Building an adapter plate for a BB Turbo

[AudiVWguy]

Hi everybody,
Welcome again to another installment of Diesel Workbench. Other wise known as what the heck's he try'in ta do now?
Today, I'm  going to build an adapter plate to bolt an IHI VF14 BB Turbo to a VW manifold.
Here's kinda what we're going for.


What I need to do next is slice the mounting base off an old turbo.

and then weld the two pieces together.

There's only one small problem, I don't have a broken turbo to cut the flange off of.
So, if you guy's could check your stuff and see if you have a broken turbo that I can use the mounting flange, I would really appreciate it.
Thanks for the help,
-Jb

[theman53]

http://weirtech.ca/catalog/index.php?cPath=13_16
There is some stuff on that page that "could" help and they might even have the correct one for you. I think you might want to check out a fab shop and ask them for a piece of scrap 1/2" or 3/8" piece of flat steel. Mark your holes, torch the inlet out, and drill your bolt holes. Carbide burr or cartridge roll the torch marks out and weld it up. I would hate to see a turbo cut up. I also think it is made of NiCr202 which probably won't weld well.

[AudiVWguy]

Ya, I've been thinking about that, I have a 3/8ths plate that will work. But I was thinking it would be better to weld two "like" materials rather than steel and cast. I was only wanting that trapezoid  flange off a broken turbo. let me know if you got something that qualifies.

[clarkrep]

I don't know if you've considered a different manifold of not but I found the factory log style manifold to be limiting the top end(3500-5500ish) on my 1.6 td with a k24. I used a flipped dual outlet manifold and built an adapter for the k24. I can elaborate on it and upload some pics if your interested.
Btw what did the BB come off of originally?

[rallydiesel]

I used to have one but I threw it out. 

[GTD_MK2]

I would really be interested to see some pictures of the flipped dual outlet mani with the k24 on it...

[AudiVWguy]

clarkrep, lets see some pics, its sounds interesting. The turbo was on a JDM Subaru Imprezza. 2ltr motor, made 280 hp. But, it used two turbos, a smaller VF13 and a VF14. I believe this was a compound setup.I think like the way the RX-7 works. Based on recent reading on compound setups, possibly the single might not be large enough. Although, I measured the compressor side is 35mm across and the exhaust side is 40mm. This is about the same as the K-14 on the intake side (34), but the exhaust is smaller (37). So, we'll see what happens. I still need that turbo flange.
Cheers,
-JB

[clarkrep]

Had some trouble uploading pics...I'll try later maybe tomorrow.
Aaron.

[theman53]

Ya, I've been thinking about that, I have a 3/8ths plate that will work. But I was thinking it would be better to weld two "like" materials rather than steel and cast. I was only wanting that trapezoid  flange off a broken turbo. let me know if you got something that qualifies.

I didn't realize that what you have already was cast. Well, if you can't find a junk turbo*GeeBee always tells people to contact G prop shop* you could make both pieces out of flat stock with a small section of pipe.

[clarkrep]

Here are the pics I'll add explanations later.....

[AudiVWguy]

WOW, you have access to some way cool toys! 

[GTD_MK2]

WOW! , thats cool...
Did it made a big differrence in top end power ?
Because i want to install a GT1852V on my 1.6 mk2 GTD, and I'm thinkink about exh. manifolds, i could use the stock mani, one from a GTI, one of a 90HP MK3 (almost like the dual GTI one, but with one big square flange) or build my own out of an old stainless steel header of a 1.8 GTI mk1.
For now ive got a K24 on it, but i think its a bit restrictive on the exh. side.

[clarkrep]

Thanks guys they aren't my toys of course. I did most of this in the lab at school. Shouldn't have graduated...  
As far as top end power I wouldn't say it was a huge improvement although it seemed more happy up there,the roll on power and general way it ran compared to before was great. It lowered my egts about 150* and boost pressure was a couple psi lower too. That's cruising at 70 flat ground down from 9-10psi to about 6-7psi, egts were about 900* before and after they were around 750*. I really think this can be attributed to the better runner design getting more exhaust energy to the turbo. I think the relative equal length of the runners and the fact that they aren't all that large(compaired to an aftermarket t3 manifold) helps.