Author Topic: feeler; thoughts on a G60 supercharger on TD engine ? (Read 45649 times)

Mk2Fanatic · « **Reply #60 on:** July 03, 2007, 07:15:27 pm »

Well by this weekend I hope to have "modified" enough of the G60 mounting bracket to have them play nice. I have a mk2 pump bracket, mk1 pump brackets, AAZ pump brackets and all the G60 mounting hardware. I figure with a dead diesel block in my basement or the one in the garage I should be able to figure out how to physically fit them to the engine. Plumbing and belt routing other than the IP stuff will be interesting...hope to have it mocked up with pictures, by saturday...

blkboostedtruck · « **Reply #61 on:** July 04, 2007, 04:17:13 pm »

all right Mk2Fanatic,
good to see that someone has a real interest in this project! you will be a real pioneer with some breakthrough info on this! you will proabably push the view counter over 3 thousand by sunday!! I'm looking forward to see what you come up with! and thanks for taking this a step closer to realiaty for everyone that has an interest in this!!
thanks Duane

Mk2Fanatic · « **Reply #62 on:** July 04, 2007, 11:17:38 pm »

WellI have gotten an AAZ Injection pump bracket, modified g60 bracket, a 1.6 td pump and a g60 to actually fit together. I still have to trim out the area for the original g60 tensioner set up in order for the IP pulley to mount. As the motor currently sits everything is bolted on. I plan to make a bracket mounted on the block (Where MK1 style p-side motor mount goes) to use an A4 1.8t serp belt tensioner. The normal G60 AC position will be occupied by the serpentine belt driven alternator. No AC, No PS, just G60 and water pump. I've drawn out a diagram of how my belts will be mounted. I will Definately have pics posted within the next couple of days.

As for plumbing, it will go: Air filter to G60 to stock g60 Intercooler, mounted below battery. Out from IC to turbo out from turbo to my current MKV TDI intercooler (currently on car). From MKV IC to 1.8GTI(MK1) gas intake Manifold with a modified G60 inlet adapter. The two intercoolers are to reduce pumping hot air from one charger to the other.

I figure running a G60 with a 68mm pulley, a giles super pump, PP IDI cam, 3" DP and stage 3 1.9 td head with a k26/k27 hybrid (.63AR) Mercedes 300TD injectors, I should get to at least 170Whp with At least the same amount of torque as B6 Passat TDI (210-220ft-lbs)...Boost off the line and a nice torquey powerband with almost a flat torque curve from idle to 5000rpm...

So now any insights, ideas or flaming may now begin...

burn_your_money · « **Reply #63 on:** July 04, 2007, 11:41:10 pm »

I can't wait to see some pictures and videos :twisted:

Mk2Fanatic · « **Reply #64 on:** July 05, 2007, 04:41:25 am »

The reasoning behind the idea for an A4 1.8t serp belt tensioner, is for the G60/alternator setup. Because of the portion of the G60 Bracket that is removed, there is no longer anywhere to mount a tensioner to tension the charger belt; the A4 20V uses a nice little 2 bolt tensioner that is held stationary on one end, and uses the stationary end as a pivot to set tension for the AC system. By mounting it approx. 1 1/4" away from the block, it will sit inline with the stock pulleys, and allow tensioning of the charger and alternator.

lord_verminaard · « **Reply #65 on:** July 05, 2007, 12:15:16 pm »

Go to it man! You're getting there faster than me!

Hope it all works! Your setup sounds like it should do well. I wouldn't worry about some sort of bypass for the supercharger, even with the charger turning at full song and the turbo at full "suck", I doubt there would be enough restriction to cause any problems. I think the only reason why the (very few) OEM setups like this have a bypass is to help overall engine efficiency by reducing the drag caused by the charger when the turbo can take over. The way I see it, the turbo will pull enough of the drag off of the charger that it really won't matter anyway.

Pics!

Brendan

MikkiJayne · « **Reply #66 on:** July 06, 2007, 03:16:54 pm »

Pics pics pics pics pics!!!!!

It'll be fascinating to see how this works. I've always wondered about a bypass valve in this setup, so I'm extra keen to see how it works without one

On and btw - pics please

jtanguay · « **Reply #67 on:** July 07, 2007, 01:13:17 am »

i wonder if you could use some type of servo setup from a duct system to re-route the air. (of course the ducting would need to be drastically reduced, but the servo setup is all that you want... oh and it should be 12v too!) plus have a clutched supercharger to kick off when the turbo starts producing 5 psi or so with a hobbs pressure switch

or when the car is stationary (go pedal is released)

for N/A's with the supercharger, it would be nice to have the cvt system like on the snowmobiles... as revs increase, so would the boost! (most definitely too complicated to create... any engineers out there? :lol: )

Mk2Fanatic · « **Reply #68 on:** July 07, 2007, 03:20:22 pm »

As promised...

jtanguay · « **Reply #69 on:** July 08, 2007, 09:28:38 am »

pictures don't work

Mk2Fanatic · « **Reply #70 on:** July 08, 2007, 01:01:55 pm »

Fixed...and a couple of the car that will be getting a Twin Charged Diesel 1.9

blkboostedtruck · « **Reply #71 on:** July 08, 2007, 03:33:38 pm »

Ahh good job Mk2Fanatic!! looks like a Mki diesel I.P. and motor mount will work too!! I just thought of something :idea: how about using the G60 intake plennium that has that air deverting throttle body! somehow getting the thing to work in conjuction with the throttle cable on the I.P. ? to me that sounds like a good way to put air when and where you want it!!
ME i'm trying to come up of a way to change the compression ratio to handle the air on a continious basis and a pump that does the same !! has anyone thought about this? thats my reason for using the G60 S.C. is taking advantage air that it provides from the start!do ya think i should use pistons from something like a pumpduese that has chamber in the top of the piston?
I need some ideas for what to do with the head IDI-TDI can i convert one to the other ? let me know what you guys think!! Thanks Duane

jtanguay · « **Reply #72 on:** July 08, 2007, 11:19:43 pm »

i can't wait to hear more info on this project!!!!

burn_your_money · « **Reply #73 on:** July 08, 2007, 11:30:15 pm »

Maybe it's the camera angles but it looks like the timing belt is not going to fit on there?

jtanguay · « **Reply #74 on:** July 09, 2007, 12:48:36 pm »

Quote from: "burn_your_money"

Maybe it's the camera angles but it looks like the timing belt is not going to fit on there?

it looks like the timing belt will fit, but maybe not the timing cover.