Turbo high flowing!!

[Valver.]

man we need pics and details of all these secret projects of yours!

Don't we just

[twin eng, twin turbs]

Haha i've seen all this stuff. Many times.

I'd rather my carbied NA engine though....

HA HA! My mums mk1 is faster than your car for at least the next year before you get yours running.....

[Preen59]

HA HA! My mums mk1 is faster than your car for at least the next year before you get yours running.....

Yeah whatever. I'm getting there..

[richo]

I'll get photos of all this stuff and post it next week seeing as marty will never get round to it.

[twin eng, twin turbs]

I'll get photos of all this stuff and post it next week seeing as marty will never get round to it.

Ha! heres some photos then, Starting with the massive turbo that will be helping make the 500hp goal power output from my 2.1 litre 16v.

[twin eng, twin turbs]

Heres a shot of the 4" coned outlet on the well modified exhaust housing sitting on the 16v turbo manifold i made from scratch. You can see the ports which are polished all the way through on the manifold with webbing welded all the way between the runners to prevent any warping under the high temperatures it will endure causing leakage at the gasket to the head. I will get the manifold and exhaust housing high temp coated in the future... What isn't pictured is the 38mm tial wastegate to go with it all..

[twin eng, twin turbs]

Heres the custom inlet manifold i fabricated. The runners are 56mm diameter at the plenum with bellmouthed ends tapering down to the oval shape to suit the ports of the head. At the head they are 6mm bigger in diameter than stock and ported, polished and port matched with dowels fitted so once in place the join is smooth without any step at all. The plenum is 100mm diameter tapering off at the end and i am currently machining up a billet 80mm throttle body to suit the manifold so they are matched. I will polish all of this once finished.

[Oneofthegreats]

Nice work.

What model/spec is that turbo?

I like the pipe expansion. Just like a expansion chamber on a motorbike. My friend used this style on a FJ20 with a GT3540 in a mk1 escort with huge success & power too!

Just for interest sake, I personally wouldn't web a hig hp turbo exhaust manifold like that.

They do expand a fair bit & if there contained like that, they will crack elsewhere & in a bigger way. they'll also crack the hell out of the ceramic coating.

My race 4-1 pacemaker's on my old ute with high temp coating even cracked under the temp. put on it in a burnout comp!

The flange & stud holes should also be cut & separated from each runner for the same reason.

[twin eng, twin turbs]

Heres a pic of one of the front brake calipers for the scirocco that will require at least 17" wheels, custom mounts and 13" rotors to suit. All polished up its a willwood 4 pot with almost 2" diameter pistons. Should be up to the task! Thats all the pics i am sharing for now...

[twin eng, twin turbs]

Nice work.

What model/spec is that turbo?

I like the pipe expansion. Just like a expansion chamber on a motorbike. My friend used this style on a FJ20 with a GT3540 in a mk1 escort with huge success & power too!

Just for interest sake, I personally wouldn't web a hig hp turbo exhaust manifold like that.

They do expand a fair bit & if there contained like that, they will crack elsewhere & in a bigger way. they'll also crack the hell out of the ceramic coating.

My race 4-1 pacemaker's on my old ute with high temp coating even cracked under the temp. put on it in a burnout comp!

The flange & stud holes should also be cut & separated from each runner for the same reason.

I used 4mm wall thickness mild steel steam pipe bends for the runners for good reason. On my 1.8t audi a4 i made a similar manifold running a GT 25/40 turbo without any problem for years. Its so solid that it dosn't warp or crack. My mk2 has a similar set up with water cooling around the turbine flange which has kept the temps down preventing any cracks or gasket issues. After having made stainless manifolds in the past with thinner wall thickness (1.6mm) i have had issues with them cracking and flanges warping causing leaking gaskets. Thats why i make mine from mild steel with much thicker wall thickness.

Turbo is based on a GT35r with modified housings, ported and polished for improved flow etc

[Oneofthegreats]

I used 4mm wall thickness mild steel steam pipe bends for the runners for good reason. On my 1.8t audi a4 i made a similar manifold running a GT 25/40 turbo without any problem for years. Its so solid that it dosn't warp or crack. My mk2 has a similar set up with water cooling around the turbine flange which has kept the temps down preventing any cracks or gasket issues. After having made stainless manifolds in the past with thinner wall thickness (1.6mm) i have had issues with them cracking and flanges warping causing leaking gaskets. Thats why i make mine from mild steel with much thicker wall thickness.

Turbo is based on a GT35r with modified housings, ported and polished for improved flow etc

Makes perfect sense.

The watercooling idea sound's like a beaut too. Would like to see some pic's of it.

I'm not a big fan of the stainless gear either.

All the the stuff I've been involved with has also been steam pipe straight from Reece plumbing. Strong, easy to work with & almost every bend you could ever need.

This is how I'd like mine setup on the "one day" 20vt.

Have the turbo hanging off the side, on top of the gearbox, shortening the pressure piping by at least a foot, reducing the exhaust down pipe radius & also being able to get fresh air straight into it.

Only draw back is relocating the booster/master cyl. assembly remotely.

[twin eng, twin turbs]

That looks awesome! you have been putting a lot of thought into this... I made a similar manifold setup on a nissan ET pulsar running a CA18DET with a t3/t4 though the exhaust was at the front the 3" down pipe i had going over the gearbox and down.

One thing to consider is manifold length although tuned length is good the longer the runners are the less heat energy and pulse from the exhaust stroke hits the turbine. Shorter runners will have improved low end response but dont flow the top end nearly aswell as longer tuned length manifolds.

[Preen59]

Autodesk Inventor CAD model?

[Oneofthegreats]

Autodesk Inventor CAD model?

Nah matey.

Didn't mean to fool both of you.

Christ I'm not that good on a computer. Can't even circle item's in pic's or draw arrow's on photoshop!!!!

Found the pic somewhere, like the idea, design & thought it would work really well on a golf, due to turbo, intercooler & intake placement.

I didn't really matter about the tuned length runner's or the length. More placement.

I learn't from a friend who has alot do do with rotary's, that if it's all smooth & no sharp kink's, it doesn't matter about if there the same length or not. It will still work!

Look at how much power can be made on standard early headed cast holden v8's exhaust manifold's with a single turbo. 600+hp is easily achievable!

It's to run a GT3076R with a .82AR ex. housing by the way.

[Golf Houso]

Looks like an auto-desk inventor jobbie, would love to see that in real life!