Compound pics

[andy2]

The head is just not up to the challenge for these high hp IDI's.The coolant ports and pre chamber are the week spots.We would need 6 head bolts per cylinder to have any hope of keeping the aluminum from flexing.

All 4 cylinders are leaking so an intake manifold will not fix that.

Daves setup is completely different to mine his engine has smaller pistions (1.6) and has a big single turbo making much lower torque and HP than my setup.With the compound turbos my engine produces lots air flow at lower rpm and having bigger pistons ony helps push the head off.

The last dyno 2 years ago my engine produced 161 whp @ 4250 and 225 torque @ 4000 on only 30 psi and 86cc's fueling and no head or gasket issues.

Now The fueling is 120cc's boost is 50 psi the engine now pulled well past 4500 RPM you do the math?

[jtanguay]

The head is just not up to the challenge for these high hp IDI's.The coolant ports and pre chamber are the week spots.We would need 6 head bolts per cylinder to have any hope of keeping the aluminum from flexing.

All 4 cylinders are leaking so an intake manifold will not fix that.

Daves setup is completely different to mine his engine has smaller pistions (1.6) and has a big single turbo making much lower torque and HP than my setup.With the compound turbos my engine produces lots air flow at lower rpm and having bigger pistons ony helps push the head off.

The last dyno 2 years ago my engine produced 161 whp @ 4250 and 225 torque @ 4000 on only 30 psi and 86cc's fueling and no head or gasket issues.

Now The fueling is 120cc's boost is 50 psi the engine now pulled well past 4500 RPM you do the math?

 :shock:

hmmm have you tried o-ringing it? (would need to o-ring the coolant ports)

what about running evans coolant with the cap drilled out to run it at 0 psi?

guess theres probably no way of keeping the stock head with your setup then?  

[andy2]

Nothing more can be done to the head but we are pondering the idea of making a steel cyl head :roll: .

[DVST8R]

Nothing more can be done to the head but we are pondering the idea of making a steel cyl head :roll: .

What about a bigger head stud using arp custom age 625, and then ~ 150 ft lbs clamping force? Another common thing to do in the cummins world is to use a .020 overbore HG on the stock cylinder size, seems to help seal as well. If you goto the work of a custom steal head at least goto cross flow. If I was going that crazy I would take a honda B or K series head and model it after that but with swirl chambers instead of spark plugs, as they are known for there head flow, with 300cfm+ a port on stock ports. Alas that is getting a  little crazy.

[gnavs]

this is getting crazy.  But I like it  :twisted:
Don't get discouraged and keep brainstorming.

[jtanguay]

Well, If you're going to make a custom head, how about making a custom casting for a block/head combo as a single unit?  Have to make it so the pistons can slide in the bottom and it would make machining valve seats a bit of a pain, but would eliminate the headgasket and it's resultant issues entirely.   :lol:

Andrew

thats a really interesting idea... seems like it would be wayyyyy too complicated though

getting the precups in there would be a PITA  :lol:

i wonder how hard it would be to weld the head right on???

[andy2]

The IDI will never run again :cry:, its prechamber design that we enlarged really weakens the head also every point between the headbolts flexes up and thats with 14mm headstuds.

We are going to build up an ALH TDI and make a cyl head for it.Higher hp TDI's have the same head issues so we figured make a iron head for it instead.The direct injected setup is easier on the head/gasket and is overall stronger due to not having the prechamber and easier to make.We might even use long studs to hold the head and main bearing caps together like the tractor pullers do.Custom main caps/Girdle.

Does anyone have any thoughts on running the TDI engine on a single spring injector setup with the opening pressure setup like an IDI at 155 bar?

Would the lower pressure still atomize the fuel well enough.The reason I was thinking of this was that aparently the M-TDI pump has fueling limitations for high hp 200+ Perhaps Tintin would know this .I would Possibly use the exact same pump thats on my IDI with the IDI camplate for better revibility and higher fuel delivery on the TDI.

[DVST8R]

Sad day for IDI, two of the big ($$$$ and Time, R&D) motor's are dead, and will not be revived. In the light of this I'm putting a celling on IDI power at about 200hp. Both of these cars produced ~200hp but neither could live for any length of time with it.

So for everyone pushing for a powerful, reliable, IDI I would call it quits at about 170. If you are down for the $$$$ and time it takes to push the limit, absolutely I applaud your effort.

[MJF]

Sad day for IDI, two of the big ($$$$ and Time, R&D) motor's are dead, and will not be revived. In the light of this I'm putting a celling on IDI power at about 200hp. Both of these cars produced ~200hp but neither could live for any length of time with it.

So for everyone pushing for a powerful, reliable, IDI I would call it quits at about 170. If you are down for the $$$$ and time it takes to push the limit, absolutely I applaud your effort.

Damn

I´m still running my Scirocco almost daily. Broke the first 02A at weekend, but other one is coming. Still looking for more hp´s...

[jtanguay]

you should talk to the pump builder over in the Czech republic.  i bought a pump off someone who had it built over there for m-TDI (got it from vw4motion - peter).  just ask Giles when he tested my pump to see how much fuel it was delivering.   :lol:  he said with how much fuel it was putting out, it would have ate my engine  :shock: and because there was practically zero pressure inside the pump, the dynamic advance would have took a dump.  glad i had him check it over  :lol: i'm sure he could reproduce the fueling and have the dynamic timing work as it should.

[lord_verminaard]

Does anyone have any thoughts on running the TDI engine on a single spring injector setup with the opening pressure setup like an IDI at 155 bar?

I had posted a question about this a while back: http://www.vwdiesel.net/phpBB/viewtopic.php?t=13400&highlight=

Although I would think the pressure should be a bit higher, like a middle ground between the TDI's initial break pressure and the 2nd stage break pressure.  Keep the injection event as short as possible for optimum timing and RPM's.  It'd probably be loud as hell but who cares?  

Brendan

[RabbitJockey]

Sad day for IDI, two of the big ($$$$ and Time, R&D) motor's are dead, and will not be revived. In the light of this I'm putting a celling on IDI power at about 200hp. Both of these cars produced ~200hp but neither could live for any length of time with it.

So for everyone pushing for a powerful, reliable, IDI I would call it quits at about 170. If you are down for the $$$$ and time it takes to push the limit, absolutely I applaud your effort.

Damn

I´m still running my Scirocco almost daily. Broke the first 02A at weekend, but other one is coming. Still looking for more hp´s...

yeah... i think people forget about your car too often haha.

[the4ork]

we need MORE pics!!!!!!!

[MJF]

I´m still running my Scirocco almost daily. Broke the first 02A at weekend, but other one is coming. Still looking for more hp´s...

1,7 is history. Con rod was broken and everything is junk now :? The best 1/4 mile is 14,5/166kmh now, there could be a little more power than in dyno last year.

[smutts]

This is all so wonderfully deranged! Keep it up! :twisted: