mk1 1.9TDI in progress

[Preen59]

i like things i can see and adjust and tamper with, none of this chip flashing or laptop-in-car-crap.

this way, i can remap my fuel and advance curve any day for free!!

Ahh good to see there are people that think like I do.

[Volvo Driver]

Soon enough though, aftermarket ecu's like Megasquirt will be able to control the electronic pump and then it will be very easy to tune and more accurate too.

I've fiddled with VE pumps at trade school as well as work, not much fun the mechanical ones, not much to adjust either.

[mollins]

not much fun the mechanical ones, not much to adjust either.

apart from almost every part being interchangeable across the VE pump range, and the different governer modifications, and the boost pin angle, and the max fuel screw, and the advance mechanism spring rates, and the stroke of the control lever, and the diffent cam plates. not much really.

btw, i can see the value in the electronic pumps, i'm sure you could get your own perfect map a get power/efficiency increases, but i just dont have the money/experience/bother, to play with all that. My engine will have about 5 wires running to it. And thats it . Just the way i like it. Best thing is, if i ever get a computer and want to put the electronic pump back on, i could do it in an hour or two.

[99gti]

I'm curious to know what K03 or K04 they use. The K03 would never be able to sustain that kind of boost and depending on what K04 you use, you would be pushing it at 25psi.

What K04 are you looking to run on it? Any more specs of the turbo? (hmmm, hybrid me thinks )

[mollins]

I'm curious to know what K03 or K04 they use. The K03 would never be able to sustain that kind of boost and depending on what K04 you use, you would be pushing it at 25psi.

What K04 are you looking to run on it? Any more specs of the turbo? (hmmm, hybrid me thinks )

1Z or AHU (96-99 golf/jetta/passat) uses K03 or T15 i think. The K03 is the 12 blade compressor similar to the standard early 1.8T turbo.

the k04 i have is a cheapo chinese copy with a 2inch turbine dunno what model its copied from. I have also in the post a genuine KKK K04-003 from an izuzu 2.5 of which i hope to use the core only, along with the compressor/turbine housing from the chinese one. This will hopefully make me a frankenturbo which will bolt straight on but have genuine kkk components and not cost a million dollars.

neil, have you found any info on the -003?

i guess i'll see what happens when it arrives.

[mollins]

depending on what K04 you use, you would be pushing it at 25psi.

ps. remember my redline is at 4500rpm ..

therefore i need less air to keep the boost up.

[Greg Roles]

1Z or AHU (96-99 golf/jetta/passat) uses K03 or T15 i think. The K03 is the 12 blade compressor similar to the standard early 1.8T turbo.

the k04 i have is a cheapo chinese copy with a 2inch turbine dunno what model its copied from. I have also in the post a genuine KKK K04-003 from an izuzu 2.5 of which i hope to use the core only, along with the compressor/turbine housing from the chinese one. This will hopefully make me a frankenturbo which will bolt straight on but have genuine kkk components and not cost a million dollars.

neil, have you found any info on the -003?

i guess i'll see what happens when it arrives.

I'm loving the tinkering going on here.
You'd make Tim Allen proud.
"Frankenturbo" - love it.

[Volvo Driver]

ps. remember my redline is at 4500rpm ..

therefore i need less air to keep the boost up.

Our one revs out to 5, needs more power though, gotta convince dad to fit a decent bar and plate to it :p

Well cam plates and governor mods and spring are a bit more advanced mods then the max fuel screw and boost pin angle. Can't exactly change them without the pump off the vehicle. But yeah it does make it simpler.

[mollins]

Our one revs out to 5, needs more power though, gotta convince dad to fit a decent bar and plate to it :p

nice to know it will go to 5K.
yeah the stock coolers are tiny. would make a reasonable difference i reckon. Its a shame theres not much space in the front of a mk3!

Can't exactly change them without the pump off the vehicle.

that wont stop me!

[mollins]

franken turbo...

ok.. so the story is.. i have a chinese turbo. its a K04 copy made by the reputable manufacturer "YEQI". Definitely my favourite brand!

anyways, its crap. So.. Aydan found a real K04 on the net for 300 bucks. so i bought it. Its a genuine 3K K04-003 from a chrysler 2.5.

here are the two turbos side by side




the problem is, that the turbine inlet on the new turbo doesnt match my exhaust manifold. so... we pulled off the turbine housings to see what we could see


here they are again side by side


They looked pretty similar, so all we had to do was swap the turbine housings!!

almost..

the problem was that the turbine blades were just a smidgen taller at the outer diameter on the 3K turbo, which meant the blades contacted the casing from the YEQI. so... we used the backing plate from the YEQI.. with a bit of modification:



we got this!



which when placed under the turbine housing, gave the perfect clearance for the turbine wheel!




a quick test fit:



then to mount the wastegate actuator. had to tap some holes on the 3K turbo. then:

[mollins]

its alive!!!!

FRANKEN TURBO:

[Jarred]

Nice one. Hope it all holds together! Wouldn't want to see half a turbo flying through the bonnet...

well, a small part of me would, but that's for another day

[smithy010]

That would be well wicked!

Note to self: Carry video camera wherever you go..

I have total faith in Mike and Aydan's Franken turbo expertise.

[GoLfMan]

nice one mate, as Jarred said i hope that housing is good quality
you guys are the ultimate DIY's!!

[gldgti]

I have total faith in Mike and Aydan's Franken turbo expertise.

admittedly, there is no exper(ience)tise to be had here... but both of us are mechanical engineers, and both of us agreed that there should be no reason for anything bad to happen.

FAMOUS LAST WORDS