Let the tinkering begin...

[Transporter]

Guys relax, it's gonna get bonded. I've been putting devcron and the like into inlet ports, crankcases, you name it on motors for years, especially high performance motorbikes with immense success. A plug is indeed a good idea though greggo, and I have one coming from 42draft designs with the other bits. I'll devcron it in ok?

My engine warranty is going to end this year anyhow with what the next "phase" involves, will be very very obviously modified.

Stay tuned!

No! You'll weld it up or replace it! Just do it!
Take a pride in your workmanship.
Just kidding man. Of course the plug will do. Especially when it is not visible too much. Just a hint - be careful with the epoxies (I would use JB Weld if I had to glue it), especially if you want to keep the oil in your engine.
Good posts mate.
Cheers.

[Greg Roles]

No one is really going to notice the plug over the about to be fitted 2.5" / 3" shiny inlet plumbing guys! My Dad is on the lathe for me this week.

[DubSteve]

Nice write up man I love your work so far

[POLARBEAR666]

Just remember that hot side, you only need 2-2.5 inch pipework depending on the outlet size of your turbo. 2 inch flows about 600hp @ wheels.

I know this because I have seen 3 or 4 wrx's that ran 2 inch pipework from turbo to intercooler that made between 400 and 600 @ wheels. Anything bigger than that and you are just creating additional lag.

Also. Once the air has cooled down it is time for bigger pipes, 3 inch is normal but 2.5 inch is all that is needed on our low hp figures.

Don't get caught up in pipe size e-peen and just create more lag for yourself!!!

Check out the small pipe size on WRC cars hotside!

PS- my old wrx made 300kw@wheels with 2 inch turbo to intercooler and 2.5 inch from cooler to manifold.

[Greg Roles]

I totally understand my man, and appreciate the thoughts. The 3" is just from pod to turbo, and the rest is 2.5". Basically because it's what I have on hand, and it's not really that different from stock, post intercooler anyway. I will re-consider the hot side though, as it is smaller stock, thanks for the tip! I guess too, a low revving diesel doesn't need super high flows....but there is the much higher pressure thing too...hmm, you've got me thinking.....

[POLARBEAR666]

Yeah, intake you can go as large as you want. My turbo in my subaru had a 4 inch intake so I had 4 inch pipework and a huge pod filter in the inner guard. When I was running 2 inch from the turbo I had a 2.5L stroker running 1.8 Bar boost, not the mini-me motor I have now. Your diesel should be amazing once its tweaked. In a way, I am glad the TSI is not as easy to tune and has no parts available as I have a chronic car problem (spent $25k on my last motor).

Here is a water intercooler setup for some inspiration for you.

[Greg Roles]

Yeah the next step will be to decide on a shorter inlet by placing the plazmaman W2A core between radiator and engine, and thus avoid the extra drop down to the A2A stock core, or to run it stock-ish and out the front behind the bumper to avoid heatsoak ( a big problem with diesels always boosting ). The "more stock" location is the most likely option, as I will probably need the "other space".

[gldgti]

i agree on the piping size thing.

for my 1.9 i went with 2" everywhere.

note that a comparison of petrol and diesel HP figures and piping size is a little inappropriate though - a diesel has to flow a lot more air all the time, and makes less power.... if you want to talk about power. we should all be talking about torque

for instance, a 2.5" exhaust on a petrol car might be fine for 3-400hp.. but it'll be borderline to w for a 150-175hp diesel.

if you have the necessary chemistry and physics background - then talking in terms of mass flow rates will make all that more understandable.

[POLARBEAR666]

I stand corrected. I don't know much about diesels. I do know that a lot of guys get pipe size complex and end up with 3.5 inch intercooler pipework on a stock 2L motor lol The only thing they get is more lag but they think the car is faster because the turbo comes in later with more of a bump.

My next car will be a TSI diesel if they ever bring one out heheehahah

[gregozedobe]

My next car will be a TSI diesel if they ever bring one out heheehahah

I think a compound bi-turbo seems more likely (little turbo for zero-lag low-mid revs boost, handing over to a big turbo for mid-high revs POWAH ! ). IIRC both M-Benz and VW have been dabbling in this pond recently.

The current trend seems to be towards smaller motors (with big boost) to get better economy and emissions when cruising, but still able to supply plenty of power when required.

[POLARBEAR666]

The TSI is already a compound turbo setup... the blower blows into the inlet of the turbo and the turbo makes the boost. So I think this is most likely for the diesel as they already have it all sorted.. all they need to do is make the TSI a diesel fuelled car with the rest of the diesel stuff.

Back on topic. LETS GO CODGOC LETS GO ***CLAP CLAP***

[gregozedobe]

I know the 1.4 Twincharger is a compound supercharger/turbocharger petrol engine, that's why I said "compound bi-turbo". Unfortunately due to VWs marketing boffins the label "TSI" is pretty well meaningless these days.

I think we'll have to agree to disagree on what setup VW will choose for their next small capacity high performance diesel

There are rather a lot of differences in tuning and engine management betwen hi-po petrols and hi-po diesels, and seeing as VW are already trying out bi-turbo diesels I'll still put my money on the bi-turbo. Don't forget that turbos are particularly well suited to diesels because diesels effectively run wide open throttle all the time, thus keeping some boost going even when you have backed off the accelerator completely.

From what I've seen over recent years the compound supercharger/turbocharger petrol setup is still only one VAG production engine - the 1.4 "Twincharger", and therefore while it is interesting technology, so far it appears destined to be an evolutionary "dead-end" for VAG at least.

Time will tell who's right (or maybe VW will surprise us all and bring out a hydrogen rotary hybrid or something)

And who's to say this discussion isn't right on topic ? We all know Cogdoc is ambitious and loves his diesels, so he may already be planning his own compound bi-turbo diesel weapon, using the 2.5l R5 motor from the VW transporter to get extra 500cc capacity, and adapting an R32 or Skoda Octavia 4x4 drivetrain to overcome any pesky traction problems

[Greg Roles]

You guys certainly have active imaginations, an overestimation of my play money, and musn't read your VW magazines....

[Greg Roles]

[RhysQ]

multi-tasking i see greg. reading a magazine, taking photos AND eating biscuits....good work!