VW 1.6 NA to Turbo swap! Questions and Progress.

[Tmarkle]

Easiest way to post photos by far is to install Tapatalk on your phone and do it from there... Becomes pretty straight forward that way.

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Thanks, I'll get that tonight and get some pictures posted

[Tmarkle]

What exhaust did you use? Old one made to fit td? Gear lever system doesnt hit toilet bowl?

I built a custom plate and downpipe. Pictures will be up soon.

[Tmarkle]

[IMG]https://uploads.tapatalk-cdn.com/20170419/7d5119dfa848d5a0509c3732f3af0ba4.jpg[/IMG]


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[Gizmoman]

Good to see you stuck with it to the end! Nothing like driving "your" work around!

[Tmarkle]

Good to see you stuck with it to the end! Nothing like driving "your" work around!

Heck yeah I love it. Way more get up and go. It's been a very fun project. It will probably never be done though, as I'll always be testing and tuning lol.


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[Tmarkle]

What's everyone doing for exhaust on a TD? I've got a 2" down pipe and I would like to do 3" out the back but can it fit over the rear axle? Right now it's just open down pipe and it sounds good but I do want a full system.


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[libbydiesel]

On the next project, I'd recommend getting mandrel bends instead of doing the diagonal cuts.

There is no reason to go any larger than 2.5" unless you're planning on running monster boost (30+psi) with fuel to match and that would be counter-productive with the k03.  I don't even think you'd notice a difference between 2.25 and 2.5 with the k03. 

[Tmarkle]

On the next project, I'd recommend getting mandrel bends instead of doing the diagonal cuts.

There is no reason to go any larger than 2.5" unless you're planning on running monster boost (30+psi) with fuel to match and that would be counter-productive with the k03.  I don't even think you'd notice a difference between 2.25 and 2.5 with the k03.

And that wouldn't have any clearance issues going over the rear axle? The egts are very controllable so I guess I probably don't have to go much bigger.


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[libbydiesel]

You can fit 3" over the rear axle.  It's obviously easier to fit 2.25".  It is a challenge to make any larger-than-stock exhaust so that it clears without noise/vibration.  I have gotten some 3/8" thick medium durometer silicone sheets.  Gluing a pad in places where the exhaust might contact the body can make life easier (and less noisy).   

I'll say again that your k03 is currently a significant limiting factor.  The turbine side is quite restrictive.  I don't think you will see any difference at all with anything larger than 2.25" with that turbo regardless of the amount of boost you run.

[Tmarkle]

You can fit 3" over the rear axle.  It's obviously easier to fit 2.25".  It is a challenge to make any larger-than-stock exhaust so that it clears without noise/vibration.  I have gotten some 3/8" thick medium durometer silicone sheets.  Gluing a pad in places where the exhaust might contact the body can make life easier (and less noisy).   

I'll say again that your k03 is currently a significant limiting factor.  The turbine side is quite restrictive.  I don't think you will see any difference at all with anything larger than 2.25" with that turbo regardless of the amount of boost you run.

The K03 is small for sure! I appreciate the very fast spool though. It was the easiest turbo for me to find near me. I just didn't want to put on exhaust that was "too restrictive." Thanks for the good tips! Straight pipe for a flow through muffler?


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[Tmarkle]

https://youtu.be/rtMdSxawcFc Here's a cool video I made of the project, go check it out!


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[Tmarkle]

So I installed a boost controller tonight. I can peak the boost @18 psi. I try not to go that high, I like to stay around 15 psi max. A slight problem has risen though. I am beginning to believe the head gasket is on the way out. The thing runs like a raped ape, tons of power, idles smooth, so on so forth but after it's warmed up and been ran for a while, it leaks water and steams underneath the water outlet on the drivers side of the head. The reservoir has enough pressure to spray coolant if you crack the cap open. The water temp gauge got to about 2/3 after some heavy acceleration. No coolant in the oil or vise versa. No white smoke or coolant smell out the exhaust. A head gasket replacement seems intimidating...


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[libbydiesel]

Are you sure that the water under the coolant flange isn't coming from the coolant flange gasket?  It's completely normal for the temp to hit 2/3 on the gauge sometimes.  It is also completely normal for the coolant to spew from the pressure tank if you open it when it is hot. 

[Tmarkle]

Are you sure that the water under the coolant flange isn't coming from the coolant flange gasket?  It's completely normal for the temp to hit 2/3 on the gauge sometimes.  It is also completely normal for the coolant to spew from the pressure tank if you open it when it is hot.

It could be from that gasket... I have a new one I'll toss in and see. The steam is the part that made me wonder, but I guess hot coolant would steam at operating temp.


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[RabbitJockey]

check the flange itself as well, they like to crack, even the aluminum ones, i had one that cracked on the bottom side.