cold start video of the engine with lowered compression,no glow plugs and no cold advance device on pump,either only.We had 50 psi boost last night while test driving so now that the turbo end is figured out I'll pull the head to get the cracks welded up and see how the gasket is holding up.There is excessive pressure in the cooling system as soon as the engine is started cold so that is why we suspect the head is cracked.Coolant pours out the overflow vent onto the whole car during test drives.

We removed the hood so we could run the exhaust and see the smoke better while driving.Off boost fueling is high and full boost fueling is much higher but when 40+ psi boost comes on it cleans right up

.

If we can get this back together and holding together we would like to make it for a dyno day that I saw on TDIclub.So 3 weeks should be enough time to get it ready :wink:.

zaprzal · « **Reply #251 on:** May 12, 2008, 04:08:49 pm »

Quote from: "andy2"

Off boost fueling is high and full boost fueling is much higher but when 40+ psi boost comes on it cleans right up

crazy project :twisted:

smoken u · « **Reply #252 on:** May 12, 2008, 09:02:55 pm »

wow!!!!!!!!!!!!

when and where is this dyno meet?
and is that a Hood stack I see!

andy2 · « **Reply #253 on:** May 12, 2008, 09:16:11 pm »

Big problems!! The head is off and will not hold its shape under power.Looks like the Aluminum head can no longer hold up to the pressure.It would either need 6 bolts around each cylinder or need to be made of steel.This was the problem all along,not the OEM headgasket or even the 12mm ARP headstuds.The TDI can make 200 hp before having the same issues with its head.My engine was making 200+ hp but had huge head sealing issues.My dad and I are brain storming up some ideas to get this working.Needless to say it will not be ready for the dyno but I will likely attend it anyhow to see what happens with the other tunned TDI's.

jtanguay · « **Reply #254 on:** May 13, 2008, 07:44:33 am »

Quote from: "andy2"

Big problems!! The head is off and will not hold its shape under power.Looks like the Aluminum head can no longer hold up to the pressure.It would either need 6 bolts around each cylinder or need to be made of steel.This was the problem all along,not the OEM headgasket or even the 12mm ARP headstuds.The TDI can make 200 hp before having the same issues with its head.My engine was making 200+ hp but had huge head sealing issues.My dad and I are brain storming up some ideas to get this working.Needless to say it will not be ready for the dyno but I will likely attend it anyhow to see what happens with the other tunned TDI's.

i wonder if there would be a way to make some sort of 'girdle' for the head like the mains down below. basically to reinforce the structure of the head. otherwise you'll need to make your own head.

another idea might be to make a special intake manifold to even out the pressure between the cylinders and hopefully reduce the stress by spreading it out? and maybe pulsed exhaust mani? some pretty involved machining/fabricating, but it might work. Dave's 1.6 is pushing some crazy hp and holding up.

have you pressure tested the head to 50+ psi? no leaks?

good progress man! maybe some day i could drop by to see this beast again :?: