Turbo Setup suggestions for 1.5/TurboBlock/1.9 head Franken engine.

[Jetmugg]

Within the next couple of weeks, I'll be getting all of the long block parts back from the machine shop to begin putting my engine together.

The engine is a 1.6TD block, 1.5 rotating assembly, and 1.9 AAZ head. ARP head studs, ARP main studs, ARP rod bolts, plenty of money is being dropped at the machine shop. I have a modded pump purchased from a memeber in Canada, which should be able to provide plenty of fuel.

I don't yet have an intake manifold, exhaust manifold, or turbo purchased.  I'm looking for suggestions for those items, including any gasser parts which can work or be modified to work with this engine.  Cutting and welding is OK, and it doesn't need to fit within the confines of a stock VW engine compartment.  A larger-than stock turbocharger is expected to be part of the configuration.

For those of you who don't know, this engine is going to be used in a land speed racing effort.  It will not be a street engine.  Driveability is not especially important.  Turbo lag isn't important.  What is important is the ability to make good power and live for multiple WOT 3 mile long runs on the salt flats.  A conservative setup that can make an "easy" 125 hp would be nice, and would leave room for further power development in the future.

The setup will include a water-to-air intercooler chilled from an icewater tank.

All suggestions for the intake, turbo, and exhaust configuration will be appreciated.  Let the ideas flow.

Thank You,

Steve M.

[RabbitJockey]

do you have any idea at about what rpm you will be at for the record you intend to break?  that will help with knowing what boost pressure you need for your power goal, and also what turbo is ideal at that rpm and boost pressure, obviously, a tubular equal length turbo manifold will be best ;^P.  Also a scientific rabbit manifold(scientificrabbit.com) is something i would suggest considering, they take gas intakes and port them so they all flow equally, they might even mod one to fit the d ports of the aaz head.

[theman53]

Where do you want peak torque? I am making a manifold for my 1.6 that will have peak torque approx. 2,800 rpm according to the calculations. If you want help making an intake or just want me to figure out some dimentions for you I would do that.

[Jetmugg]

There is some fine-tuning to do with tire diameters, but basically, I will be turning about 4500 rpm in 5th gear to hit my goal.  I will probably rev past 5,000 in 4th before shifting.

As far as a tubular header style exhaust, I agree that it would be the best option.  I've seen some turbo header exhaust manifolds for gasser engines.  I'm not up to speed on compatibility between the gasser and AAZ exhaust configurations, though.  Will a 1.8 turbo exhaust header work on an AAZ head?

I have also heard that some of the gasser intake manifolds make a good starting point for a turbo AAZ head.  I need to learn more about those.

Theman - thank you very much for the offer.   I don't really know where the peak torque needs to be.  I have been thinking more in terms of making the most power at or just below the target rpm in top gear.  The lower gears should pull relatively easily, compared to the power that I'll need at higher rpms in top gear.

Steve.

[Blocksmith]

There is some fine-tuning to do with tire diameters, but basically, I will be turning about 4500 rpm in 5th gear to hit my goal.  I will probably rev past 5,000 in 4th before shifting.

As far as a tubular header style exhaust, I agree that it would be the best option.  I've seen some turbo header exhaust manifolds for gasser engines.  I'm not up to speed on compatibility between the gasser and AAZ exhaust configurations, though.  Will a 1.8 turbo exhaust header work on an AAZ head?

I have also heard that some of the gasser intake manifolds make a good starting point for a turbo AAZ head.  I need to learn more about those.

Theman - thank you very much for the offer.   I don't really know where the peak torque needs to be.  I have been thinking more in terms of making the most power at or just below the target rpm in top gear.  The lower gears should pull relatively easily, compared to the power that I'll need at higher rpms in top gear.

Steve

From what I understand, I believe the 'proper' 1.8T motors have newer, crossflow heads, and the manifolds are not compatible with the AAZ head in any way. Old, non-crossflow 1.8 gassers have the same exhaust ports, but I don't know if they ever got turbos. Either way, there are suitable cast iron manifolds for our motors available on ebay for fairly reasonable, if you're wanting a normal t3 or t4 flange. A tubular manifold really would be best, though, which will have to be fabbed up, I think. I've never seen a non-crossflow tubular manifold for sale for less than huge money. 
The gasser intake manifolds will fit, but the port shape is different. You'll need to remove some material to make it match the D-shaped ports on the AAZ head (but you knew that already  ). They definitely do flow better than a stock, 'pancake' TD intake manifold, due to the longer, equal length runners. Just a little more difficult to make the turbo fit; but it sounds like you're already factoring that in.

[carrizog60]

vw 1.9d intake, engine code 1Y

[Blocksmith]

A little tougher for us yanks to find, but that would definitely do the trick 

[theman53]

There is some fine-tuning to do with tire diameters, but basically, I will be turning about 4500 rpm in 5th gear to hit my goal.  I will probably rev past 5,000 in 4th before shifting.

As far as a tubular header style exhaust, I agree that it would be the best option.  I've seen some turbo header exhaust manifolds for gasser engines.  I'm not up to speed on compatibility between the gasser and AAZ exhaust configurations, though.  Will a 1.8 turbo exhaust header work on an AAZ head?

I have also heard that some of the gasser intake manifolds make a good starting point for a turbo AAZ head.  I need to learn more about those.

Theman - thank you very much for the offer.   I don't really know where the peak torque needs to be.  I have been thinking more in terms of making the most power at or just below the target rpm in top gear.  The lower gears should pull relatively easily, compared to the power that I'll need at higher rpms in top gear.

Steve.

The exhaust manifolds are the same between the aaz and all 8v watercooled gas and diesel. The intakes have a different  shape as you see the D in yours obviously. If there is no room limitations I would build and intake from something like a gasser or if you can tig make it yourself. Short runners will move the peak torque in the higher RPM range, but from what I gather you will have more flat torque if you make them longer and it will come on sooner. If you are going to shift so early I wouldn't even put a tach in it. The 1.5 with the lowered compression should rev to 6,000 or more if the pump doesn't skip on the rolllers.