VWDiesel.net The IDI, TDI, and mTDI source.
Engine Specific Info and Questions => IDI Engine => Topic started by: Alcaid on August 20, 2015, 09:30:43 am
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Check out this video revving the engine in neutral
Green needle = boost
Red needle = EMP
https://www.youtube.com/watch?v=YgUR2jIDEv4
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That's awesome. Very impressive.
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that is quick too, very impressive.
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sweet where did you get that boost gauge?
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Gauge from http://www.hewittindustries.com
Quality gauges!
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This truck seems to be the exception to the rules. When we have time we have no money and when we have a bit of coin we are totally out of time to spend it. Very nicely done sir.
My bad, I got distracted and didn't notice that the video had run its course and went to the next one in line. This one.
Toyota Truck VW Turbo Diesel Swap 1.6 Engine Cold Start Ver 2.0
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Truck? This is in a Jetta mk1 ;)
(http://i14.photobucket.com/albums/a345/Alcaid/Jetta/AD5C7305-6114-4A64-BD1C-E74637DCB755_zpsoztr1ovg.jpg)
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Very Nice. How much power does she make?
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Don't know yet ;) trackdays, tweaking and testing next weekend and dyno after that. Should be seeing at least 260-270whp
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Ah yes the daily driver, just what one needs for those straight stretches in the country.
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Not my daily driver, that's what I have a Golf mk4 PD130 4Motion for (GTB2056VL running 30psi of boost) ;)
The Jetta is built for trackday fun
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I'm very glad to see this news! Hoping to follow in your footsteps. I'm thinking about 250 HP for my 1.5.
Steve.
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Don't know yet ;) trackdays, tweaking and testing next weekend and dyno after that. Should be seeing at least 260-270whp
thats absolutely insane... do you have a build thread for that engine?
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Only in Norwegian in an access-to-members-only forum. Will write up an English build thread soon.
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What turbos are u running? PLEASE post some pics!
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maad stuff :D 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 ;D)
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 :P )
Your jetta coupe looking great, I dont know how rare they are for you but AFAIK they are nonexistant in my country.
Cheers, Matevž
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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
(http://i14.photobucket.com/albums/a345/Alcaid/Jetta/63599821-3F92-49FE-AD3D-2858CC2C38BF_zps2d6quuhm.jpg)
(http://i14.photobucket.com/albums/a345/Alcaid/Jetta/FullSizeRender%202_zpspcfhaxrx.jpg)
(http://i14.photobucket.com/albums/a345/Alcaid/Jetta/FullSizeRender%204_zpscsqii90x.jpg)
(http://i14.photobucket.com/albums/a345/Alcaid/Jetta/9A4337EC-C338-4805-9BA8-34B7773F3DE2_zpseiae7lrh.jpg)
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Oh my. Lanta.
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Wow finally 1.6 franken gone all in :D
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?
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Wow finally 1.6 franken gone all in :D
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.
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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
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Great job! Please post some vids!
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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
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(http://i14.photobucket.com/albums/a345/Alcaid/Jetta/C83DDF06-1340-43D4-A3F9-9918996BE01C_zpswjxatosk.jpg)
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I tried clicking on it, but it wouldn't play.
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It's just a pic ;)
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I know. Tease. Post a vid. :)
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Small inboard vid here: https://www.youtube.com/watch?v=tMJ-7_faEZg
(http://i14.photobucket.com/albums/a345/Alcaid/Jetta/B382130A-D0C5-4ACF-B672-700AB930D269_zpsqixrf0ub.jpg)
(http://i14.photobucket.com/albums/a345/Alcaid/Jetta/86A36050-2481-46FE-A611-A2AC8BF25DB5_zpshgy5t5wd.jpg)
(http://i14.photobucket.com/albums/a345/Alcaid/Jetta/Jetta%20Rudskogen%202_zps18cq90e5.jpg)
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(http://i217.photobucket.com/albums/cc228/beernutsonline/VACN/Ruskogen%202015/2015_21992_zpsl7z1fkfb.jpg)
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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!
Sent from my Nexus 5 using Tapatalk
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Anyone seen the movie "The Pinchcliffe Grand Prix"? ;)
(http://i14.photobucket.com/albums/a345/Alcaid/Jetta/Jetta%20vs.%20Flaringklypa_zpsklnl4tec.jpg)
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Short video from me. Not from the track, but som testing in the middle of the event
https://youtu.be/T6zJEtXzS88 (https://youtu.be/T6zJEtXzS88)
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This is awesome :) Scaring the sheit out of drivers behind you because they cannot see through smoke
and when it clears- you are gone 8)
I find it interesting that you even have smoke at such boost levels ;D
Your injectors are stock GTD I quess?
What is your max EGT you saw on this setup?
I always wondered what is the limit with IDI diesel with your headwork, valves and everything..
I believe you achieved it :P
What is you tire brand and tire size? I plan on federal rsr 195/50 but your look like more ''meat'' and different profile...
Almost drag racing-fat haha loving it!
Keep up great work!
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185/60-13 Yokohama A048 track/competition tires ;) Wanted to keep the 80s look on the car. Pump delievers a ***load of fuel, will up the boost soon
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Fratelli Bosio GTD nozzles on AAZ two stage injectors. Didn't have time to hook up the EGT gauge so will have to check that in the dyno. But it's easy to cool down the EGT with addee boost if needed since I am running compounds. ;)
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Holy crap, that's awesome.
Fantastic job, Petter.
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it is truly impressive, if it can dyno the 300whp that is like a 5.9L cummins turbo diesel making well over 1000hp
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Wow I never knew they let freight trains run on the track, because that thing HAULS!! What an amazing setup. I've never seen an IDI this massively built before. I've seen some great high-flow single turbos (shout-out to theman53!), but no one runs compound around here outside of trucks.
On another note, Rudskogen looks like a very fun track! I've heard it from mentions of the motorsport event Gatebil. How is driving on it?
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That's nuts Alcaid - I didn't know a turbo could even boost at idle.
Still loving my Holset
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On another note, Rudskogen looks like a very fun track! I've heard it from mentions of the motorsport event Gatebil. How is driving on it?
Rudskogen is a demanding track for both car and driver. You need lots of HP to drive fast, lots of guts to brake late even approaching blind turns and a challenging track, but it is very fun! :) I am more comfortable in my Golf 4Motion PD130 (now 191awhp) on tracks so need to drive more with this Jetta to get comfortable with FWD, lower weight, no power steering, poor brake assist etc. etc.
That's nuts Alcaid - I didn't know a turbo could even boost at idle.
Still loving my Holset
What's better than a Holset, right? ;) (The answer is TWO Holsets!)
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Long time no update on this project as I got really sick and tired of it....
I initially had some head studs made from the Finnish guy that calls himself AKI-76. They stretched and all came loose on initial test driving... Tried to re-torque and they started stretching real bad and one broke.... Tried saving the head gasket by changing out one and one stud with ARP but gasked was blown. Later I changed the head gasket but was still blowing coolant out of the expansion tank (running 60psi of boost on the last tests with great power and low back pressure!). Took a long break from the project as I was really sick and tired of it....
Finally got the interest to continue the project and took the head of again to pressure test it and resurface if necessary. Head was warped on cylinder #2 and #3 so really in need of a resurfacing. Will get the engine back together again soon and do further testing on 60psi of boost.
Pic showing the head after the first pass, easy to see why I had coolant blowing out of the expansion tank!
(http://i14.photobucket.com/albums/a345/Alcaid/Jetta/84C83EF0-5C5A-4807-8EA6-A5FFF4B5FADD_zpsnoypxkhg.jpg)
finally head is flat again!
(http://i14.photobucket.com/albums/a345/Alcaid/Jetta/8F7B81EB-37CF-4CB9-9B5F-0FD80C9F2522_zpsuvq3spwi.jpg)
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Do you line bore the cam when you surface the block?
Center journals are going to be high and make the cam teeter totter.
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Do you line bore the cam when you surface the block?
Center journals are going to be high and make the cam teeter totter.
Not done anything to them, not had to do that before either when surfacing a head...
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any opinion about resurfacing with the prechambers still in place?
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I thought it weird. But apparently it didn't do they any harm. Just a few thousands less for wear. I wouldn't expect a problem unless they were loosened in the process and not tapped tight to prevent being blown out now.
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I would be more scheptical about taking them out of their press fit tolerance bore, having to machine the top of them or the profile they sit in to get them to the perfect install height and then press fit them again into the same press fit tolerance bore, now already used once before.
(https://scontent-arn2-1.xx.fbcdn.net/v/t1.0-9/304456_10152109489225371_1572978745_n.jpg?oh=fc84e0569972424d2f5b4f104fdd2523&oe=5811B9CD)
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Wouldn't EGT skyrocket with so much boost and fuel? Is this setup only for a drag strip?
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Wouldn't EGT skyrocket with so much boost and fuel? Is this setup only for a drag strip?
Boost actually cools down EGT if it is produced efficiently. with 60 psi total boost both turbos are operating very efficiently at only 18-19psi each. A proper build head also helps, better flow = cooler operation. It is my trackday car, not for the dragstrip.
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I can personally attest to what happens with too much fuel for a given amount boost. It's not pretty. I was running about 40 psi of boost from a single turbo, but still too much fuel when this happened.....
(http://i468.photobucket.com/albums/rr44/Jetmugg/Dodge%20Rampage/F9ABC0B8-BCAF-406F-9599-4F7B191EE245_zpsdbcm7umv.jpg)
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I still enjoy this build after all this time. Are you going to use ARP studs? I'm surprised to hear about the stud failure. That guy had some big builds himself.
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I still enjoy this build after all this time. Are you going to use ARP studs? I'm surprised to hear about the stud failure. That guy had some big builds himself.
Using ARP now, they hold 60psi boost and a ***load of fuel no problem. My head however has washouts around all 4 injectors so no way to get injectors to seal anymore. My fault, in a hurry to get it up and running an my cam can be timed correct and 180deg off - and guess what I did..... :p Will build a new head and try again but project has been put on shelf for a little while as I just bough a new house so money will be spent on other stuff for a while.
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What do you mean by "wash outs"?
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What do you mean by "wash outs"?
You know the shoulder that you bottom out the injector and heat shield against? It's not there anymore - the aluminum has melted away by exhaust that has made it's way out the injector holes. Even washed out the head sheads and one injector shows signs of erosion as well...
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that is unfortunate, congrats on the new house
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Sorry to hear that about your cylinder head, Alcaid. This has not been a particularly good year in the VW world in terms of pushing HP limits and damaging engines.
Steve.
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especially you steve, id say turn the fueling down a 'notch' or 2, and the turbo down 2 'notches' as well. you busted the class on top of yours, right? the 1.9 class, you ran faster than that, last year.(in a 1.5 class). so youll bust the same records a notch or 2 slower, and hopefully do some saving at the engine.
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Yeah - I broke 2 engines this year - nobody to blame but myself. I am making a promise to myself to go a little easier on the "tune ups" for 2017. I'm tired of breaking stuff, buying new parts, and paying machine shop bills.
You are right, at Bonneville, the 1.5L record we hold is faster than both the 2 liter and the 3 liter record.
At Ohio, the 1.5L record we hold is faster than the 2 liter, 3 liter, and 4.25 ( G, F, and E).
I think there's a lot of room for improvement in all those classes, particularly as the DT classes become more popular with wider availability of small diesel engines.
Alcaid has had his problems this year, and Darrell Vitone has blown up a couple (I believe 2) air cooled engines running land speed events in California.
This is a good time of year to start setting specific goals for 2017 and start working towards them.
Steve.
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Meanwhile the engine I have has been running great and cool. I think besides buying my head the next time you could run a little more gear to get the rpms up steve. I wish you were buying my head, I know it would help you.
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I wish you were buying my head, I know it would help you.
(obvious sales pitch(hehehjoke).
well if your talking about vw air-cooled engines, they have a serious problem when you add racing before name of motor or after. you see the problem right there, its right in front of you, pretty obvious, yep you got it,,its -the cooling. you have a stock air-cooled motor, stock shroud, stock fan setup (w/generator or alt), no cooling problems, then again its rated for about 4500rpm, springs i think, cam stock isnt any better. mild performance, not many immediate cooling problems, put this guy on a track, (hi-performance) and about 4grand (4.5k i think) the fan belt just slips. so cooling efficiency gets very low. and these guys are easily getting up to 7k rpms and more, i mean there were a slew of CA shops with performance cams, and extensive setups. all you needed to start up above 4.5k rpms to 7k rpms, was basically a set of high-rev springs. so some 'racers' used a power pulley, well it wasnt very good for the street, and for the track maybe marginal, and well youd get air, but at a reduced speed, amount. so the majority of speedsters deleted main fan shroud, and fan, pulley, take a pair of electric fan blowers, one to each bank of cyls, well youd get some air for cooling, and iirc none to oil cooler, then again for a 1/4 mile volume of oil getting hot, or overly hot isnt the problem. cause your running an extra 'oil pan'(too). this is most bug, typeI racing, drag, 1/4 mile, so they went in many spots to 1/8 track racing. i dont know what they did for specs for the kaffer cup racing they did, but the drags, would get hot spots, for a stock case, and you now over-bore for (foolish) over-big jugs, you may not get a couple of runs, you could shoot out of the starting blocks(first time), and blow the base of a cylinder. it just adds up. and your guy there is trying to do what a 3mile run, a good few runs in a weekend. i havent seen type4 motors punched out, or hopped up, then again the T4 motor i had had i looked like a direct drive fan, fan may have been part of cam, well that may just limit you right there, you cannt direct-drive-drag crank(&cam). so you can only get so much cooling off this set-up. porsche had a good fan set-up, it was single v-belt, with a generator. motors could rev up to oh about 7grand, i never had a cooling problem. then again (and these were early 70s models) if you were a kid, you might want to stick you hand down fan and see,,,well, old set-up.