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Engine Specific Info and Questions => IDI Engine => Topic started by: lord_verminaard on August 01, 2009, 07:41:28 pm

Title: TD Exhaust manifold flip on A2: Not possible
Post by: lord_verminaard on August 01, 2009, 07:41:28 pm

Ran into a major snag in my project today.  Did all of this work on the stock TD manifold that I have grinding it down to fit on the head with the 8v Gasser intake.  Finally got it all to fit, and just then I realized- the turbine outlet of the turbo is pointing directly at the passenger side engine mount bracket.   :'(  It would work fine on an A1, since there is only 1 rear trans mount in the middle.

So what are my options?

- Find and buy a factory TD intake manifold and just run it that way?

- Make 4 spacers to fit between the manifold and head, and run the exhaust manifold the "right" way only spaced out to work with the gasser intake?

- Buy a generic 8v turbo manifold, and make an adapter to fit the factory T3 turbo?

What else, anyone?  This sucks.  :(

Brendan

Title: Re: TD Exhaust manifold flip on A2: Not possible
Post by: theman53 on August 01, 2009, 08:07:38 pm

I think I feel your pain...its like dejavu all over again. I never got as far as the mount since I had made all of my oil lines and decided not to change anything else.
I am really considering going to a waterjet place and having them make me a few 3/8" thick intake flanges out of steel. Then make some runners out of similar sized tubing then into a log on the top. I can weld steel, and bending tubing or getting 90 degree bends in small stuff is easy. If I were you I might try this route or something similar, if nothing else I am giving you another option to think about.


Of the options that you have I like the 4 spacer idea best especially if you don't have your downpipe made. Also the turbo to manifold could have an angled spacer made so your port spacers wouldn't have to be so long.

Title: Re: TD Exhaust manifold flip on A2: Not possible
Post by: ryanp on August 02, 2009, 01:23:15 am

A guy on TDi CLub made a new mount bracket, just found the link!

http://forums.tdiclub.com/showthread.php?t=231158

Hope that helps!

Ry

Title: Re: TD Exhaust manifold flip on A2: Not possible
Post by: fatmobile on August 02, 2009, 07:32:21 pm

Option 4,...
 buy a Rabbit, ha.
 I know,... I'm no help this time.

Title: Re: TD Exhaust manifold flip on A2: Not possible
Post by: lord_verminaard on August 03, 2009, 03:36:22 pm

Well, the 4 spacers idea is out.  They would have to be about 9" long just to clear the intake.   :o

It looks like I will have to make a "flip flange" to turn the turbo back around while keeping the TD manifold flipped.  I really don't see any other way to do it that doesn't involve using a different intake manifold or a different turbo/manifold all together.

Basically it would be a square plate to go between the turbo manifold and turbo.

I don't suppose anyone has done this before?  :P

Brendan

Title: Re: TD Exhaust manifold flip on A2: Not possible
Post by: foxracer1 on August 03, 2009, 05:59:01 pm

I wanted to do the same thing but found out what you did. I plan to buy an aftermarket manifold with an external gate. Don"t know what to tell you you've listed your only options.

Title: Re: TD Exhaust manifold flip on A2: Not possible
Post by: BellCityDubber on August 04, 2009, 07:56:37 am

have you tried clocking the compressor housing yet?

Title: Re: TD Exhaust manifold flip on A2: Not possible
Post by: lord_verminaard on August 04, 2009, 10:56:12 am

Wouldn't matter which way you clocked it, the outlet is literally pointing directly at the rear mount.  A 90-degree intake hose to the inlet side of the compressor would be possible, I think...  so I'm going to explore the possibility of rotating the turbo 180-degrees back around and see what happens.

Thanks,
Brendan

Title: Re: TD Exhaust manifold flip on A2: Not possible
Post by: lord_verminaard on August 06, 2009, 08:23:33 am

GAH!

Rotating it around 180 won't work either- I'm using a junk turbine side for mock-up (no compressor side) and I realized that with the compressor on there, it would hit the rear mount- no way to make it work.

So now I'm down to just getting a stock TD manifold and turbo and making it factory, even though I have this nice gasser manifold and the $80 BBM throttle body adapter...

Or get an aftermarket T3 manifold and "standard" T3 turbo.  The wife wants to use this method.  But what turbo to use?  Would a T3 40-trim with a .42 exhaust A/R work or would it be too big???

This is making my hair turn grey....


Brendan

Title: Re: TD Exhaust manifold flip on A2: Not possible
Post by: Rabbit on Roids on August 06, 2009, 08:40:54 am

i had a T3 from a chrysler on my manifold, the exhaust outlet was about straight over from the motor mount. i just took and went up and around it, then back down. but idk if it would work as well with a VW turbo.

Title: Re: TD Exhaust manifold flip on A2: Not possible
Post by: lord_verminaard on August 06, 2009, 12:23:36 pm

Ok, decided on this:  Going with a T3 45 trim, same as Mercedes 300D.  Getting one locally.  E-bay T3 8v manifold.

Hopefully this will all work out better.  This car needs to get on the road like NOW!

Brendan

Title: Re: TD Exhaust manifold flip on A2: Not possible
Post by: BellCityDubber on August 10, 2009, 09:24:37 am

Now that I've re-read everything... I know kinda get what you mean...

the hot-side outlet is being obstructed....

http://forums.vwvortex.com/zerothread?id=544667

maybe that'll help???
maybe some of those guys who've had success could help?