TDI HEAD PORTING

[rallydiesel]

I'll keeplooking for an explanation on the swirl bump, and for sme pics.......

It's just an asymmetry in the intake port that closes off one side of the port between the wall and valve guide. It's quite obvious. It forces the air to increase in velocity and vortex around as it enters the cylinder.

[RabbitJockey]

hey i am an expert googler

http://www.competitiondiesel.com/forums/showthread.php?t=139276

[rixy]

yeah, its 120 i've got, not 180, lol.....just checked ha ha, its been a while since i done one and couldnt remember.

Will wait to see how you get on with your head once its refitted, be nice to see some pics of the ports etc :-)

[RabbitJockey]

When I did mine I used 120 for the final then the shop that did all the valve work sand blasted the ports

[burn_your_money]

Remember, it was the TDI in a van. It went finally to Colorado or something where the new ower put a new head on. It checked out fine otherwise. I think Libby may have even looked at it.

That rings some bells. If Libby checked it over, I'm pretty sure he covered the bases. Thanks

[libbydiesel]

I did deal with the smokey TDI van.  Swirl bumps were not the issue.  Although the head was ported some, the swirl bumps were present and accounted for.  I still do not know what the issue was.  The owner did not want to replace the head which was the next step I would have taken and instead sold the van.  The new owner did replace the head and the smoke issues went away.  Again, the swirl bumps were not the issue. 

[theman53]

My bad, I thought the guys said the swirl bumps were taken out with the porting. If not the velocity must have been down and not mixing with the diesel well for some reason. Wasn't the HG replaced too and then a new head after that? If so the head was the culprit, I just thought the swirls were gone.

[snakemaster]

excellent, some pics would be awesome if you could :-) when you say cleaned the swirl bump up, do you mean removing it, or just polishing it up a bit??

Im hopefully gonna be removing the engine this weekend, and will split it, and start the work fter the weekend hopefully :-)

I took 1mm off the bumps and smooth off the edges , i did not polish any of the ports the exhaust ports were finnish of the smoothest tho , and i forgot to take some pics but get them for next week 

[JFettig]

I just finished my head rebuild with porting. I didn't do any flow bench stuff, all ported by feel and pictures of other porting jobs.

[410]

Very nicely done jfettig.  I love the sharp angle of the ends of the swirl steps and the exhaust ports are massive!  Do you plan on running a stock cam or something a little more aggressive to compliment those ports?

[JFettig]

I am running a Colt Stage 2 cam and will continue to run that. I could get a Colt Stage 3 cam but I've spent enough money recently

[RabbitJockey]

beautiful port job!  certainly more consistent than i have the patience for, looks great, like a robot did it

[JFettig]

Thanks

I can't believe the hours I spent on it, it was quite the learning experience. I mostly used 3/8" and 5/16" rounded end burs as well as a 1/4" for a little bit of it. I also used sanding rolls. next time I do it, I'm going to get a more course grit sanding roll, probably around 80. I think I was using 120.

Burs should be 2-4" long. I had a 6" that I shortened up because it was just too much.

I plan to tune my new turbo/injector setup with the old head then do an after comparison. Hopefully I don't loose any part of the RPM range.

[410]

A comparison between a stock head and a ported head would be awesome.  I'll be waiting patiently for results.

[Smokey Eddy]

Awesome job. I'm going to do the same when i inevitably have to take it apart to clean out all the EGR crap.