My 1.6TD Compound Turbo is up and running, 30psi of boost in neutral!

[golfmk1tdr]

maad stuff  finally! How come you didn't use your old thread 
Some good stuff there I think you would better post future updates there 
No seriously, updates, TODAY!!! (just kiding,take your sweet time teasing us to death  )
Egts, dyno sheets, videos... you know, usual porn for vwdiesel members. I would pay to read your thread but can't read norwegian, so please have mercy haha

1 question: Since you plan trashing it on track so I am curious if you believe this power should last with your components or is it more top dragster replace-everthing-after-5-runs style... Do you know anyone else track racing with this engine?
I ask because I read recently that old gti golf's are rather unreliable in LeMons racing (even if they are taking it to extreme there still I expected better from famous VW) basically same head&bottom so I quess our engines could have some issues too being pushed a lot.
Also is the golf with 204whp still runing strong? (you know me having the same turbo I have to ask  )

Your jetta coupe looking great, I dont know how rare they are for you but AFAIK they are nonexistant in my country.

Cheers, Matevž

[Alcaid]

Compound Turbo Setup:
HP Turbo: Holset HE200WG-5cm
LP Turbo: Holset HX30W-12cm, custom comp wheel and housing (73/77/50mm extended tip 11-blade billet compressor)

LP wastegate: internally wastegated
HP wastegate: external 50mm wastegate (initially planned to be a sequential setup with full bypass but changed my mind, could have used a smalled one)

HE200WG has done 204whp on 1.6TD, this build has 50% more air available so in theory 300whp is possible (got plenty of fuel as well)

Bottom end (1.6TD SB GTD):
 - Rosten Performance H-beam rods
 - SB (GTD) pistons
 - Block Girdle
 - ARP rod bolts
 - 12.9 main cap bolts
 - ARP head studs
 - Drilled cooling ports to match the AAZ head
 - Sputter TDI rod bearings (rosten rods are designed for these wider bearing shells)
 - New intermediate shaft bearings
 - 36mm oil pump
 - Bottom end fully cleaned, resurfaced, rebuilt and rotating assembly balanced (component balanced and assembled)

Cylinder Head (1.9TD AAZ):
 - Based on a AAZ head with no(!) cracks between valves
 - Custom 21-4N intake valves
 - Custom 23-8N exhaust valves
 - Titanium retainers
 - Custom dual valve spring setup for up to 12mm lift and 7500rpm
 - Custom camshaft
 - Head machined to clear high-lift cam lobes
 - Head developed in flowbench, testing various valve sizes, seat designs and port designs on spare cylinder head

Fuel:
 - 12mm Dieselmeken pump, bench tested delivering 185cc and tested up to 5800 engine rpm
 - Carter P4601HP Feed Pump Lift Pump
 - Audi 3.0BiTDI inline fuel filter

Drivetrain:
 - Darkside Developments Organic/Feramic clutch disk based on a Sachs TDI disc (with floating centre aka "Silent")
 - Darkside Developments Perfomance Pressure Plate (heat treated Sachs TDI pressure plate)
 - ACT Prolite flywheel (3.7kg/8.2lbs)
 - CTN 02A gearbox with Quaife o2J ATB LSD and shorter 5th gear (0.837)
 - 02J Shift Tower, mounted on top of tunnel
 - Hydraulic clutch conversion

Suspension:
 - Spax RSX Coilovers
 - H&R 22mm Front Swaybar
 - H&R 26mm Rear Swaybar
 - Prothane Poly Bushings

Interior:
 - Sparco Evo Seats
 - 4-point harnesses
 - Half Roll Cage
 - 350mm deep dished suede steering wheel

[Jaceb-GLI]

Oh my. Lanta.

[golfmk1tdr]

Wow finally 1.6 franken gone all in 
How thick is your block girdle? I think about making one since it's looks simple, I was planing to machine 8 mm plate.
Is balanced botom end big difference when idle? Someone said it idles like petrol engine when balanced, should I take him seriously?

Also, PD tdi intake-Did you take that for lack of space or do you think its as good/better than custom equal lenght runners?

[Alcaid]

Wow finally 1.6 franken gone all in 
How thick is your block girdle? I think about making one since it's looks simple, I was planing to machine 8 mm plate.
Is balanced botom end big difference when idle? Someone said it idles like petrol engine when balanced, should I take him seriously?

Also, PD tdi intake-Did you take that for lack of space or do you think its as good/better than custom equal lenght runners?

My block girdle is only 6mm thick, stiff enough I hope. Bought it back in the days on this forum: http://www.vwdiesel.net/forum/index.php/topic,27133.0.html

Still sounds like an IDI on idle but engine noise is silenced by two turbos so really quiet. I did the balancing mostly to keep everything together at high RPMs as it will be punished on the track. The sound of this car at high RPM with two turbos boosting is sweet!

Still need to see if cooling is sufficient or if I have to do some more modifications there. I have an external oil cooler, all aluminium radiator and I am running Caterpillar Extended Life Coolant (got this tip from a guy with an Audi 2.2 with 800hp+, no boiling issues what so ever and he drives like he stole it on tracks. With normal coolant he had lots of issues)

PD intake is because it fits, there is lots of stuff to fit behind the engine on this build! Engine mounts have been changed to tilt up the engine for more room behind the engine.

[theman53]

I didn't notice much difference at idle on my stuff and it is all balanced, pulleys and clutch/flywheel/pressure plate as well as all internals. I notice more above 4,000rpm where it never gets more harsh, unbalanced idi's seem to have more vibration the more RPM in my experience

[rallydiesel]

Great job! Please post some vids!

[Rising]

Wow!! Been away from the vw forums for a bit and look what I just came back in time for! What a beast alcaid! Can't wait to see more of this.

Sent from my Nexus 5 using Tapatalk

[Alcaid]

[libbydiesel]

I tried clicking on it, but it wouldn't play.

[Alcaid]

It's just a pic

[libbydiesel]

I know.  Tease.  Post a vid.   

[Alcaid]

Small inboard vid here: https://www.youtube.com/watch?v=tMJ-7_faEZg

[Alcaid]

[Rising]

The forum is broken. It only let me click like on his post once instead of 19 times like I wanted to.

What an amazing piece of machinery!

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