swallowtail goodness

[mollins]

update

So as many of you saw on Sunday.. the TDI mk1 is alive and well! .. and registered!! Walked out of the RTA on saturday with my plates!!

Here are some pics from the last little while

no exhaust, high oil pressure and no boost, makes for leaky turbo..
oil smoke anyone??


homemade downpipe



it's awkward at the start so that it clears the linkage..



homemade exhaust in progress.. with a new mount near the fuel tank to stop that mk1 exhaust jiggle



at the nats .. thanks to Golf Houso for the photo (and thanks to Aydan for the lend of his BBS )



at work.. parked with the other diesels...



It's running well now, boost is limited to 10psi until i get the intercooler in. Still running with no smoke, even with the 1.6TD boost pin in the LDA.

Ive got a plan for trying to measure EGT so that I do not melt my turbo.

I will try to keep you all updated to some more progress. Will get some more pics of the interior reco and the other upgrades soon..

[GoLfMan]

cool matey, the home made exhaust looks the goods, are you going to remake the downpipe when you have more time? that tight bend my restrict flow?

how does it go? quick?

[gldgti]

cool matey, the home made exhaust looks the goods, are you going to remake the downpipe when you have more time? that tight bend my restrict flow?

how does it go? quick?

although it is a tight bend... we're going from 38mm turbine outlet to 60mm exhaust pipe, i dont think the downpipe is going to cause much if any performance problem (the whole exhaust is 2.5"). the problem with it is that in order for the linkage to work, we can't get the downpipe in any other way, there just no room. usually, this configuration is used in a mk3 body, where you dont have this interference problem. it would be easier and better to mount the turbo up the other way, with the manifold flipped upside down, to give heaps of room, but we couldnt forsee the linkage issue when we were building the engine on the stand

frankly, i reckon we're ahead anyway, because for a full turbo back system from a shop, they'd have charged at LEAST $1200bucks for the same thing... without the $300 hi flow washable cat.

[Golf Loon]

Inspirational stuff Mike.

Good to see you blokes getting stuck in and doing things with ingenuity and good engineering on a budget.

Not enough build threads on here I reckon.

Also great to see it at the Nats, sounded the goods as you drove off.

Can you bend the linkage bar up or down and cut a bit off. The setup I have on the rocco is pretty unique.

Now get out there and drive the thing

[DubSteve]

Thats soo cool well done man

[GoLfMan]

although it is a tight bend... we're going from 38mm turbine outlet to 60mm exhaust pipe, i dont think the downpipe is going to cause much if any performance problem (the whole exhaust is 2.5"). the problem with it is that in order for the linkage to work, we can't get the downpipe in any other way, there just no room. usually, this configuration is used in a mk3 body, where you dont have this interference problem. it would be easier and better to mount the turbo up the other way, with the manifold flipped upside down, to give heaps of room, but we couldnt forsee the linkage issue when we were building the engine on the stand

frankly, i reckon we're ahead anyway, because for a full turbo back system from a shop, they'd have charged at LEAST $1200bucks for the same thing... without the $300 hi flow washable cat.

ahh i see

love your guys work, would love to have a ride next Nationals

[Preen59]

Great work guys. Really really cool! Big props for getting it going.



Now all you need to do is get rid of that hair dryer and bolt a blower onto it.

[twin eng, twin turbs]

Great to check this out at the nats! Its original and your doing the hard work yourself, respect. Nice exhaust work, i didn't check under it at the nats but im sure when you get it tuned up with an intercooler it will hammer!

[mollins]

TDI mk1

thanks for the encouragement guys.

We sized up an intercooler setup for it on saturday. The cooler fits snugly in front of the radiator. We mapped out a path for the plumbing. We have to get some bends off ebay, so it will be done soon!

I thought the wastegate was opening at 10psi, but it turns out that when we disconnected it, it didnt beat 11psi. So the problem is the fuel.

We turned up the fuel to as high as we could so it would still idle. We turned the boost pin (which uses boost pressure to increase fueling) to the maximum level. After taking out all the slack from the cable, and adjusting the linkage to get maximum travel, it went significantly faster, and boost got up to 15psi. I think we will have to pull the accelerator linkage from inside the pump and modify it to allow more plunger travel (ie more fuel!!!). more info
I want enough fuel to be able to run 20psi once I have the intercooler on.

After all these changes, I noticed the fuel consumption rise from 4.8L/100ks to a guzzling 5.1L/100ks. Shocking..

I have a dead battery so I have been roll starting everywhere. Gotta fix that soon.

Cheers

Mike

[GoLfMan]

get some footage

[gldgti]

intercooler is IN. we spent sunday installing the biggest intercooler we could fit into the front of the car, and plumbing it in, along with replacing all the heavy guage wiring in the engine bay (the source of mikes starting issues) and sorting a couple of other minor issues.

the 'cooler is acting just as predicted - keeping the intake air nice and cold (evidenced by the really hot compressor outlet pipe but ambient temp engine inlet pipe after a run up the hill) but nateably throttle response is down a bit because of the increase in lag. even still, 3rd gear around a wet corner is tricky, because understeer comes on fast as the wheels break traction.

lets just say, LOTS of torque.

[oracle1]

handling with 1.9 block

did you find the heavier block changed the handling much?

[mollins]

i haven't noticed any difference to any other mk1 i have driven.

the block/turbo etc is only marginally heavier as far as I know.

with the intercooler added, my guess is that i have increased the total weight by 50kg.. ?

[gldgti]

PICS for people!!!

as promised, i finally got un-busy enough to upload some pics for you all - apologies for the quality, from my phone

heres the intercooler to be fitted


and heres the hole where it goes:


the intercooler is hung from the top by threaded rods from the bonnet slam panel, and sits on the radiator support/crossmember with rubber feet. its a 600mm wide cooler so it only just fits between the headlights once the hoses are on. the inlet/outlets are at the bottom, so exiting underneath the battery tray on the pass. side and out infront of the too-cool alternator setup on drivers side.


with the radiator in, the intercooler is sandwitched tight between the radiator and tha little steel bracket that goes between the slam panel and the rad support. note the clearance between the IC and the top panel, since the bonnet locking pin must protrude down so far.



finally, we finished off all the pipework. all the piping is 2" stainless steel with studded ends to prevent the hoses blowing off. otherwise, all the joiners are silicone. since the inlet/outlet of the IC are in 2.5", we used a flared stainless 2-2.5" pipe reducer to join onto them.
for neatness and ease of working on the car, we routed the return pipe back towards the brake booster out of hte way, rather than infront of everything. heres what we were left with:


i reckon it looks tops

[DarkRanger]

Sorry for bringin up an old thread. I think it looks tops! Well done!! Very neat mk1 you have there.

Keep up the good work.

Do you have any numbers? kw/hp, NM?