The inlet manifold after sand-blasting:
And this is how it looks after all the layers of paint and clearcoat:
I'll still have to grind off the thread pieces and their support, that you can see on the third picture, since they won't clear my new exhaust manifold.
...which looks like this:
Stainless steel, and again, made by Aki. But it's not yet finished - some smoothing and flange work still to be done, apart from the small job of adding a feed pipe for the external waste gate, which is also Aki's custom work. And of course, the mandatory ceramic coating
Sorry, no pictures of the W/G yet, but it's pretty trick, I can tell you. And I do like that fact that the W/G is going to be external; it'll be so much more accurate and reliable, not to mention easier to work on and adjust as needed. Way easier to hook up twin downpipes too!
On to the reason why a new exhaust manifold was needed.
The S1GB Schwitzer is a good turbo, but experience from other engines showed that it is still undersized for my kind of power goal. Now that I'm adding H-profile con-rods to the mix, I can reach for as much hp as I can get with driveability still preserved. I think 220 hp should do fine. Anyway, we came to the conclusion that a bigger turbo is a must.
Aki's ample supply of Schwitzer turbo parts resulted in a choice of S2B Schwitzer family as a staring point.
The turbo you see here is basically just a template, this one I'm using to measure everything up and fabricate the exhaust, oil lines, boost pipes, heat shields etc. The S2B that's going to be on my engine will be bigger than this, at least the wheels will be on both sides. About 45 mm inlet and 55 mm outlet sizes, I suspect. Of course, it may require some trial and testing to find the perfect combination on this particular engine. And I will be after a broad, nice power band rather than peak hp, so don't expect any records broken here!
And here's the first part of the downpipe, stainless steel once again:
The D/P and the exhaust manifold were both originally going to be on Aki's own twin-charged 1Y, but I managed to persuade him to part from them, since they really are a perfect fit for for my engine/inlet combo. My job was once again made so much easier with the outlet pipe Aki had made, because it fits exactly with this turbo and the SB rear engine support. The turbo will sit "the wrong way round" since this manifold / downpipe combo had originally been designed for a compound-turbo solution. That also means, that it'll be really easy to convert my system to compound turbo in the future, if that's what we want!
This is all for now, and if you wonder why it took such a long time since the last update, I actually lost my camera battery charger (!) when moving to my current home, and thus could not upload any pictures. Work and school have really taken their toll too, but at least the christmas and new-year holidays have lent me time to get some work done on the Jetta at last!
I really hope my predictions will be more accurate this time when I say I believe I will be able to drive this thing to Mantorp, Sweden, for this year's Bug Run - that's June, so I'll have to be quick about the build!
Topic: Jetta project 200 (Read 132023 times)
