Time to start assembling 1.5 TD / 1.9L Franken Diesel.

[Jetmugg]

I need to get a number in my head for EGT that I'm comfortable with.

I want power, but I don't want to burn the thing to the ground.

I hit as high as 1400F, maybe a little more, on an early pull.

It actually stayed cooler with full boost than with the boost somewhat regulated.  I need to re-plumb the regulator with a "bleed" line to give the excess pressure in the wastegate line somewhere to go.

Steve.

[theman53]

I bet the 2056 you are running doesn't have a 360 main bearing. I didn't realize how big a difference that makes. It lets the turbo spool earlier and for me it took away all the residual heat that I normally had prespool, since it spooled just a fuzz earlier. Also, if you were running the stock wastegate then there is tons more to be had.

Yeah plumbing that in should look like Turbo to LDA, to boost controller, to wastegate.

[RabbitJockey]

yeah more boost should make it run cooler.

are you allowed to run water/meth injection?  that could help alot

were all runs at 30psi?  did you play with fueling or timing at all?  i would not want to push egts on an idi, for fear of dropping a swirl chamber.

[RabbitJockey]

http://www.squirrelpf.com/turbocalc/index.php?version=4&target_peak_power=195&pr_ref=14.696&engine_disp=1.5&engine_disp_factor=0&target_af=18&bfsc=0.36&max_ic_loss=1.7&rpm_redline=5500&rpm_peak_power=4600&rpm_max_boost=3000&rpm_min_boost=2000&vol_1=89&vol_2=93&vol_3=90&vol_4=87&vol_1=89&vol_2=93&vol_3=90&vol_4=87&intake_temp_1=90&intake_temp_2=120&intake_temp_3=135&intake_temp_4=140&turbo_n=1&map_sel0=24

my guess as to where you're at, considering drive train loss.

[Jetmugg]

I was only able to run at about 16 psi, which is the as-delivered condition for this turbo, or at 30 psi, with the WG essentially choked off.

I didn't have good control of the boost level, as I had not incorporated a "bleed" for the excess boost in the air line feeding the regulator.

I'm trying to upload video to Youtube, which is moving in super-duper-slow motion.

When I'm done uploading, I should have both in-cab video, hopefully showing the gauges, and a separate out-of-vehicle video footage, showing the truck on the dyno and the appearance of the exhaust.

I have a couple of screenshots of the first dyno test, but it wasn't the "best" dyno test results.

[RabbitJockey]

How much power on 16psi?

How many questions am i allowed to ask

[Jetmugg]

I don't remember how much power at 16 psi.  Seems like it was in the 140's.

I'll have to wait to get the full dyno results sent to me.

[Jetmugg]

Ask as many questions as you like, and I'll try to keep up.

Basically, the students and instructor were running the dyno, and I was just operating the truck.

There was plenty of brainstorming and BS-ing going on.  It was a great night for gear-heads.

I'm still trying to upload to Youtube - it's stuck on 0%.  I might have to bail out and start over.

Steve.

[Jetmugg]

Screen shot from the first dyno pull, only running to 4500-ish rpm

[Jetmugg]

Tabulated numbers from the first pull

[burn_your_money]

Wow, nice work.

[Jetmugg]

Video link...

http://www.youtube.com/watch?v=1NYikOly9S0

[libbydiesel]

That's great.  Your little 1.5 IDI is putting out 175ish ft-lbs of torque @ 2500 rpms.  That's better than a stock 1.9 eTDI.  240 ft-lbs max is excellent. 

[libbydiesel]

Did you have an ice bath for the intercooler coolant?

[Jetmugg]

Yes, I have a 48 quart cooler in the bed of the truck.  I started with 20 pounds of ice and 2 gals of water.  After 3 dyno pulls, all the ice had melted.  At that point, I put in at least 10 more pounds of ice.

Steve