IC and Intake mods :) underway!!

[Staley]

I installed my raceware headstuds last week and heat cycled and retorqued them this morning.

I decided that my original tiny disesel intake was WAY to small.. so I installed one from a G60. I modified the throttle body adapter and bolted it right up!

I am now in the works of installing my IC.. I am going to make a box for it where the battery was and install a hood scoop.
Here are some pics that I took with my cell phone.

[BellCityDubber]

Staley... that's some remarkable work, I wasn't aware the G60 intake would match up (but vw's are the lego of engineers)...  

I'm rather impressed.... the longer runners wouuld probally prove to be quite effictive over the standard manifold, I've been looking into getting a eco-diesel manifold for the purpose of not having a  DV valve opening, but a modified G60 intake would probally take care of all of that.

just have to modify the throttle side of the intake eh? looks sharp

I like the IC setup too...

[RabbitJockey]

i always thought that long runners didn't really do anything on a f/i car.  but i'm sure that the g60 intake will flow much nicer than the stock td one.

[935racer]

Hope you at least attempted to port match that manifold, other wise you are gonna have mad turbulence in your ports. Which is gonna be hurting all sorts of things.

[Staley]

I thought about the turbulence issue.. and I made an adapter that goes between the O-port manifold and the D-port head. It is a thin stainless adapter that uses 2 gaskets.. the D-port gasket seals the adapter to the head and I use a oval port gasket against the manifold.. smooth transition to the head and no turbelence!  I'll see how it works in a few days
I made the intake to IC hose before I left the shop.. left the hard one last!

[Dr. Diesel]

nice work, man! what turbo and manifold are you using?

[RabbitJockey]

waht's that intercooler from?

[Staley]

My 4 year old daughter Hannah calls it my Blueberry!

Here are my current buildup details.
1.9L 1Y diesel
Raceware headstuds
ATP 8V turbo manifold
T3 Super60 Turbocharger (with internal wastegate)
Corrado intake manifold I cut off the bypass valve and welded it closed on the throttle body adapter.
I removed the hose bungs from the intake and installed freeze plugs where the holes were
Giles pump (enough said)
I made a 2 1/4 into 2 1/2 Stainless downpipe w/ 2 flex couplers
TT 2.5" exhaust with a Borla muffler.
5 speed diesel transmission
210mm clutch kit with a 16v pressure plate and lightweight flywheel.
I am not real sure what the IC is out of. I liked it because the inlet
and outlets are on the same side and they are 2 1/8 in/out.
I am making my IC piping out of 2 1/8 Burns 304SS.

I have an Autopower roll bar with harness bar.
Drivers side 4 point harness
Neuspeed Sport Springs
Front upper Neuspeed tie bar
Rear Neuspeed sway bar
I ordered the Bilstein Sports today because the KYB stockers
SUCK REALLY BAD WHEN YOU HIT BUMPS.

I know.. it's a disease.. and I have it REAL bad.
and there is NO cure   thank god.. I would hate to take up needle point or something else.

[Staley]

HOSES ARE FINISHED!




ill take better pictures when i actually remember to bring my camera to work!
now I need to relocate the battery

[Staley]

I decided to bolt on this cool little fan that I had laying around.
I think i might intstall a pressure switch to kick it on.
It REALLY pulls some air..

[dubCanuck1]

Sooo. that would make it forced-forced induction or RAM-Forced Induction?

[Staley]

Got it all finished tonight.
I took it for a testdrive with the boost controller set to 23psi and
WOW it is alot faster than before and seems to have
alot more top end power.  I am going to try and hit the dyno
or the dragstrip tomorrow
catcha later!
mike

[greggearhead]

Actually, I think better than a pressure switch would be a thermistor or temperature switch.  My buddy with an old New-dimensions turbo kit on his A3 2.0 Golf has a kinda similar top mount intercooler and was getting heat soak.  I gave him a motorcycle rad fan, and he hooked it up to an adjustable temp switch and reports that it works AWESOME in stop and go traffic, where before he would heat soak.