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Engine Specific Info and Questions => TDI Engine -General Info => Topic started by: Sierra94 on November 29, 2012, 12:34:28 pm
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Thought Iīd share some pics of my newly made intake.
Iīm finally going to fit an intercooler to my M-tdi so I thought I might just go ahead and make myself a new intake while I was at it.
I hardly have any experience in welding aluminum with my old Tig welder but how am I gonna learn if I never try? ::)
Itīs gonna be glass beadblasted and painted before mounting it on the engine. The slit inside is slightly tapered towards the end.
Well, here are the pics:
(http://imageshack.us/a/img62/8145/20121129001.jpg)
(http://imageshack.us/a/img836/116/20121129005.jpg)
(http://imageshack.us/a/img651/5320/20121129003.jpg)
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does that even fit the engine?
i tried doing that, and it hit the timing belt cover, and the charge piping would have hit the strut tower..
heres my engine, with both manifolds mounted..
(http://i702.photobucket.com/albums/ww28/Dubsmoke/DB86851B-89B7-4907-A17C-3FC11660B094-13333-00000A4986BA9D1A.jpg)
and a few shots of just the intake..
(http://i702.photobucket.com/albums/ww28/Dubsmoke/P1000562.jpg)
(http://i702.photobucket.com/albums/ww28/Dubsmoke/P1000565.jpg)
(http://i702.photobucket.com/albums/ww28/Dubsmoke/P1000564.jpg)
good job tho.. you might have either turned your heat down tho, or welded faster.. yes, i know, cast aluminum is HARD to weld nicely..
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My engine is longitudinally mounted, and the pipe is gonna be cut to the right lenght and joined with a slight angled pipe once I start mounting the intake in the car.
Yeah, I was a bit high on current but the cast intake wouldnīt melt otherwise. And the pipe being in such thin material. But Iīm pretty satisfied with it being one of the first times ever to weld aluminum ;D
Thanks for your comment, always nice to share something if you get feedback one way or another. If you click the pic of the mazda in my sig you can se some pics of the setup.
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What kind of exhaust mani is that kevin? is that a vnt turbo?
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manifold looks very nice, I couldn't weld ally that well anyway, and i'm sure it does the job.
Will be interested to hear if it makes any difference compared to standard
Looks like a GT2052V turbo like i have ^
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What kind of exhaust mani is that kevin? is that a vnt turbo?
its a Street Toys 2000 tubular "space saver" header.. its been modified to fit my setup tho.
and yes, its a VNT, a GT2056V, basically the same turbo used on the V6 TDI engines.. GT
2052 is basically identical from the outside tho..
the upgraded intake DEFINITELY makes a difference over stock..
my EGTs/boost went down while cruising down the road..
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I will surely notice a huge difference since I'm also adding intercooler to my setup. I've only used water/meth injection soo far. Now I will run this new intake along with ic and water injection.
If you look at this pic you will see the restrictive intake I run now:
http://www.garaget.org/?car=81419&image=2779262 (http://www.garaget.org/?car=81419&image=2779262)
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Ah I imagine so then! Need to look into water/meth myself.
By the way i love your mazda; very cool 8)
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nice truck, u don't see those trucks hardly at all in pennsylvania anyway, but we are a very rusty area. not as bad as ohio, michigan and canada tho!
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Some new pics of the IC install. (Sorry for the bad picture quality)
The IC is from a Saab 900.
Just missing a pipe and some clamps. And I have to make spacers for the radiator mounts.
(http://imageshack.us/a/img829/6661/20121206003.jpg)
(http://imageshack.us/a/img22/6276/20121206002.jpg)
(http://imageshack.us/a/img546/8972/20121206001.jpg)
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they make those intercoolers in an all-metal version too..
blackstone builds it for them.. identical to your plastic tanked model, but all aluminum..
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Apparently from my readings, the Saab plastic tanks will hold up to ~20psi. In reality? There is no need to go above this number off boost pressure, unless your running some awesome setup to cool that air it is unnecessary heat and hurts performance.
Put a strap around it if you want 18-20 reliably.
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Apparently from my readings, the Saab plastic tanks will hold up to ~20psi. In reality? There is no need to go above this number off boost pressure, unless your running some awesome setup to cool that air it is unnecessary heat and hurts performance.
Put a strap around it if you want 18-20 reliably.
my intercooler (the plastic tanked one) cracked a tank.. i didnt run much past 25psi thru it.
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Iīll have to look out for an all-metal one ;D. My max boost pressure peaks at 28 with vanes fully open. (I donīt have a vane control system setup yet) I guess Iīll be seing higher pressures with faster variations once I get a control system setup.
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Iīll have to look out for an all-metal one ;D. My max boost pressure peaks at 28 with vanes fully open. (I donīt have a vane control system setup yet) I guess Iīll be seing higher pressures with faster variations once I get a control system setup.
28psi with your vanes OPEN?!
holy crap..
you should see no higher pressures with vane control..
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Yes, my IP flows fuel like crazy. I even get black smoke at thoose pressures. I could use a wastegate ::) Or get a 10-11 mm head for the IP. It fuels pretty much even with the fuelscrew way out. With my old K24 and T3 it peaked at 35 psi without wg. I broke 3 turbos in one summer. The axle snapped just behind the turbine wheel on all 3, sending the turbine wheel all the way out the exhaust, ground down to a small ball in size ;D
After that I started using my wastegate. But then I made the switch over to the dark side (vnt GT18) but still run without vane controller. The boost comes on at 2200 rpm anyway.
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nice ,what gearbox/adapter plate you got there any pics , would love a RWD MTDI sport gld drift master set up .
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I made it myself. I did a template out of MDF board and aftera testfit in the car I had a small weldingcompany cut it out of a 12 mm steelpate.
(http://www1.garaget.org/archive/64/63772/81419/81419-764698.jpg)
(http://www1.garaget.org/archive/64/63772/81419/81419-764701.jpg)
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So you have a 9mm pump, that blows black smoke at 30psi with the vanes open ???
I feel that something is not adding up here and that you may be having issues. What all has been done to the pump??
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No no no. 12mm, built properly as M-tdi pump. Check the M-tdi pump faq. I made a couple of posts back when I built it. So nothing wrong with it.
How is it possible you misundersttod that I had a 9mm head on when I wrote that I would want less fuel out of my ip by installing a 10-11mm head?? ::)
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that plate looks good , a audi 80 tdi a4 starter? what gearbox and flywheel you using
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Itīs an audi 80 td starter and a gasser audi 80 flywheel and pressure plate. KEP 4 puck sinter clutch plate and a volvo 740 M47, 5 speed gearbox. And a volvo 240, dana 30 rearaxle. 3.54 gear.
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And some ready pics of it ready, sorry again for the bad quality.
(http://img809.imageshack.us/img809/7196/20121211003.jpg)
(http://img6.imageshack.us/img6/1476/20121211005.jpg)
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How is it possible you misundersttod that I had a 9mm head on when I wrote that I would want less fuel out of my ip by installing a 10-11mm head?? ::)
That was the root of my confusion, plus the fact I didn't even realize I was in a M-TDI thread.
What are your EGT's whilst at 30 psi and blowing black?
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It's around 800 degres celcius. But that was before my IC install and with water/meth injection. And I have 3 inch exhaust from turbo and back.
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So with egts in check it would seem your turbo is too small for this application.
Yet its not causing stupid egts as a restriction.
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Yes, I need a 2056 or a 2256. I can borrow a turbo from a friend. Itīs from a bmw x5 diesel.
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Yes, I need a 2056 or a 2256. I can borrow a turbo from a friend. Itīs from a bmw x5 diesel.
should be equipped with a 2056V
thats the turbo you need on that truck...
i LOVE my 2056 i have on my 1.6D, and i still have a 9mm plunger.
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GT2052V off the Audi A4 V6 TDi is fairly available over here, not sure about for you guys in the US, but I got mine for i guess ~$100
sounds like the 22 might well be the better bet though!
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2052v isnt as capable as the 2056v or 2256v
the 56mm exducer vnts are better..
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what power could you get with a good set up GT2052V 210hp ? i picked up one from a goosed a4 v6 tdi $8 yes been in the right place at the right time ;)
Sierra94 what power you puting out with your vnt and when does it start to spool up
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I estimate around 160-170 engine hp. My wife has a -00 Passat with a chiped AFN that puts out 140hp and the mazda feels alot stronger. The Passat weighs a little more and has higher gear ratios but I think my estimate ain't that far of.
It starts to spool at 2200 rpm without vnt controller. I have it in the garage during the winter so I will try to get a controller setup as soon as I get some time over.
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what power could you get with a good set up GT2052V 210hp ? i picked up one from a goosed a4 v6 tdi $8 yes been in the right place at the right time ;)
Sierra94 what power you puting out with your vnt and when does it start to spool up
wow, madness. yeah i'm aiming for around 200rwhp, should be within the limits of the turbo (and possibly another)
Sierra, i bet this would be even better to drive with a controller on (what do you have in mind by the way?) as you should see spool a lot earlier, i imagine full boost at about 2100
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@Henk:
Iīm gonna go with a cable/boostcan controller to start with.
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http://www.vwdiesel.net/forum/index.php?topic=19521.0
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Thanks for the link. But I can get one at the local scrap yard for $30 ;)
Merry x-mas!
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Thanks for the link. But I can get one at the local scrap yard for $30 ;)
Merry x-mas!
well, thats good.. ive never paid more than $40 for a used intercooler..
least you know what you are looking for now tho.
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Yes, Iīll buy a spare Alu one just in case the plastic one cracks. I havenīt tried the truck since installing the ic. To much snow here right now.
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Yes, Iīll buy a spare Alu one just in case the plastic one cracks. I havenīt tried the truck since installing the ic. To much snow here right now.
lol, perfect time to go try it out.. not like you will be able to load the engine much..
without engine load, you dont make much boost, least on my car you dont..