GT2056V on a 1.6TD...

[R.O.R-2.0]

not to mention, ive got wiring issues this time around.. i hooked the injection pump and lift pump into the original coil power circuit, and it does not like that circuit. ive gone thru 2 relays soo far. thought it was the key switch at first. not so..

i have a good german fuse box, that im going to swap in, if i cant fix my issues..

[libbydiesel]

Cable or rod connecting vanes to the accelerator coupled with a wastegate to bypass the turbine and control max boost is workable.  The downside to that approach is that with the pedal floored, the vanes will be in their closed position.  At higher rpms the restriction of closed vanes will significantly impact maximum power.  At higher rpms with boost controlled by vane position instead of wastegate, the vanes will be positioned in a very open position allowing excellent flow and considerably more power for that boost pressure.

[Rock3tman]

For your consideration tonight...

I just finished my VNT-15 linkage to adapt an ALH turbo to my 1.6TD this afternoon!!!  It is primarily based on the work of libbydiesel (he supplied the converted vacuum-to-boost can) and tdihuntdawg, with a LOT of lessons learned from all of the rest that have gone before me on this journey to IDI goodness.   

It includes:
 2 bellcrank arms from Speedway motors,
 3 10-32 heim joints, 2 10mm heim joints, 6mm threaded stainless and various hollow aluminum rod from McMaster-Carr, and
 a return spring, a roll pin, metric and SAE nuts etc from Ace hardware.
The rest was designed & fabbed by me...so if it needs additional work I'm the guilty party.

here's a video link:   http://s1264.photobucket.com/albums/jj492/Rock3tman/?action=view&current=MVI_7211.mp4

(there's a few still pictures of the rig as well).   I hope to have the rebuilt 1.6TD engine/FN trans w/ 3.67 R&P installed into my 1983 Jetta within a month with performance results to follow shortly.
 

[R.O.R-2.0]

Cable or rod connecting vanes to the accelerator coupled with a wastegate to bypass the turbine and control max boost is workable.  The downside to that approach is that with the pedal floored, the vanes will be in their closed position.  At higher rpms the restriction of closed vanes will significantly impact maximum power.  At higher rpms with boost controlled by vane position instead of wastegate, the vanes will be positioned in a very open position allowing excellent flow and considerably more power for that boost pressure.

im going to be doing the linkage control setup. so that the vanes are worked by my foot. its gonna be KINDA like libbys setup, but a little different.

i WILL NOT have my vanes closed at full pedal. i need my vanes open at full pedal..

[libbydiesel]

ROR, with my system, the vanes are only closed at full pedal until boost rises.  Steady state full pedal will result in the vanes being as open as possible while being able to achieve max boost. 

[Rock3tman]

The way I understand it, when boost pressure rises (probably quite quickly w/ a vnt-15 vs. your GT2056) then the boost will expand the actuator diaphragm and move the vanes to a more open position, reducing boost until equilibrium is reached for a given throttle position.  I have a 0-30 psi boost/1500f EGT combo gauge, so I'm planning to use that to get out of the throttle if there's still too much boost.   Will this work?

[R.O.R-2.0]

ROR, with my system, the vanes are only closed at full pedal until boost rises.  Steady state full pedal will result in the vanes being as open as possible while being able to achieve max boost. 

i know, thats why i want to run them that way..

i want the turbo to not be a restriction..

but i think im going to need to limit the amount of travel the vanes can do. right now, once the vanes open, the turbo quits boosting.. i think i need a stop, as a way of adjusting max boost levels..

[libbydiesel]

If you installed a stronger spring in your wastegate actuator, you would increase your max boost. 

[R.O.R-2.0]

If you installed a stronger spring in your wastegate actuator, you would increase your max boost. 

i really want an ADJUSTIBLE wastegate.. im about this far [--] from taking the adjustible wastegate off my K24, and using it.. i know that thing will work as i want it..

and its kinda hard to just open up a wastegate can.. all the ones i have are dinky, and fully open by 10 psi.. i know you can un-crimp a wastegate, but idk where i would find stiffer springs..

[libbydiesel]

For turning VNT actuators into boost cans, I have used micro nuts and bolts around the perimeter to make them resealable without messing with crimping and un-crimping.  I have gotten stronger springs from McMaster and then cut them to size to dial in the boost pressure.  You also have the option of adding an MBC to the boost can if you don't want to mess with the springs.  With MBCs, tho, I've run into the issue that the smaller VNTs build boost so quickly that an MBC cannot react fast enough to regulate boost and so it can spike high and then drop back to the control pressure.  Using LARGE hose and fittings can help with reaction time. 

[R.O.R-2.0]

For turning VNT actuators into boost cans, I have used micro nuts and bolts around the perimeter to make them resealable without messing with crimping and un-crimping.  I have gotten stronger springs from McMaster and then cut them to size to dial in the boost pressure.  You also have the option of adding an MBC to the boost can if you don't want to mess with the springs.  With MBCs, tho, I've run into the issue that the smaller VNTs build boost so quickly that an MBC cannot react fast enough to regulate boost and so it can spike high and then drop back to the control pressure.  Using LARGE hose and fittings can help with reaction time. 

tried a boost controller.. my turbo doesnt like it. even with 1/8" ID line, it still boost to 25, blows the vanes open, goes back to 15psi, and then closes the vanes back up to 20psi.. i was using large hose. the fitting on the manifold was the smallest portion of the line..

[libbydiesel]

Yup, that's why I went to the stiffer springs.  You could also add an external spring which would be easier to swap.  It just has to act opposite the boost pressure.

[R.O.R-2.0]

Yup, that's why I went to the stiffer springs.  You could also add an external spring which would be easier to swap.  It just has to act opposite the boost pressure.

i was thinking about adding an external spring(s) actually..

im gonna pull the turbo today, and rig up some linkages to it. i need to get my actuator up higher. right now, its about impossible to get to, so adjustments are basically out of the question..

i wanna get my vane actuator up higher, like up by the intake manifold..

[Rock3tman]

my linkage has the boost can & just about all of the adjustments at the top of the engine by the intake manifold - - the centerline of the manifold lines up with the axis of the shaft that has the adjustable arms.

[libbydiesel]

Rock3tman, your linkage looks great.  I look forward to hearing about it when you get it up and running.  With the VNT along with the liquid to air system your car should perform very well.