76er Swallowtail K-Jet turbo build

[Preen59]

Great car. Lots of fun to drive. Soooooo smooth off boost. It's a credit to Tim for being able to do so much with very little. Just goes to show if you use your noggin and you have some skill, you can make something pretty cool without spending a lot of money!

Even on the "Golfworx certified" calibrated arse gauge 10psi, i reckon it goes pretty hard for what it is.


Oh by the way Tim.. You forgot to mention I pulled the Timing belt off for you and passed you some tools.. Where's the recognition, man?! Haha.

[Oneofthegreats]

Great car. Lots of fun to drive. Soooooo smooth off boost. It's a credit to Tim for being able to do so much with very little. Just goes to show if you use your noggin and you have some skill, you can make something pretty cool without spending a lot of money!

Even on the "Golfworx certified" calibrated arse gauge 10psi, i reckon it goes pretty hard for what it is.


Oh by the way Tim.. You forgot to mention I pulled the Timing belt off for you and passed you some tools.. Where's the recognition, man?! Haha.

hahaha

Yeah. Was more like 6psi! hahaha. Was still slow!

After mucking around with it tonight, I've got a funny feeling I've been running it on 20psi the whole time too! haha.

Cause 15psi doesn't stutter & light the tyres up like it used too! I'll get there soon enough.

More timing & more boost is the key!!!!!!!!

Poor old engine!


& yes preeny. Sorry matey. You did help out with dismantling the car & passing some tools!

But you also rethreaded the boost reg too with a file too!

I have got a good memory!

[Preen59]

Now if it blows up you can say "Well.. It's my fault.. But it's kinda your fault too!" haha.

[Geoffrey Hale]

Hi all ...... I hadn't looked at this thread till Preeny put me onto it. Excellent job Golfworx. What a sleeper. I'm sure there must be a few motorists out there wondering why they paid so much for there cars when they cant keep up with an old Mk 1 Golf. ....... cheers ....... Geoff

[16v_kid]

Nice work!

[gldgti]

True.

Still haven't got back to the strip yet, but have had some good runs with it & have upset a couple of low 13 sec cars incl. a cammed up gen3 with 250rwkw! Now he wasn't a happy camper!

please come up to NSW and beat my workmate in his new VE Maloo. He got it chipped/dyno tuned before it left the dealership (holden eh...) and made nigh on 275rwkw - i would love to see his face when beaten by a mk1 golf, haha.

maybe i'll have to build a turbo golf...

The hot running only became an issue on really hot days like 37+.

Plus it also has a blacked out intercooler pumping added hot air across the radiator, so in extreme weather it can run hot on the highway, but I don't get all that worried. When I come back into traffic, the fan bring's the temp down.

On the earth side of things, I can understand where you are coming from. I made new battery cables,along with alot of other little bits & pieces when I built this car to make sure all the electrics were spot on first off.

On normal days it runs on 1/4 on the highway & get's upto 1/2 in traffic which is exactly how all my mk1's have been

Thanks again. After all, its all food for thought.

Ahh i suspected as much - but never hurts to mention anyway.

Like you said, if you've been running 20psi all along, that could well have something to do with the sputtering, etc.

[Oneofthegreats]

please come up to NSW and beat my workmate in his new VE Maloo. He got it chipped/dyno tuned before it left the dealership (holden eh...) and made nigh on 275rwkw - i would love to see his face when beaten by a mk1 golf, haha.

maybe i'll have to build a turbo golf...



Ahh i suspected as much - but never hurts to mention anyway.

Like you said, if you've been running 20psi all along, that could well have something to do with the sputtering, etc.

As much I'd like to say I could keep up with the ute you speak of, thats a mid to low 12 sec & the poor boosted stock engined mk1 won't get within a wiff of it. Plus its a 6.2L which carry's alot more torque too.

The sputtering is the warm up reg. not being able to cope with how it develop's boost when wound up to what I had it at. As its not nice & smooth, rather 4000rpm & "BANG" & it over fuels & fuel dumps pretty violently with A/F ratio jumping into the low 9's for a split second!

In the lower gears it can power through the sputtering very fast & turn the tyres. In higher gears eg. 5th @ 100km/h, it will just sputter without boosting.


On 15psi with conservative timing, it unbelievably nice & smooth, with the turbo getting a big surge at 4000rpm. But just doesn't give you the kick in the pants. Its funny. Once you've had power, its hard to detune & go back! haha



The joy's of a turbo'd mechanical fuel system.

Can't wait for next turbo'd engine. 20V, EFI & big turbo all the way.

[POLARBEAR666]

If you seal around the intake area that goes to the intercooler / radiator complex you will find you run much much cooler. I know you have sealed the gap at the top but you need to seal the sides and bottom so that air has no place to go except through the whole lot.

Half the air that comes in the front will be pissing out the sides or going underneath the radiator and intercooler.

Get some aluminium sheet from bunnings for about $12 a sheet.

Bend it to make air trays that close the sides/bottom and watch your temps drop! My radiator struggles to get past 86-87' on very hot days even though it used to sit religiously on 88' before my mods and use the fan often to bring temp back to 88.

[Preen59]

Way to go, Tim! Good to see you've got it sorted.

Polar's post does make sense. I know of quite a few people who have made similar shrouds to get the same effect of a variety of different applications, with positive results. I've experimented with that a few years ago in Karts and trapping the air does make quite a difference.

[Oneofthegreats]

Make good sense Polar.



You really have to have a look with everything in there to see how everything is mounted & routed though. Its a bloody tight fit.


Next time the rad. is out I may look into bending something up with some thick foam seal ends

But at the moment on a normal day, its fine. Its only on really stinking hot days eg. 37+.



The opening on the grill being a small open version is right at the edge on the intercooler core.

The rad. is alittle wider than the intercooler & run's all the way to the bottom on the rad. support.

The only place for major bleed off would be the passenger side & there is bugger all room there to fit in a tray/deflector.









In a factory Mk1 it has a top & side deflectors. Nothing on the bottom, as the rad. runs all the way to the rad. support.

[Oneofthegreats]

Well after Preeny came down & drove this around alittle bit.

We sat down, had some drinks & threw some ideas around about the tune & how to improve & fine tune it. Cause after the boost regulator unscrewed & boost regulator hose split, it threw the tune way out & I just couldn't find the old tune again.

So I thought I'd give a few of the idea's a try & play around with them.

First off, I cleaned the K&N air filter which hadn't been cleaned since I built the car. So more or less 50+K!!!!! To say it was black & chocka block with dirt is an understatement. I've seen cleaner filters in vacuum cleaners!

Then replaced the fuel filter too.

Then onto refitting both the tuning equipment, being the Boost gauge & Air/Fuel Meter Gauge.

I started off repairing one of the cyl. head plastic fitting's that broke after a backfire yesterday which was basically the start of whole process of playing around with the tune.

I removed the Hobbs adjustable pressure switch for the Aux. injectors (cold start valves) & bench tested & then readjusted it from a 7psi cut in to 13psi cut in.

So when it hits the magical 13psi mark the extra injectors cut in & supply extra fuel on boost. Instead of dumping fuel in earlier at 7psi. Now it has a fair amount of extra air volume before dumping in extra fuel.

Then I readjusted the system pressure of the K-Jet system. I reshimmed up the system pressure regulator from 82psi to 94psi.

Then redjusted the ignition timing to approx 10BTDC.

Reset the Air/Fuel mixute at idle to approx. low 14's/high 13's:1 & seemed very happy.

The onto the R/test to reset the boost regulator. This took several start/stops to get it right. As when bench testing it, you don't get the same volume of air from the turbo as you would from 60 gallon air compressor tank.

After alot of R/testing & playing around, I ended up with it set at 20psi & adjusted the timing retard to approx 1.5 degrees per pound of boost.

With these few changes, the car has now come alive.

It certainly doesn't have the same amount of kick it did, but now it doesn't have any stutter or fuel dump at all. It will pull cleanly in all gears with a nice smooth surge & then when it hits 4K the surge gets greater!

So you can cruise along in 4th@100km/h, plant it & without any stuttering, it can (let your imagination take over).

Now it doesn't wheel spin like it did & makes bugger all boost in 1st due to not building up enough engine load, but in 2nd it will boost & turn the tyres, hook up & away you go, 3rd & 4th come about very fast!

If you in 3rd at 60, it will also squeal the tyres on hot mix & pull nice & smoothly past the legal speed limit.


So overall. Even though the car isn't as fast as it was or turn the tyres as violently as it did , its feels only a fraction slower & it's a much nicer & heaps easier car to drive. Which is also pretty bloody fast.

Big round of applause to Preeny! Without the booze he's useless! haha

P.S. but it wasn't all him!

[GoLfMan]

good to hear you've sorted it mate

now I need to have another ride in it!

[DubSteve]

After being in the car the other week, anyone can ask Tim the laughs I had with this car with just the sheer awesomeness that comes out of it! A pure sleeper I love it!

[Jarred]

You still owe me a drive!

Glad to hear you have refined the tune though.

[Preen59]

Great stuff, Tim! Glad to hear you got it all sorted.


PS.. The invoice is in the mail mate. hahahaha.