Let the tinkering get serious!!....

[POLARBEAR666]

2nd blower installed.

[gldgti]

Now I have the EGR insufficient flow registering, but it beats me how it knows, the O2 probe is what measures that, and it's been tricked by the wayne angle block.

I'm doubtful that the angle block will completely defeat the logic in the ECU, as all it will really do is offset the readings a bit, and introduce "lag" in the data from the probe.

As far as EGR and EGT's go, my own experience (having driven around with an EGT guage fitted pre-turbo for 60,000km's now) is that;

1) It is near impossible to make the egt's "dangerous" even when blowing nightmaking smoke, if the engine is at low rpm and making little/no boost (when i have turbo lag) - This adds weight to your theory Greg.
2) Once on boost, smoke = high EGT's. This also adds weight to your theory.
3) Always, without fail, if you add enough boost, EGT's go back down. Even with a massively aggressive tune, adding enough boost will always reduce egt's (although i'm positive that the NOx emissions go up).

So yeah, I reckon we're both right. Something I have realised of late (since I put the big T3 back in) is that its much more difficult to get into the dangerous EGT range for a given 'load' - especially high loads like high speed acceleration (at freeway speeds, up hills). I really attribute this to the larger flow abilities of the t3 exhaust side... less restriction.

[Greg Roles]

Polar, any reason your blower blows from the hot side across the cold side????

I'd understand if it was sucking.....


Yep I agree Aydan, fuel equals heat, not air. I'm avoiding flat out efforts till I get the snow kit in, which will give me true pre turbo EGT's digitally, and water meth to keep it safe as the controller can reference EGT's as well.

In stock tune I think it'd still be pretty safe, but better safe than sorry.

[Jarred]

Wait a min, what are the NASCAR blowers for?

blowing cool air/suckin hot air out from the engine bay?

[Greg Roles]

In MY car they are to circulate engine bay air on idle, to reduce heatsoak in turbocharged cars.

In POLAR's car it's to heat up the inlet side of his turbo to tame the response of his overly powerful 1400cc big block.

[gldgti]

In MY car they are to circulate engine bay air on idle, to reduce heatsoak in turbocharged cars.

In POLAR's car it's to heat up the inlet side of his turbo to tame the response of his overly powerful 1400cc big block.

So he doesnt bake off the tires every time he moves off?

[Greg Roles]

Back to the important stuff, the Autobahn88 bead roller arrived this week. Makes up to 2mm high beads beautifully, even in my thicker 2mm alloy pipework. Obviously thinner is a piece of cake, but stainless would be a test! Takes all of 30 seconds too!

My 2mm beads to the right, beads from china on the left of small pipe. Rolled beads WAY better!





I've a full weekend of tinkering ahead, not much stopping the pipework going in now!

[gldgti]

nice bit of kit there! I use 1.6mm 316L stainless for my pipework, so i reckon it would have a lot of trouble. But, the stainless is easy to weld onto, so i just weld 6-8 "knobs" around the circumference of the end of the pipe. that works fine.

[POLARBEAR666]

Hey cog, I just removed the windscreen wiper shroud and the black metal shroud at top of engine bay. This creates a 2-2.5 inch gap along the whole length of the windscreen and you can't really see it even when standing next to the car. It absolutely pours heat when the car is stopped. Of course high pressure cold air will rush down that spot when going fast but I think the main issue with heat soak is when sitting at the lights and this will outweigh any reduction in airflow through radiator and intercooler. I will report back once I have watched my water and intercooler temps for a while. I did this mod after seeing that quite a few of the mk5 and scirocco race cars have either half or all of the windscreen wiper shroud and metal shroud removed. This must be for the cooling (and also to reach the strut tops).

[Preen59]

That roller looks nice. If i ever need to do that stuff I might make myself one of those....

[Greg Roles]

Thanks to a rainy weekend, got into the engine bay once again. Tided up my new battery wiring, and put all my electronics kits into one big box which will be far more weather proof. Nearly at the stage of having it all running!

Spent the rest of the weekend getting the intercooler pipework from the turbo to IC completed, and bolted into the factory mounts. Took a lot of messing around to keep the joins minimal, in line, and not hitting anything. Also made several mockups and sacrificed some pipes to avoid 90 degree elbows, and keep it all as short as possible. It's a fair bit shorter than stock, with much better bends, according to theory. Ignore the amount of blue on the pipes, there's some there to act as potential rub guards where it comes close to the gearbox. All joins bead rolled and siliconed, just to be sure. Test drive later today!

[Buller_Scott]

man, this is so inspirational to me (went to ReVolks on the weekend, fell in love with my car after seeing it all polished up etc from a distance, lined up to some other watercoolers).

i gotta save for a cheap daily so i can do some of what you're doing.

by the way, how's the egr situation going? still playing things relatively safe?

[Greg Roles]

Driving fine so far, but driving quietly till all the silicon dries. Be interesting to check the spikes in comparison, but expect little from this end of the plumbing.

EGR is throwing error codes and the engine light comes on, but otherwise it's running fine. I've ordered a EGT gauge to put back in my car ( I'll bet hiho wil laugh when he sees this! ), and need to do another max EGT effort up my local test mountain with VCDS logging, but if that comes back OK, I'm all go for the IC to manifold plumbing. I'll have the EGR valve and flap mechanism left plugged in but hanging in the breeze till I can defeat them electronically / via a tricky tune.

That piece of plumbing will be where any effect will be, that plus the water meth finally working.

Then it's onto the dump pipe!

[Transporter]

I see you went with Odyssey battery now. That should last no worries.


Sent from my HTC Desire using Tapatalk

[gldgti]

So Greg, is that 2" hot piping and 2.5" cold?

Pipework looks good, nice job. I think its overkill with silicone on the joints (at least for keeping the air in) - but in my car, all the pipework is high up in the engine bay and so I like to be able to remove it easily, where I don't think you have that issue so much.

IIRC, when you last logged EGT's you saw over 800C?