2.5TDI + bi-vnt-turbo

[shadowmaker]

Sorry this a copy-paste of my build from another forum. Maybe this might interest some even down under...


The build up has started. Recepy:

-Evo3 head. It will be taken as far as it needs. Currently using Evo2 with bigger valves etc.

-New intake manifold.

-Performance cam. This will be something new and maybe it will need multiple takes to get it right.

-Twin turbo setup: I'm going to stick with the current one (gt23v-AMG) and add another vnt, gt37v to it. Luckily I have a big trunk... Things will be electronically controlled. This is the hardest part. I hope I get it right. For you that haven't ever seen a gt37v, this one is HUGE. Even HX50 is small compared to it.

-Additional A/W cooler.

-Fueling mods to get power up to 6000rpm, but I think I'll eventually need an additional pump to keep that bigger turbo happy. That's not going to happen with this build as this is too tricky as it is.

-New rods, lighter/modified pistons, knife edge crank.

-Lightweight SMF + twin carbon disc clutch. This is going to be the worst part for driveability.

-New gearbox with some exotic stuff in it: longer 1st, LSD from WRC Focus, dog engagement.

-330mm brakes in front + 8 pot calibers.

-Original rear discs + 4 pot calibers.

-Anti-lag system.

-Weight shaving up to 200kg, but that big turbo isn't going to make it easy (as it weights about 40kg).

-New angel-eye lights with custom look in the nose section. 6xHID.

I think I have almost every part ready, but it's not going to be a walk in the park...

Van:

http://i5.tinypic.com/455m13p.jpg

Old engine compartment with 350hp, 700Nm:

http://i16.tinypic.com/2laep0n.jpg

In action:

http://www.youtube.com/watch?v=hkSTslJf7Z4

http://www.youtube.com/watch?v=BDUgkusl6Uk

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Tearing it apart.




New Isotta chairs.


THE turbo.

[shadowmaker]

Intake will be looking something like this (left one). Long runners are going to be taken from D24 Volvo (6syl).


Here's some pics of the home made collector.


Small end.


Also decided to make a girdle to beef up the bottom end.

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Here's my new dual disc clutch. I'm a little afraid how it is going to behave...


Here's a donor for my dual plenum intake. Runners are 50cm long.


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We have a long winter here and nothing to do.

Some progres.




I think the old one served for some four years IRC.


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Now things are cooking. Exhaust is ready and intake is nearly ready.




It's time to take of the head and see what can be done to it.

Gearbox is long way from finished, but it seems that it can be done with the diff lock I have. Sadly it will require a lot of machining and special (=expensive) parts.

Custom made injectors are on their way and pump is under some serious construction.

[shadowmaker]

Manifolds were test fitted today for clearances. Both seemed ok.




It's time for sauna and refresments...

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Some ongoing electrical work.


Next one I don't recommend to anyone as lightening crankshaft is plain madness...

Original:


Under construction:


PLEASE DON'T DO THIS AT HOME!

[Greg Roles]

Freakin awesome. I SO get what you're up to, and why.

Quite the sleeper!

[shadowmaker]

Freakin awesome. I SO get what you're up to, and why.

Quite the sleeper!

Well, my goal is to get road usable 450bhp out of it and with some weight reduction + traction upgrading maybe low 13´is doable on 1/4 mile. So it's not going to be THAT fast, but maybe will give a nice suprise to someone...

[Greg Roles]

One of the funnest cars I've ever driven was my Brothers modified Ford transit van with a Commodore (opel ) VN V6 in it ( the jap motor i think ).
That van weighed stuff all stripped out, and it was an absolute monster, burnouts everywhere, and it could drag anything the late 80's produced. Many a fun time had till it ripped the diff out of itself.

THAT sure surprised people!

Go the shadow hell bus!

[gldgti]

wow man, this is a serious build.

i'm impressed with your intake plenum design - like the idea of the large plenum to feed the runners and the feed plenum for the larger one to try to distribute the inlet air into the main plenum chamber evenly - and i guess a good idea for the street - given the amount of pressure you'll be putting on the internals, you want it all to be balanced nicely across the cylinders for engine longevity.... nice work.

that GT37 is HUGE. pointless remark i know, but mate, thats just plain BIG. i guess this kind of build could only really happen with a van, 'cos i reckon a turbo that big in a golf would just have to go somewhere inside the cabin - get lost passengers!

i watch with baited breath

[Mischa]

holy beegesus batman! now this isnt a thread you see everyday. cant wait to see how it turns out

[jayjay]

you have some quality fabrication skills! good luck with the project. you're not in AUS are you?

[shadowmaker]

holy beegesus batman! now this isnt a thread you see everyday. cant wait to see how it turns out

BIG BANG?

jayjay: I'm from Finland, so lot's of spare time during the long winter...

[jayjay]

you nordic fellows! hahaha. it seems that every mind blowing ridiculous project comes from a back yard garage out of finland or norway!

[GoLfMan]

this project is just awesome

I also cant wait to see how it turns out!!!!

[shadowmaker]

Making the EvoIII head is taking time at the moment and I'm not sure that my van will be ready this summer at all, so I have decided to speed up some of my other projects: A Volvo S60 2.5T AWD AT -04 and Suzuki RG500 Gamma -86.

With Volvo there's just a matter to make gt40v (yes, a vnt) to fit under the bonnet. Goal is +500 streetable hp. Turbo needs to be located over the GB as it is volley ball size. Darton sleeves are also in progress, but almost everything else is already done (head with bigger valves, fuel system, IC, beefed up AT and turbine...)





Suzuki had some professional care and has ~150bhp with 142kg. It only needs few things and a good assembly.

Here's my pride and joy before I decided to tweak it some more .



Hopefully I get to test both these before our short summer is over...

We already know that vnts work with gas engines as my friend has been using gt17v with his previous ATV engines with succes. Here's my friends latest ATV with Aprilia V-2 1000cc and gt22v. Goal 240bhp.



Dual plenum intake is under construction. You can see it above IC, on the table.

And the other side.

[gldgti]

Goal 240bhp.

widow maker right there.

[shadowmaker]

It has been a while. I had my back surgered and got a baby girl, my third child. Now everything seems to be back to normal and I can focus on my projects.

Some ongoing aluminum work.






Here's my new dual airbox setup from Fiat Ducato under construction. Two 3" airducts will feed those from a roof scoop and boxes will be fitted into the trunk divider wall. This way I can use big paper filters instead of free-flow crap and have enough flow for far more than needed.







It's not going to look this spacy after I'm done. I'm going to need my trunk with second turbo, all the plumbing, heat shields, wastegates, WAIC, scavenge pumps...