Author Topic: 81 Rabbit LS AAZ (2023: now tdi-m)  (Read 37543 times)

Reply #45January 30, 2015, 12:47:51 pm

RabbitJockey

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Re: 81 Rabbit LS AAZ
« Reply #45 on: January 30, 2015, 12:47:51 pm »
well, the compressor wheel i ended up getting was chinese, and not genuine garrett like i thought, the seller insisted that he sells garrett parts and that i must have been sent the wrong one by accident, so now i will be receiving a billet aluminum compressor wheel, which is pretty sweet, this next iteration will have a 360* thrust bearing and billet aluminum compressor wheel.  should be pretty durable, but we will see.
01 Jetta TDI 100% stock daily
81 Rabbit:TDI-M ported head, Frank06 cam, PD intake, hybrid T3 turbo, Renault intercooler, Syl20 11mm pump, light weight fw, and yellow California Clutch clutch kit

Reply #46April 23, 2015, 11:44:03 am

RabbitJockey

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Re: 81 Rabbit LS AAZ
« Reply #46 on: April 23, 2015, 11:44:03 am »
So i have just now begun working on this again.  I rebuilt my turbo with a completely different center housing, compressor backing plate, kts billet alluminum compressor wheel, and turbine shaft/wheel.  the only things i've reused from the last turbo is the compressor and turbine housings.

i've resolved two issues with this rebuild, first off is that the billet wheel is designed to flow much more air, so the fins are thinner and have a better design, and also the center hub cone is much much smaller.

the problem is that the normal t3 compressor nuts are too large and actually block part of the flow area since they are a larger diameter than the compressors hub.  i considered a few different compressor nut solutions but i decided to use  a jet nut from mcmastercarr they're a distorted flanged lock nut made from some a steel alloy designed to handle temperatures of over 1300*f, so i will be using that along with high temp red loctite.

http://www.mcmaster.com/#98892a500/=wvmj9g

normal t3 nut:




the second issue was that the fitting to connect the boost signal to my wg had broken off, which i am pretty sure is why my first turbo failed, so i drilled and tapped the whole for a 1/8" npt fitting, and added an elbow and 1/4" barb.

and heres a picture of how it will look all together




01 Jetta TDI 100% stock daily
81 Rabbit:TDI-M ported head, Frank06 cam, PD intake, hybrid T3 turbo, Renault intercooler, Syl20 11mm pump, light weight fw, and yellow California Clutch clutch kit

Reply #47April 23, 2015, 06:07:58 pm

theman53

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Re: 81 Rabbit LS AAZ
« Reply #47 on: April 23, 2015, 06:07:58 pm »
I hope it works for you. Looks good anyhow.

Reply #48April 26, 2015, 09:46:56 pm

RabbitJockey

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Re: 81 Rabbit LS AAZ
« Reply #48 on: April 26, 2015, 09:46:56 pm »
thanks lucas. 

i really love all these small details on projects, i spent way more time on all this than it was worth especially since i don't intend on running this car very hard or even running an intercooler.

i got the nuts in the mail and was able to thread one on a little to see how these fit, and they're absolutely perfect.  i didn't run it on the whole way because i need to find some high temp red loctite first.





and here it is compared to some normal compressor nuts off of some various t3's ive disassembled.  it is a lot smaller which worries me a little bit.

01 Jetta TDI 100% stock daily
81 Rabbit:TDI-M ported head, Frank06 cam, PD intake, hybrid T3 turbo, Renault intercooler, Syl20 11mm pump, light weight fw, and yellow California Clutch clutch kit

Reply #49May 20, 2015, 09:08:50 am

RabbitJockey

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Re: 81 Rabbit LS AAZ
« Reply #49 on: May 20, 2015, 09:08:50 am »
I spent time last night and got the turbo installed back on the car and ran it for a minute on jack stands.  No real progress other than that it's back together.  heres a few pics

turbo together in my kitchen with boost line and proper sized compressor nut




and the untidy view from underneath

01 Jetta TDI 100% stock daily
81 Rabbit:TDI-M ported head, Frank06 cam, PD intake, hybrid T3 turbo, Renault intercooler, Syl20 11mm pump, light weight fw, and yellow California Clutch clutch kit

Reply #50May 21, 2015, 12:43:04 pm

RabbitJockey

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Re: 81 Rabbit LS AAZ
« Reply #50 on: May 21, 2015, 12:43:04 pm »
Finally got to drive this car some more last night, i took it and washed it and ran a few errands with it, the turbo and engine were running great, turbo boosted to 12psi and stayed there nicely.  spool up is just ok with this turbo its very responsive in higher gears and on hills, the car has good power especially for 12psi, but once i have a boost controller on it will spool faster, it spooled up really fast when i was running it with a closed wastegate.  i plan to run 15-20psi to try and stay safe.

but before i get to turn up the boost, i have to deal with what ever this issue is.

http://www.vwdiesel.net/forum/index.php/topic,35891.0.html
01 Jetta TDI 100% stock daily
81 Rabbit:TDI-M ported head, Frank06 cam, PD intake, hybrid T3 turbo, Renault intercooler, Syl20 11mm pump, light weight fw, and yellow California Clutch clutch kit

Reply #51December 08, 2015, 09:31:58 pm

RabbitJockey

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Re: 81 Rabbit LS AAZ
« Reply #51 on: December 08, 2015, 09:31:58 pm »
Well the issue i had must have been that i did not properly torque the pressure plate to crank bolts.  so the pp came loose and the holes got egged out.

i had planned on swapping the backing plate of my pressure plate with a good back plate from a used pressure plate that i had.  but then i tore the car apart and left it sit all summer, and eventually i decided that wasn't going to happen so i stopped procastinating and just ordered a new pressure plate.

got everything back together this weekend, and so probably put 40 miles on it, which has been really fun to finally drive it.  I had a few small issues but so far the turbo seems to be holding up fine.

i am waiting on my oil pressure gauge before i wire everything up, but heres a video of me revving with my sweet dual boost gauge showing boost(green) and emp(orange).  Alcaid shared that cool gauge

01 Jetta TDI 100% stock daily
81 Rabbit:TDI-M ported head, Frank06 cam, PD intake, hybrid T3 turbo, Renault intercooler, Syl20 11mm pump, light weight fw, and yellow California Clutch clutch kit

Reply #52December 09, 2015, 11:54:57 am

theman53

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Re: 81 Rabbit LS AAZ
« Reply #52 on: December 09, 2015, 11:54:57 am »
I like that gauge. I hope you have better luck than I did with garrets.

Reply #53December 10, 2015, 10:48:41 am

RabbitJockey

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Re: 81 Rabbit LS AAZ
« Reply #53 on: December 10, 2015, 10:48:41 am »
I like that gauge. I hope you have better luck than I did with garrets.

i have about 80 miles on the new turbo now, so far so good, but the last one died at high boost, so we will see how this one does once i get to increasing the boost pressure.
01 Jetta TDI 100% stock daily
81 Rabbit:TDI-M ported head, Frank06 cam, PD intake, hybrid T3 turbo, Renault intercooler, Syl20 11mm pump, light weight fw, and yellow California Clutch clutch kit

Reply #54December 10, 2015, 11:04:00 pm

Ian0391

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Re: 81 Rabbit LS AAZ
« Reply #54 on: December 10, 2015, 11:04:00 pm »
I spent time last night and got the turbo installed back on the car and ran it for a minute on jack stands.  No real progress other than that it's back together.  heres a few pics

turbo together in my kitchen with boost line and proper sized compressor nut




and the untidy view from underneath



What's that curled up copper line for?

Sent from my SM-G920W8 using Tapatalk


Reply #55December 11, 2015, 07:45:24 am

RabbitJockey

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Re: 81 Rabbit LS AAZ
« Reply #55 on: December 11, 2015, 07:45:24 am »
the copper is to cool down the air coming out of the exhaust manifold so that i can attach a hose with out it melting and measure the exhaust manifold pressure, and see how efficient or inefficient that my turbo is working.  if you watch the video above you can see my boost gauge has 2 needles, the orange needle is the exhaust manifold pressure, and the green one is the boost pressure.  i thought this was important since this is a custom turbo
01 Jetta TDI 100% stock daily
81 Rabbit:TDI-M ported head, Frank06 cam, PD intake, hybrid T3 turbo, Renault intercooler, Syl20 11mm pump, light weight fw, and yellow California Clutch clutch kit

Reply #56December 12, 2015, 10:36:52 am

Ian0391

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Re: 81 Rabbit LS AAZ
« Reply #56 on: December 12, 2015, 10:36:52 am »
Oh that's cool, I wasn't able to open the video so that's why I wondered, how much of a difference in pressure are you getting and where did you find a dual needle boost gauge?

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Reply #57December 13, 2015, 10:50:46 pm

RabbitJockey

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Re: 81 Rabbit LS AAZ
« Reply #57 on: December 13, 2015, 10:50:46 pm »
http://www.hewittindustries.com/pressure_gauges_fuel-boost_dual.html


under acceleration ive seen it go as high as 20psi in the exhaust but this before the turbo actually spools up,  boost is around 10psi but can spike to 15.  but when i am accelerating and boost is holding steady at 10psi then the emp is around 15psi.
01 Jetta TDI 100% stock daily
81 Rabbit:TDI-M ported head, Frank06 cam, PD intake, hybrid T3 turbo, Renault intercooler, Syl20 11mm pump, light weight fw, and yellow California Clutch clutch kit

Reply #58January 02, 2016, 07:16:04 pm

CharlesEr

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81 Rabbit L
« Reply #58 on: January 02, 2016, 07:16:04 pm »
sweeet man... kinda reminds me of my 87 mitsu montero 2dr... it was old and people made fun of it, but it was in mint condition and I loved that thing...

Reply #59June 27, 2016, 11:49:44 am

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Re: 81 Rabbit LS AAZ
« Reply #59 on: June 27, 2016, 11:49:44 am »
I haven't posted much, the engines been driving really nice when i take it out on the weekend.  I probably have about 600 miles on the new setup now, the clutch has broken in really nicely, it used to chatter when first engaging it, but now its very smooth, almost like a stock clutch, but never slips.  Turbo seems to have loosened up, and it maintains 8psi really well.  I am driving the car more, so i will soon be able to give some mpg numbers that are accurate and dont involve any fuel leaks.  I also ordered a gtech in car dyno, which i will have by the weekend, so i will record hp and acceleration numbers, very very soon.  this will give me some base line numbers at 8 psi before i increase boost and possibly play with fueling.  previously when i ran higher boost it seem to get plenty of fuel and really hauled ass, but i don't have any numbers or anything.

so heres a picture of the engine bay cleaned up more and with the air filter installed and fuel filter relocated.  still have some ugly wires but they will be hidden soon enough.

01 Jetta TDI 100% stock daily
81 Rabbit:TDI-M ported head, Frank06 cam, PD intake, hybrid T3 turbo, Renault intercooler, Syl20 11mm pump, light weight fw, and yellow California Clutch clutch kit

 

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