Let the tinkering get serious!!....

[benough]

nice.

does the bonnet shut?

[Greg Roles]

nice.

does the bonnet shut?

Yep, it's exactly the dimensions and position of the "old" modshack setup, and I designed it to be the same. It just rubs on the underbonnet insulation, but not enough to dent it. I'm pretty pleased with the result for a first fibreglass effort actually!



Transporter, the silicon hose is WAY better than I had, bigger 22mm inner will flow much better than the old heavy duty thick red pipe I had, and mounting the Provent up high has made for a much less complex pipe route. There's definately no pumping loss now!

I never had any elbows apart from the stock tappet cover one, and the Purosil hose is definately the way to go. If I do get my kits off the ground I'll definately use this hose. Highly recommended. Got mine from Qld Diesel spares, but any decent diesel shop should carry it. It's pricey though!!

[Buller_Scott]

grrrrrrrr this is making me want the dia at the local autobarn for $250.

is there any difference with the driveability of the car that you can feel seat-of-the-pants with this higher flow unit, cog?

[Greg Roles]

Free flowing airboxes themselves do SFA for outright power, but the response is a little better. If it leaks hot engine bay air as mine used to, you actually lost power. Sounds better. As part of an overall "more air in, more air out" mod plan, they make perfect sense. Without changing the overall flow, they are just like putting a huge nozzle on a stock vaccuum cleaner, it's not going to flow any more than the motor allows. Up the entire system, and then you get the benefit.

[gldgti]

So when is the entire system getting beefed up then?
Heads, cams, inlet manifold, turbo etc

You should read all of cogdoc's threads - there are 3 of them.

being a turbo diesel, there isnt much room or benefit with camshaft modification (let alone an off the shelf performance option). The mk5 GT TDI head is already a 16V and flows very well, but would likely (as with any engine) benefit from some mild porting - but to remove the head of a near new car just to do some porting if its your daily driver seems a little silly to me - better to do it when something goes wrong.

There's already been much discussion about turbo's...

The hardest part is getting software that will run all the hardware - the diesel ecu is not catered for so well as the petrol models and as such a "custom tune" would be needed - expensive aswell.

[Greg Roles]

Only porting on the exhaust side matey! Don't want to mess with the ultra important tumble and swirl on the inlet side. But I'd only cnsider porting if I was going to get a custom exhaust manifold made up to replace the log, but at this stage I'm not, predicted power will be too much as it is.

[benough]

Screw porting, hurry up and put your down pipe on!

[Greg Roles]

Going to be several weeks yet I'm afraid...

1. Hook up electronics ( in progress... )
2. Fab up inlet plumbing, remove EGR and throttle flap.
3. Meth kit in.
4. Qld dyno day to test meth kit on stock tune / exhaust.
5. Fab up cat back exhaust.
6. Down pipe and C Code via Gav.

[GoLfMan]

Have you looked into an Allard Power pipe (EGR delete kit)??? I'm looking into one before I hit 100k mark

[Buller_Scott]

yeah cog, and whaddya reckon of this as a "scotty is retarded but even he can't bung this one up" fix for the mean time:

http://forums.tdiclub.com/showthread.php?p=845297

[gldgti]

yeah cog, and whaddya reckon of this as a "scotty is retarded but even he can't bung this one up" fix for the mean time:

http://forums.tdiclub.com/showthread.php?p=845297

anything you do to drop out some oil will help.... but that should be in the provent thread

[Greg Roles]

Have you looked into an Allard Power pipe (EGR delete kit)??? I'm looking into one before I hit 100k mark

Yep, but all it really does is replace the parts with a bit of pipe, and doesn't address the real problem of removing the exhaust gas recycled - soaring turbo impeller melting EGT's. A great idea, but not ideal in isolation.

[Greg Roles]

yeah cog, and whaddya reckon of this as a "scotty is retarded but even he can't bung this one up" fix for the mean time:

http://forums.tdiclub.com/showthread.php?p=845297

It's good in theory, but needs a pressure bypass. The Provent is indeed crazy expensive, but it's also very well designed, and has a 1psi pressure relief valve, so if it does clog up totally, it can bypass and allow the crankcase pressure to continue to escape. There's also another relief valve built into the lid, so if that first valve fails, this can vent to atmosphere, and prevent any oil pressure goes crazy engine damage, which would indeed eventually occur with a normal oil filter like that. I managed to force oil out through my turbo bearings early on by putting some scourer pad in the small stock breather pipe, and as a diesel will happily redline on oil, that's not a good move.

Finally increasing the restriction on the crankcase vent is well known to drop hp, as the pistons have to decend against extra pressure, and we can't have any of that!

[gldgti]

Finally increasing the restriction on the crankcase vent is well known to drop hp, as the pistons have to decend against extra pressure, and we can't have any of that!

thats why, if you can separate the oil out, its good to connect it to the inlet. If anything theres some vacuum there to pull it through and keep the crank case pressure slightly negative.

[Greg Roles]

Note to self: Next time you decide to run switches and several indicator LED's inside, realise that means a bijillion wires through the firewall. Thank god for Cat 5 data cable, that's all I can say! All my switches etc are wired up and ready to go, and I've run a lead from the MAF signal, so I hope to have all the electronics happening this week.

Hoping to spend the 4 days over Easter getting my inlet pipework made up, and then I can run the meth kit.

In case anyone else decides to try some fibreglass / carbon fibre, once you get a decent epoxy finish, don't get greedy and try for further layers! I've made a mess of the clear finish of my airbox trying for several layers, and it is indeed very tricky to get that nice clear dimple free finish commercial carbon products have. A lot of sanding for the rest of the weekend, taking it back to square one! DOH!!