Let the tinkering begin...

[gregozedobe]

Any TDI that is running at rpm above idle should have boost. There is no throttle like in a petrol car, only an accelerator that mainly controls how much fuel is injected (with secondary ECU control over turbo boost).

[comfortline]

Excellent. Love reading the updates cogdoc.

So what will you plug the hole in the oil filter housing with? Or will you go to the stealer?

[Greg Roles]

Any TDI that is running at rpm above idle should have boost. There is no throttle like in a petrol car, only an accelerator that mainly controls how much fuel is injected (with secondary ECU control over turbo boost).

Dude I'm seeing 1 psi at idle...this is WEIRD no?

[Greg Roles]

Hi mate, nice write up so far. You should check out 42draft designs from the US for gauge solutions as they have stuff like those t-pieces and drain plugs with the sender to fit as well. Keep it up!

Thanks for the tip, they are being very very helpful!

[Transporter]

Dude I'm seeing 1 psi at idle...this is WEIRD no?

It is normal mate.
Here is explanation.

http://wiki.xtronics.com/index.php/Pressure_Conversion_Table

[gregozedobe]

Dude I'm seeing 1 psi at idle...this is WEIRD no?

I'd guess on a GT TDI it is more likely a measuring/display/calibration inaccuracy than actual boost at idle. From what I recall my butt-ometer told me when I drove a GT TDI it starts to noticeably boost around 1600, and gets serious about 1900-2000.

My Transporter (2.5 TDI) starts to boost around 1300, and gets serious about 1600.

The aftermarket turbo I put on my 4.2d Landcruiser started work around 1000 and was working hard by about 1500 (it only had about 12psi max boost, as that engine wasn't originally engineered to be turboed). But it did have a beautifully linear, soft throttle response at lower revs, just what you needed for driving on slippery 4WD tracks without spinning wheels.

[Greg Roles]

I agree Greggo, and if higher flowing turbo's made boost that low, well we'd all be very happy. I understand with exhaust flows / pumps etc why that isn't possible.

I expect it's some calibration issue as well, and will look into it, not that a 1 psi inaccuracy is really that important. More interesting to see the spike at first and how it levels out very quickly.

42 draft designs have been uber helpful and we've been e-mailing back and forth, so I have some very nice T-piece and sump plug adaptors in the mail. Filling holes will be done pretty seriously, by bonding a large shim on the inside for strength, and some filler on the outside for looks. I wouldn't bother pricing a new VAG one, would be insane.

If I was worried about filling the hole, well I wouldn't have gone drilling! Growing up in a DIY household, well the whole family is used to undoing mistakes!

[Transporter]

I agree Greggo, and if higher flowing turbo's made boost that low, well we'd all be very happy. I understand with exhaust flows / pumps etc why that isn't possible.

I expect it's some calibration issue as well, and will look into it, not that a 1 psi inaccuracy is really that important. More interesting to see the spike at first and how it levels out very quickly.

42 draft designs have been uber helpful and we've been e-mailing back and forth, so I have some very nice T-piece and sump plug adaptors in the mail. Filling holes will be done pretty seriously, by bonding a large shim on the inside for strength, and some filler on the outside for looks. I wouldn't bother pricing a new VAG one, would be insane.

If I was worried about filling the hole, well I wouldn't have gone drilling! Growing up in a DIY household, well the whole family is used to undoing mistakes!

I would remove it and had it Tig welded or replace it, just to be sure that nothing gets unglued and blocks or restricts oil flow.

[gregozedobe]

I would remove it and had it Tig welded or replace it, just to be sure that nothing gets unglued and blocks or restricts oil flow.

Or a cheaper solution could be a short bolt with a nyloc nut or loctite (to make sure it doesn't come undone), and some good gasket goo to make sure it doesn't leak. If I was going to rely on some kind of bonding substance in a location like that I would want to be extremely confident it would never lose adhesion.

[POLARBEAR666]

Love your work cogdoc!

I have stopped doing the TSI version of what you are doing until a chip is available. No point stuffing around for 5hp here and there when my midrange could jump 50nm with a tune and get 220hp.

Can't wait to see the water-air setup you make if you make one!

Remember that you don't need a huge core if you have extra water! 15L circulating takes way longer to heat up than 5L!

[Transporter]

Or a cheaper solution could be a short bolt with a nyloc nut or loctite (to make sure it doesn't come undone), and some good gasket goo to make sure it doesn't leak. If I was going to rely on some kind of bonding substance in a location like that I would want to be extremely confident it would never lose adhesion.

Yes, that’s faster and cheaper especially on the car which is out of warranty when you know you would be selling it after 12 or more years and don’t have a problem within 3 years warranty.
Should the car need to go for warranty repair than somebody could point at it and question: What was going on there?
That’s why on a new car under the warranty repairs should be as close to the original condition as possible.

[Greg Roles]

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!

[comfortline]

I can't wait. Bloody warranties!

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!

[gregozedobe]

I can't wait. Bloody warranties!

If you don't care about your warranty just have at it now !

[gregozedobe]

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

Stay tuned!

I look forward to the 'next "phase" ' with great interest