Time to start assembling 1.5 TD / 1.9L Franken Diesel.

[Jetmugg]

The flaw in my earlier thinking was not realizing that the regulator needs to restrict FLOW, not PRESSURE.  This is not an open system, so I need to give the excess somewhere to go.

Check this video of a guy running at Bonneville in a '64 Mini Cooper....

https://www.youtube.com/watch?v=O2VHyMAv1dU

He starts adjusting the boost controller about the 2 minute and something mark.

I think I'll do something like this, but possibly mount the regulator on my switch panel.

Steve.

[CRSMP5]

what he is doing is manipulating the boost once at foot to floor trying to get that little more he can... id almost assume he has a vnt type of set up where he is playing with the vnt aspect of dialing the turbine in for best time...

the thing i dislike is how he looks to be reaching for it... im still thinking a t handle shift knob with regulater built in would be best comfort/ease imo..

[theman53]

The ball and spring type has approx. a .001" hole in the side so that it will not hold the spring open. It is almost exactly what you are looking for an electric control being perfect, this is the next best thing. It shuts off all flow to the wastegate and you are not loosing boost during that time.

http://www.ebay.com/gds/NXS-Manual-Boost-Controller-Installation-Install-Guide-/10000000004194851/g.html

[bbob203]

I think I'm gonna try a ball and spring instead of a regulator.

[8v-of-fury]

I just got a boost gauge on mine recently, and I've had a ball and spring MBC on there for a while now..

It would turn out I have been boosting my GT-15 to like 30psi! So I knocked it back on the MBC, you can watch it get to about 15 in about a half second, drop to 10 (wastegate opens) and then keep on rolling to 25psi if I keep on it.

Shweeeet. No exhaust restriction, and MAD BOOST BROTHA! Now I need an IC to take HUGE advantage of that ability.

[Alcaid]

Congrats on the great numbers and a successful dyno session!

Thumbs up for the NXS Boost Controllers (ball and spring type) from me. I've used them several times and they regulate very well, even up to 45+ psi if turbo and engine can take the beating

I've seen up to 1830°F EGT on a 1.6TD, but that's crazy high, 1400°F should work OK in the long run but watch your coolant temperature.

With your relatively low compression ratio, 30psi is just a walk in the park, I would aim higher but it all depends how much fuel you are able to get in there with your pump. No need to boost more than what's needed to clear the smoke and keep EGTs at a sane level. Looks like your governor is kicking in a bit early since HP curve flattens out. A friend just did a governor mod on a 11mm Dieselmeken pump with great success and it's pulling much harder on top now.

The 56mm 55 trim Garrett compressor you are running now is not what I would've used on a 1.5 IDI. You need more surge margin and both Holset and Schwitzer compressors with anti surge housings are more in the direction I would go. 360° thrust bearing is a must-have in high boost applications. Spool isn't all that essential for you either so a bigger turbine wheel and housing to keep EGTs and back pressure even lower would be worthwile.

Saw this green monster in the last edition of the DieselPower magazine, a shame though that they thought it was a TDI build and didn't write more about your IDI engine.

[Alcaid]

I just got a boost gauge on mine recently, and I've had a ball and spring MBC on there for a while now..

It would turn out I have been boosting my GT-15 to like 30psi! So I knocked it back on the MBC, you can watch it get to about 15 in about a half second, drop to 10 (wastegate opens) and then keep on rolling to 25psi if I keep on it.

Shweeeet. No exhaust restriction, and MAD BOOST BROTHA! Now I need an IC to take HUGE advantage of that ability.

It's called boost creep and it means your turbo is way too small 

[Jetmugg]

Alcaid:
    First and foremost - Thank you for weighing in on this topic.

    My mind is becoming more comfortable with the notion of running 1400+ F EGT's for a minute or two.  I have an oversized, 2 pass aluminum radiator which should be quite effective at keeping the coolant temperature in check, especially when running at speed.

    I am a beginner when it comes to turbocharger knowledge.  I went with the GT2056 turbo based on the recommendations of folks more knowledgeable than myself, even though I realized that it might not be the absolute optimum turbo for this application.  It got me "in the game" with what should be a workable turbo.  Depending on how things go at the World Finals, and into the future, I know of some more turbo options as well as other tuning & mechanical changes that might help to make even more power.

    I'm planning to leave the pump alone.  I don't want to tinker with Dieselmeken's work. 

    For now, I am happy with the power levels, and want to see what it will do on the salt.

    I had no idea that my Rampage appeared in Diesel Power magazine.  I didn't contact them, so I have to assume someone else sent them a link, or they came across the build thread on a website.  You are talking about the print magazine?  I'll have to go search the newsstands for a copy.

Thanks again.

[RabbitJockey]

I just got a boost gauge on mine recently, and I've had a ball and spring MBC on there for a while now..

It would turn out I have been boosting my GT-15 to like 30psi! So I knocked it back on the MBC, you can watch it get to about 15 in about a half second, drop to 10 (wastegate opens) and then keep on rolling to 25psi if I keep on it.

Shweeeet. No exhaust restriction, and MAD BOOST BROTHA! Now I need an IC to take HUGE advantage of that ability.

It's called boost creep and it means your turbo is way too small 

i told this hoser he needs more turbo and not ebay ***.  he should also try some american bacon.

[RabbitJockey]

With your relatively low compression ratio, 30psi is just a walk in the park, I would aim higher but it all depends how much fuel you are able to get in there with your pump. No need to boost more than what's needed to clear the smoke and keep EGTs at a sane level. Looks like your governor is kicking in a bit early since HP curve flattens out. A friend just did a governor mod on a 11mm Dieselmeken pump with great success and it's pulling much harder on top now.

something else i had thought here was that the low compression engine could really enjoy some timing advance, what is your take on this?

[Jetmugg]

It seems to make sense that earlier injection timing would work with the lower static compression.

I didn't have time to try different timing levels during the dyno session.

However, I should have all week to try different timing and boost settings on the salt flats. (The Great White Dyno).

[RabbitJockey]

i wouldn't be too scared to mess with your governor either ;^P  theres plenty of tech support on the forums to help u get everything running properly.  but im sure u don't want to be messing 50 factors all at onced right now either.

also alcaid, do you think gt2259 would have been a little better?  it has less surge issue, bigger exhaust side and lower compressor wheel speeds.

[Alcaid]

something else i had thought here was that the low compression engine could really enjoy some timing advance, what is your take on this?

The Dieselmeken pump has much more dynamic timing built into it, but trying a bit more static timing might be worth a shot.

[Alcaid]

also alcaid, do you think gt2259 would have been a little better?  it has less surge issue, bigger exhaust side and lower compressor wheel speeds.

The biggest Holset HE221W (60/44.2mm compressor) has even better surge margin than that one and flows a LOT more air. The one showing up on a project on this forum soon will be an even better match

[Jetmugg]

I asked Dieselmeken for timing recommendations, and he gave me a good starting point. 

He also gave me recommendations for increasing the fueling, but it is very near maximum right now.

I know the entire engine/pump/turbo/intercooler is not 100% optimized right now, but I'm still very pleased with the power.  I am not aware of any other 1.5L IDI's currently using the 1.9L AAZ cylinder head.  I am hopeful that this combination will power my little truck enough to be competitive against the existing record.

When I'm out on the salt flats, I will have time and opportunity to move the pump timing up and down a bit between passes.

That Holset HE221W seems to be a very good turbo for engines of this size.  I believe there are also some Borg-Warner turbos that are in the same size/suitability range.  I'll have to go back and check the flow maps on some of those.