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Engine Specific Info and Questions => IDI Engine => Topic started by: Alcaid on February 19, 2014, 07:03:03 am

Title: 1.6TD manifold to T25 flange (adapter plate)
Post by: Alcaid on February 19, 2014, 07:03:03 am
Had a quick look at my workshop yesterday on how much work it is to make an adapter plate so that T25 flanged turbos fit the 1.6TD manifolds, not much actually! Two of the holes align and there is only very little porting needed for a smooth transition over to the T25 inlet used on the Holset HE211W and HE221W turbos. Here is a SKETCH of the adapter plate:

(http://i14.photobucket.com/albums/a345/Alcaid/Jetta/16TDmanifoldtoT25adapterplate_zps37ad6c58.jpg)

The two top holes (horizontally) align with the 1.6TD manifold: Drill out and use bolts or studs between turbo and manifold through adapter plate
The two middle holes: Tap to M8 and use studs or bolts between these holes and turbo
The two lowest holes: These are the two last holes in the 1.6TD manifold, Countersink these holes and use countersunk screw to attach the adapter plate to the manifold

Use stock 1.6TD gasket between adapter plate and manifold and use a T25 gasket between adapter plate and turbo.

Good luck :)

Title: Re: 1.6TD manifold to T25 flange (adapter plate)
Post by: RabbitJockey on February 19, 2014, 07:38:01 am
thats awesome, could even just thread and use bolts through the manifold on the 2 closer vw holes.
Title: Re: 1.6TD manifold to T25 flange (adapter plate)
Post by: Gizmoman on February 19, 2014, 05:23:33 pm
Very helpful!
Title: Re: 1.6TD manifold to T25 flange (adapter plate)
Post by: Gizmoman on February 19, 2014, 06:16:17 pm
Maybe I received the two DXF files out of scale (one of the exhaust manifold flange and one of the turbo flange) but I don't see any relationships between the two.

(https://lh5.googleusercontent.com/-eU6fk4LjhmY/UwVmsWgZfeI/AAAAAAAADDA/hylwUkbpNwk/w839-h688-no/flanges.JPG)

I'm missing something somehow
Title: Re: 1.6TD manifold to T25 flange (adapter plate)
Post by: fatmobile on February 19, 2014, 08:14:40 pm
The 1.6  TD exhaust manifold has a trapizoid shape that doesn't match either of your drawings.
Title: Re: 1.6TD manifold to T25 flange (adapter plate)
Post by: Gizmoman on February 19, 2014, 08:22:56 pm
Quote from: fatmobile on February 19, 2014, 08:14:40 pm
The 1.6  TD exhaust manifold has a trapizoid shape that doesn't match either of your drawings.
That would explain things.

I'm just gonna wait for the turbo and go from there.
Title: Re: 1.6TD manifold to T25 flange (adapter plate)
Post by: Alcaid on February 19, 2014, 10:25:24 pm
You are trying to match up the input and output flange of the HE211W turbine

Here is the 1.6TD downpipe flange pattern:

(http://www.turbomaster.info/img/juntas/210244.gif)
Title: Re: 1.6TD manifold to T25 flange (adapter plate)
Post by: Alcaid on February 19, 2014, 10:52:37 pm
And here is the T25 flange used on the HE211W and HE221W

(http://i14.photobucket.com/albums/a345/Alcaid/Jetta/T25flangeHE211WHE221W_zpsb707a6ac.jpg)
Title: Re: 1.6TD manifold to T25 flange (adapter plate)
Post by: Gizmoman on February 20, 2014, 05:40:14 am
Quote from: Alcaid on February 19, 2014, 10:25:24 pm
You are trying to match up the input and output flange of the HE211W turbine

Here is the 1.6TD downpipe flange pattern:

(http://www.turbomaster.info/img/juntas/210244.gif)
It just "dawned" on me this morning as I was waking up ;D. Someone sat on my thinking cap, luckily, it wasn't on my head at the time.

Thanks Alcaid
Title: Re: 1.6TD manifold to T25 flange (adapter plate)
Post by: monomer on February 21, 2014, 05:43:44 pm
http://www.ebay.com/itm/VW-8V-T25-Cast-Iron-Turbo-Exhaust-Manifold-Golf-Jetta-/380395953632?pt=Motors_Car_Truck_Parts_Accessories&hash=item58915d9de0&vxp=mtr


Title: Re: 1.6TD manifold to T25 flange (adapter plate)
Post by: Gizmoman on February 21, 2014, 06:19:24 pm
Quote from: monomer on February 21, 2014, 05:43:44 pm
http://www.ebay.com/itm/VW-8V-T25-Cast-Iron-Turbo-Exhaust-Manifold-Golf-Jetta-/380395953632?pt=Motors_Car_Truck_Parts_Accessories&hash=item58915d9de0&vxp=mtr


Thanks, easier than an adapter but I'm going to wait for the turbo before I do anything else.
Title: Re: 1.6TD manifold to T25 flange (adapter plate)
Post by: Alcaid on February 21, 2014, 10:28:27 pm
Unfortunately don't think that manifold works in your Vanagon, you need to place the turbo more to the side
Title: Re: 1.6TD manifold to T25 flange (adapter plate)
Post by: Gizmoman on February 22, 2014, 04:52:18 am
Quote from: Alcaid on February 21, 2014, 10:28:27 pm
Unfortunately don't think that manifold works in your Vanagon, you need to place the turbo more to the side

I'm going to wait till I have the turbo in my hands before I make, buy or do anything else on this. Once I have it mounted properly I'll work out a new intake manifold, the WAIC location and a new intake filter and piping.