DC's 1756VK-assisted B4

Digital Corpus

Top Post Dawg
Joined
Mar 14, 2008
Location
Ontario, California
TDI
'97 B4 w/ 236K mi body, 46K mi soul
For current status/progress, click me!

A compiled chart of significant dynos I've run for this car:

  • Obviously, the "Base" tunes are my stock runs.
  • The ones from 2012 are in 3rd and 4th gears when the turbo and nozzles were first installed.
    • The 3rd gear pull is the lowest of the set where a heat soaked intercooler reduced my power output
  • In Just 2015, 12 dyno pulls were made for the Colt against the OE cam, 2 pulls each, with advancing and retarding the camshaft 2 flywheel teeth as well as standard mechanical timing.
    • I had assumed that the mid-to-high 90's that day as well as an IQ of ~6, vs an IQ of ~2 in 2012, resulted in 180-ish peak whp across the 12 dynos that day. Comparing to the 3rd gear of 2012, that seems to be the case.

The primary reason I decided to go this particular upgrade route was to minimize critical component fabrication. The parts I consider on this list are intercooler, intercooler piping, exhaust manifold, engine mounts, engine mount brackets, and even head bolts. Anything that can be purchased outright as a stock component, albeit from another VW/Audi/Brand, isn't considered such a component. The goal was to keep this simple and cost effective since I didn't want to dump $10K into the car nor break something in the process. So far, my most significant failure is a head gasket. Anything else I could do myself because it doesn't require precision machinery or a plethora of experience I've chosen to do, despite the time and associated learning curve. I think it pays off when you improve upon stock balance of piston & con rod weight differentials by an order of magnitude and your tuner tells you that your turbo is spooling faster than one two "sizes/stages" smaller than it.

I've taken the car down 4 times for completing performance related upgrades or repairs.

November 28th, 2012:
Mechanical work completed by BioChoppers with assistance from of a couple of friends, temporaptor, kooyajerms, swtlowtdi.
  • Rebuilt GTB1756VK, vacuum converted by RyanP, operating @ ~24-25 psi, ~1.7 bar during the initial dynos.
  • Adapter plate for turbo on AFN Manifold
  • AFN exhaust manifold - Though a BHW one from the US will work just fine.
  • 4-Bar replacement MAP sensor - PCB design & sensor links are in the post
  • Early MKIV N75 - The early MKIV N75, 1H0906627A, has a square electrical connector that plugs straight into the B4's harness. This used one proved to fail intermittently when warmed up, such as during the initial dynos.
  • 3-3.2 mm vane gap set by the stop screw.
  • Race 520 nozzles
  • DC Stage IV clutch replaced the planned SBC Stage II Endurance - It's a dual-sided feramic/sintered disk clutch plate, larger rivets, stronger support bolts for pressure plate, more robust pressure plate.
  • 14 lb Flywheel was installed along with the upgraded clutch.
  • Tiny little racepipe/hose adapter - Custom part made by JFettig.
  • Vacuum ball from an MKIV's - Not sure if it's needed, but it's not hurting things.
  • Tuning by Malone Tuning and TD Tuning.

Thanksgiving, 2013:
In order to drive the car without having to worry about exploding engine bits, a number of support mods were done in conjunction with the engine rebuild:

Late December 2014 to June 2015:
Misc changes and updates as I've learned more about how to have the car setup properly

November 2015 to April 2018:
  • Re-did vacuum system to support vaccum-actuated turbos. Response time rivals electronic actuators. This was accompanied by physically and electrically swapping the EGR & VNT solenoids (N75 & N18).
  • Started working on evaporative cooling for my intercooler.
  • Cleaned up the turbo a bit and made a spacer to remove mechanical slop in the ring system for the vanes. Still need to R&R the lever the actuator rod connects to.
  • Set screw set to create a 1.2 mm nominal vane gap.
  • Set screw being left at minimal opening or ~0.2 mm nominal.
  • Swapped out the thermistor in my IAT for a new one and adjusted the tune to match its characteristics after a touch of reverse engineering. It responds no less than 4x faster than stock.
  • IP tweaks, hacks, hybridization on hold until turbo & vacuum system is sorted.
  • 'Calibrated', i.e. lets average all test equipment I have, my boost and barometric pressure sensors and IAT sensor.
  • Tweaking the tune in small, appreciably nit-picky ways like playing with reduced start fuel, adjusting N75 Map, adjusting boost map, adjusting N75 PID characteristics.

May 2018 to Present:
  • Ordered new cage and vanes assembly for GTB1756VK
  • Set screw set to create a 1.1-1.2 mm nominal vane gap.
  • Installed new, faster EGT and developed a high(er) temporal resolution method of logging its data.
  • *Need* to relocate EGR probe from exhaust manifold collector to proximal to the vanes.
  • Commencement of the test-and-adjust self-tuning phase of vane control and EGT control.
  • Began modding Measuring Blocks for custom output like Volumetric Efficiency.


Photo Index
Not every photo is listed when there is a set of them in a single post, however the most significant will be in the Small and Large links.
ARL Pistons
Code:
[URL="http://forums.tdiclub.com/showpost.php?p=4355377"]Post[/URL]	[URL="http://forums.tdiclub.com/showthread.php?p=4341648#post4341648"]Post in Thread[/URL]
Unboxing	[URL="http://forums.tdiclub.com/showpost.php?p=4355377"]Small[/URL]	[URL="http://mobrienphoto.com/Misc-Pics/TDI-Pics/Strengthening/Pistons/_OB_9315-hi.jpg"]Large[/URL]
ARL balancing	[URL="http://mobrienphoto.com/Misc-Pics/TDI-Pics/Strengthening/Pistons/Removal-Top-low.jpg"]Small[/URL]	[URL="http://mobrienphoto.com/Misc-Pics/TDI-Pics/Strengthening/Pistons/Removal-Top-hi.jpg"]Large[/URL]	[URL="http://forums.tdiclub.com/showpost.php?p=4383955&postcount=1"]Post[/URL]	[URL="http://forums.tdiclub.com/showthread.php?p=4383955#post4383955"]Post in Thread[/URL]
Oil Squirter Adjustments
Code:
[URL="https://forums.tdiclub.com/showpost.php?p=4433192&postcount=235"]Post[/URL]	[URL="https://forums.tdiclub.com/showthread.php?p=4433192#post4433192"]Post in Thread[/URL]
Stock placement		[URL="http://mobrienphoto.com/Misc-Pics/TDI-Pics/Strengthening/Block/_OB_9607-low.jpg"]Small[/URL]	[URL="http://mobrienphoto.com/Misc-Pics/TDI-Pics/Strengthening/Block/_OB_9607-hi.jpg"]Large[/URL]
Adjusted		[URL="http://mobrienphoto.com/Misc-Pics/TDI-Pics/Strengthening/Block/_OB_9586-low.jpg"]Small[/URL]	[URL="http://mobrienphoto.com/Misc-Pics/TDI-Pics/Strengthening/Block/_OB_9586-hi.jpg"]Large[/URL]
Rods & Bottom end
Code:
I.E. Tuscan Rods		[URL="http://mobrienphoto.com/Misc-Pics/TDI-Pics/Strengthening/Block/_OB_9323-low.jpg"]Small[/URL]	[URL="http://mobrienphoto.com/Misc-Pics/TDI-Pics/Strengthening/Block/_OB_9323-hi.jpg"]Large[/URL]	[URL="https://forums.tdiclub.com/showpost.php?p=4355376&postcount=83"]Post[/URL]	[URL="https://forums.tdiclub.com/showthread.php?p=4355376#post4355376"]Post in Thread[/URL]
Pistons + Rods			[URL="http://mobrienphoto.com/Misc-Pics/TDI-Pics/Strengthening/Pistons/_OB_9562---enfuse-0.45-0.25-low.jpg"]Small[/URL]	[URL="http://mobrienphoto.com/Misc-Pics/TDI-Pics/Strengthening/Pistons/_OB_9562---enfuse-0.45-0.25-hi.jpg"]Large[/URL]
ARL in 1Z block			[URL="http://mobrienphotography.com/Misc-Pics/TDI-Pics/Strengthening/Block/_OB_9818---enfuse-0.55-0.4-low.jpg"]Small[/URL]	[URL="http://mobrienphotography.com/Misc-Pics/TDI-Pics/Strengthening/Block/_OB_9818---enfuse-0.55-0.4-hi.jpg"]Large[/URL]	[URL="https://forums.tdiclub.com/showpost.php?p=4420360&postcount=198"]Post[/URL]	[URL="https://forums.tdiclub.com/showthread.php?p=4420360#post4420360"]Post in Thread[/URL]
Botton end installed		[URL="http://mobrienphotography.com/Misc-Pics/TDI-Pics/Strengthening/Block/_OB_9811-low.jpg"]Small[/URL]	[URL="http://mobrienphotography.com/Misc-Pics/TDI-Pics/Strengthening/Block/_OB_9811-hi.jpg"]Large[/URL]
Adjustment to Head
Code:
[URL="https://forums.tdiclub.com/showpost.php?p=4798138&postcount=295"]Post[/URL]	[URL="https://forums.tdiclub.com/showthread.php?p=4798138#post4798138"]Post in Thread[/URL]
Old vs New		[URL="http://mobrienphoto.com/Misc-Pics/TDI-Pics/Strengthening/Head/_OB_8610-low.jpg"]Small[/URL]	[URL="http://mobrienphoto.com/Misc-Pics/TDI-Pics/Strengthening/Head/_OB_8610-hi.jpg"]Large[/URL]
Bowled old washer	[URL="http://mobrienphoto.com/Misc-Pics/TDI-Pics/Strengthening/Head/_OB_8639-low.jpg"]Small[/URL]	[URL="http://mobrienphoto.com/Misc-Pics/TDI-Pics/Strengthening/Head/_OB_8639-hi.jpg"]Large[/URL]
New Bolt & washer	[URL="http://mobrienphoto.com/Misc-Pics/TDI-Pics/Strengthening/Head/_OB_8710-low.jpg"]Small[/URL]	[URL="http://mobrienphoto.com/Misc-Pics/TDI-Pics/Strengthening/Head/_OB_8710-hi.jpg"]Large[/URL]
Installation		[URL="http://mobrienphoto.com/Misc-Pics/TDI-Pics/Strengthening/Head/_OB_8713-low.jpg"]Small[/URL]	[URL="http://mobrienphoto.com/Misc-Pics/TDI-Pics/Strengthening/Head/_OB_8713-hi.jpg"]Large[/URL]
Coated Head Gasket	[URL="http://mobrienphoto.com/Misc-Pics/TDI-Pics/Strengthening/Head/_OB_8700-low.jpg"]Small[/URL]	[URL="http://mobrienphoto.com/Misc-Pics/TDI-Pics/Strengthening/Head/_OB_8700-hi.jpg"]Large[/URL]
AFN Exhaust Manifold
Code:
[URL="https://forums.tdiclub.com/showpost.php?p=4040204&postcount=3"]Post[/URL]	[URL="https://forums.tdiclub.com/showthread.php?p=4040204#post4040204"]Post in Thread[/URL]
Bottom			[URL="http://pics.tdiclub.com/data/5768/medium/MG_5586-hi.jpg"]Small[/URL]	[URL="http://pics.tdiclub.com/data/5768/MG_5586-hi.jpg"]Large[/URL]
Closeup - PN		[URL="http://pics.tdiclub.com/data/5768/medium/MG_5591-hi.jpg"]Small[/URL]	[URL="http://pics.tdiclub.com/data/5768/MG_5591-hi.jpg"]Large[/URL]
Closeup - EGR		[URL="http://pics.tdiclub.com/data/5768/medium/MG_5594-hi.jpg"]Small[/URL]	[URL="http://pics.tdiclub.com/data/5768/MG_5594-hi.jpg"]Large[/URL]
Closeup - right		[URL="http://pics.tdiclub.com/data/5768/medium/MG_5596-hi.jpg"]Small[/URL]	[URL="http://pics.tdiclub.com/data/5768/medium/MG_5596-hi.jpg"]Large[/URL]
Closeup - left		[URL="http://pics.tdiclub.com/data/5768/medium/MG_5597-hi.jpg"]Small[/URL]	[URL="http://pics.tdiclub.com/data/5768/MG_5597-hi.jpg"]Large[/URL]
Engine & Subframe removed
Code:
[URL="https://forums.tdiclub.com/showpost.php?p=4358916&postcount=101"]Post[/URL]	[URL="https://forums.tdiclub.com/showthread.php?p=4358916#post4358916"]Post in Thread[/URL]
Engine Bay			[URL="http://mobrienphoto.com/Misc-Pics/TDI-Pics/Disassembly/_OB_9346-low.jpg"]Small[/URL]	[URL="http://mobrienphoto.com/Misc-Pics/TDI-Pics/Disassembly/_OB_9346-hi.jpg"]Large[/URL]
Front of ‘stock’ engine		[URL="http://mobrienphoto.com/Misc-Pics/TDI-Pics/Disassembly/_OB_9341-low.jpg"]Small[/URL]	[URL="http://mobrienphoto.com/Misc-Pics/TDI-Pics/Disassembly/_OB_9341-hi.jpg"]Large[/URL]
Back of ‘stock’ engine		[URL="http://mobrienphoto.com/Misc-Pics/TDI-Pics/Disassembly/_OB_9339-low.jpg"]Small[/URL]	[URL="http://mobrienphoto.com/Misc-Pics/TDI-Pics/Disassembly/_OB_9339-hi.jpg"]Large[/URL]
Initial GTB1756VK setup
Code:
[URL="https://forums.tdiclub.com/showpost.php?p=4358917&postcount=102"]Post[/URL]	[URL="https://forums.tdiclub.com/showthread.php?p=4358917#post4358917"]Post in Thread[/URL]
Return line leak	[URL="http://mobrienphoto.com/Misc-Pics/TDI-Pics/Disassembly/_OB_9331-low.jpg"]Small[/URL]	[URL="http://mobrienphoto.com/Misc-Pics/TDI-Pics/Disassembly/_OB_9331-hi.jpg"]Large[/URL]
Oily mess		[URL="http://mobrienphoto.com/Misc-Pics/TDI-Pics/Disassembly/_OB_9368-low.jpg"]Small[/URL]	[URL="http://mobrienphoto.com/Misc-Pics/TDI-Pics/Disassembly/_OB_9368-hi.jpg"]Large[/URL]
GTB heatsheild stub	[URL="http://mobrienphoto.com/Misc-Pics/TDI-Pics/Disassembly/_OB_9385-low.jpg"]Small[/URL]	[URL="http://mobrienphoto.com/Misc-Pics/TDI-Pics/Disassembly/_OB_9385-hi.jpg"]Large[/URL]
Analysis of Stock Pistons
Code:
[URL="https://forums.tdiclub.com/showpost.php?p=4360551&postcount=109"]Post[/URL]	[URL="https://forums.tdiclub.com/showthread.php?p=4360551#post4360551"]Post in Thread[/URL]
"Fresh" stock pistons	[URL="http://mobrienphoto.com/Misc-Pics/TDI-Pics/Disassembly/_OB_9422-low.jpg"]Small[/URL]	[URL="http://mobrienphoto.com/Misc-Pics/TDI-Pics/Disassembly/_OB_9422-hi.jpg"]Large[/URL]
Piston 1 in block	[URL="http://mobrienphoto.com/Misc-Pics/TDI-Pics/Disassembly/_OB_9402-low.jpg"]Small[/URL]	[URL="http://mobrienphoto.com/Misc-Pics/TDI-Pics/Disassembly/_OB_9402-hi.jpg"]Large[/URL]
Piston 2 in block	[URL="http://mobrienphoto.com/Misc-Pics/TDI-Pics/Disassembly/_OB_9398-low.jpg"]Small[/URL]	[URL="http://mobrienphoto.com/Misc-Pics/TDI-Pics/Disassembly/_OB_9398-hi.jpg"]Large[/URL]
Piston 3 in block	[URL="http://mobrienphoto.com/Misc-Pics/TDI-Pics/Disassembly/_OB_9397-low.jpg"]Small[/URL]	[URL="http://mobrienphoto.com/Misc-Pics/TDI-Pics/Disassembly/_OB_9397-hi.jpg"]Large[/URL]
Piston 4 in block	[URL="http://mobrienphoto.com/Misc-Pics/TDI-Pics/Disassembly/_OB_9396-low.jpg"]Small[/URL]	[URL="http://mobrienphoto.com/Misc-Pics/TDI-Pics/Disassembly/_OB_9396-hi.jpg"]Large[/URL]
Compressor Wheel Digestion
Code:
[URL="https://forums.tdiclub.com/showpost.php?p=4360555&postcount=111"]Post[/URL]	[URL="https://forums.tdiclub.com/showthread.php?p=4360555#post4360555"]Post in Thread[/URL]
All 4			[URL="http://mobrienphoto.com/Misc-Pics/TDI-Pics/Disassembly/_OB_9414-low.jpg"]Small[/URL]	[URL="http://mobrienphoto.com/Misc-Pics/TDI-Pics/Disassembly/_OB_9414-hi.jpg"]Large[/URL]
Hash of cylinder 4	[URL="http://mobrienphoto.com/Misc-Pics/TDI-Pics/Disassembly/_OB_9393-low.jpg"]Small[/URL]	[URL="http://mobrienphoto.com/Misc-Pics/TDI-Pics/Disassembly/_OB_9393-hi.jpg"]Large[/URL]
Cylinder 1		[URL="http://mobrienphoto.com/Misc-Pics/TDI-Pics/Disassembly/_OB_9400-low.jpg"]Small[/URL]	[URL="http://mobrienphoto.com/Misc-Pics/TDI-Pics/Disassembly/_OB_9400-hi.jpg"]Large[/URL]
Cylinder 2		[URL="http://mobrienphoto.com/Misc-Pics/TDI-Pics/Disassembly/_OB_9403-low.jpg"]Small[/URL]	[URL="http://mobrienphoto.com/Misc-Pics/TDI-Pics/Disassembly/_OB_9403-hi.jpg"]Large[/URL]
Cylinder 3 - No photos
Cylinder 4		[URL="http://mobrienphoto.com/Misc-Pics/TDI-Pics/Disassembly/_OB_9394-low.jpg"]Small[/URL]	[URL="http://mobrienphoto.com/Misc-Pics/TDI-Pics/Disassembly/_OB_9394-hi.jpg"]Large[/URL]
Old Internals
Code:
[URL="https://forums.tdiclub.com/showpost.php?p=4361880&postcount=132"]Post[/URL]	[URL="https://forums.tdiclub.com/showthread.php?p=4361880#post4361880"]Post in Thread[/URL]
Pistons + Rods	[URL="http://mobrienphoto.com/Misc-Pics/TDI-Pics/Disassembly/_OB_9437-low.jpg"]Small[/URL]	[URL="http://mobrienphoto.com/Misc-Pics/TDI-Pics/Disassembly/_OB_9437-hi.jpg"]Large[/URL]
Piston 1	[URL="http://mobrienphoto.com/Misc-Pics/TDI-Pics/Disassembly/_OB_9454-low.jpg"]Small[/URL]	[URL="http://mobrienphoto.com/Misc-Pics/TDI-Pics/Disassembly/_OB_9454-hi.jpg"]Large[/URL]	
Piston 2	[URL="http://mobrienphoto.com/Misc-Pics/TDI-Pics/Disassembly/_OB_9455-low.jpg"]Small[/URL]	[URL="http://mobrienphoto.com/Misc-Pics/TDI-Pics/Disassembly/_OB_9455-hi.jpg"]Large[/URL]
Piston 3	[URL="http://mobrienphoto.com/Misc-Pics/TDI-Pics/Disassembly/_OB_9456-low.jpg"]Small[/URL]	[URL="http://mobrienphoto.com/Misc-Pics/TDI-Pics/Disassembly/_OB_9456-hi.jpg"]Large[/URL]
Piston 4	[URL="http://mobrienphoto.com/Misc-Pics/TDI-Pics/Disassembly/_OB_9457-low.jpg"]Small[/URL]	[URL="http://mobrienphoto.com/Misc-Pics/TDI-Pics/Disassembly/_OB_9457-hi.jpg"]Large[/URL]
Original Lifters
Code:
[URL="https://forums.tdiclub.com/showpost.php?p=4361944&postcount=134"]Post[/URL]	[URL="https://forums.tdiclub.com/showthread.php?p=4361944#post4361944"]Post in Thread[/URL]
Cylinder 1		[URL="http://mobrienphoto.com/Misc-Pics/TDI-Pics/Disassembly/_OB_9429-low.jpg"]Small[/URL]	[URL="http://mobrienphoto.com/Misc-Pics/TDI-Pics/Disassembly/_OB_9429-hi.jpg"]Large[/URL]
Cylinder 2		[URL="http://mobrienphoto.com/Misc-Pics/TDI-Pics/Disassembly/_OB_9430-low.jpg"]Small[/URL]	[URL="http://mobrienphoto.com/Misc-Pics/TDI-Pics/Disassembly/_OB_9430-hi.jpg"]Large[/URL]
Cylinder 3		[URL="http://mobrienphoto.com/Misc-Pics/TDI-Pics/Disassembly/_OB_9431-low.jpg"]Small[/URL]	[URL="http://mobrienphoto.com/Misc-Pics/TDI-Pics/Disassembly/_OB_9431-hi.jpg"]Large[/URL]
Cylinder 4		[URL="http://mobrienphoto.com/Misc-Pics/TDI-Pics/Disassembly/_OB_9434-low.jpg"]Small[/URL]	[URL="http://mobrienphoto.com/Misc-Pics/TDI-Pics/Disassembly/_OB_9434-hi.jpg"]Large[/URL]
Intake Cyl 4 Cam	[URL="http://mobrienphoto.com/Misc-Pics/TDI-Pics/Disassembly/_OB_9463-low.jpg"]Small[/URL]	[URL="http://mobrienphoto.com/Misc-Pics/TDI-Pics/Disassembly/_OB_9463-hi.jpg"]Large[/URL]
Connecting Rod Bearings
Code:
[URL="https://forums.tdiclub.com/showpost.php?p=4361954&postcount=136"]Post[/URL]	[URL="https://forums.tdiclub.com/showthread.php?p=4361954#post4361954"]Post in Thread[/URL]
Top Bearings		[URL="http://mobrienphoto.com/Misc-Pics/TDI-Pics/Disassembly/_OB_9470-low.jpg"]Small[/URL]	[URL="http://mobrienphoto.com/Misc-Pics/TDI-Pics/Disassembly/_OB_9470-hi.jpg"]Large[/URL]
Bottom Bearings		[URL="http://mobrienphoto.com/Misc-Pics/TDI-Pics/Disassembly/_OB_9477-low.jpg"]Small[/URL]	[URL="http://mobrienphoto.com/Misc-Pics/TDI-Pics/Disassembly/_OB_9477-hi.jpg"]Large[/URL]
AFN Exhaust Manifold
Code:
[URL="https://forums.tdiclub.com/showpost.php?p=4364194&postcount=146"]Post[/URL]	[URL="https://forums.tdiclub.com/showthread.php?p=4364194#post4364194"]Post in Thread[/URL]
Bad turbo sealing	[URL="http://mobrienphoto.com/Misc-Pics/TDI-Pics/Strengthening/Porting/_OB_9484-low.jpg"]Small[/URL]	[URL="http://mobrienphoto.com/Misc-Pics/TDI-Pics/Strengthening/Porting/_OB_9484-hi.jpg"]Large[/URL]
AFN E.M. nub		[URL="http://mobrienphoto.com/Misc-Pics/TDI-Pics/Strengthening/Porting/_OB_9486-low.jpg"]Small[/URL]	[URL="http://mobrienphoto.com/Misc-Pics/TDI-Pics/Strengthening/Porting/_OB_9486-hi.jpg"]Large[/URL]
AFN port matching	[URL="http://mobrienphoto.com/Misc-Pics/TDI-Pics/Strengthening/Porting/_OB_9498-low.jpg"]Small[/URL]	[URL="http://mobrienphoto.com/Misc-Pics/TDI-Pics/Strengthening/Porting/_OB_9498-hi.jpg"]Large[/URL]
AFN EGR lip delete	[URL="http://mobrienphoto.com/Misc-Pics/TDI-Pics/Strengthening/Porting/_OB_9504-low.jpg"]Small[/URL]	[URL="http://mobrienphoto.com/Misc-Pics/TDI-Pics/Strengthening/Porting/_OB_9504-hi.jpg"]Large[/URL]
GTB port matching	[URL="http://mobrienphoto.com/Misc-Pics/TDI-Pics/Strengthening/Porting/_OB_9496-low.jpg"]Small[/URL]	[URL="http://mobrienphoto.com/Misc-Pics/TDI-Pics/Strengthening/Porting/_OB_9496-hi.jpg"]Large[/URL]
GTB 1756VK hotside
Code:
[URL="https://forums.tdiclub.com/showpost.php?p=4364196&postcount=147"]Post[/URL]	[URL="https://forums.tdiclub.com/showthread.php?p=4364196#post4364196"]Post in Thread[/URL]
1st pass w/ carbide	[URL="http://mobrienphoto.com/Misc-Pics/TDI-Pics/Strengthening/Porting/IMG_1427-low.jpg"]Small[/URL]	[URL="http://mobrienphoto.com/Misc-Pics/TDI-Pics/Strengthening/Porting/IMG_1427-hi.jpg"]Large[/URL]
Depth notches		[URL="http://mobrienphoto.com/Misc-Pics/TDI-Pics/Strengthening/Porting/_OB_9525-low.jpg"]Small[/URL]	[URL="http://mobrienphoto.com/Misc-Pics/TDI-Pics/Strengthening/Porting/_OB_9525-hi.jpg"]Large[/URL]
Final result		[URL="http://mobrienphoto.com/Misc-Pics/TDI-Pics/Strengthening/Porting/_OB_9530-low.jpg"]Small[/URL]	[URL="http://mobrienphoto.com/Misc-Pics/TDI-Pics/Strengthening/Porting/_OB_9530-low.jpg"]Large[/URL]
Minor Head Porting
Code:
[URL="https://forums.tdiclub.com/showpost.php?p=4398070&postcount=164"]Post[/URL]	[URL="https://forums.tdiclub.com/showthread.php?p=4398070#post4398070"]Post in Thread[/URL]
Stock head			[URL="http://mobrienphoto.com/Misc-Pics/TDI-Pics/Disassembly/_OB_9405-low.jpg"]Small[/URL]	[URL="http://mobrienphoto.com/Misc-Pics/TDI-Pics/Disassembly/_OB_9405-hi.jpg"]Large[/URL]	[URL="https://forums.tdiclub.com/showpost.php?p=4360593&postcount=119"]Post[/URL]	[URL="https://forums.tdiclub.com/showthread.php?p=4360593#post4360593"]Post in Thread[/URL]
Strapped down			[URL="http://mobrienphoto.com/Misc-Pics/TDI-Pics/Strengthening/Head/_OB_9581-low.jpg"]Small[/URL]	[URL="http://mobrienphoto.com/Misc-Pics/TDI-Pics/Strengthening/Head/_OB_9581-hi.jpg"]Large[/URL]
Before vs After			[URL="http://mobrienphoto.com/Misc-Pics/TDI-Pics/Strengthening/Head/_OB_9578-low.jpg"]Small[/URL]	[URL="http://mobrienphoto.com/Misc-Pics/TDI-Pics/Strengthening/Head/_OB_9578-hi.jpg"]Large[/URL]
Cyl 1 exhaust final		[URL="http://mobrienphoto.com/Misc-Pics/TDI-Pics/Strengthening/Head/_OB_9629-low.jpg"]Small[/URL]	[URL="http://mobrienphoto.com/Misc-Pics/TDI-Pics/Strengthening/Head/_OB_9629-hi.jpg"]Large[/URL]
Cyl 2 exhaust final		[URL="http://mobrienphoto.com/Misc-Pics/TDI-Pics/Strengthening/Head/_OB_9631-low.jpg"]Small[/URL]	[URL="http://mobrienphoto.com/Misc-Pics/TDI-Pics/Strengthening/Head/_OB_9631-hi.jpg"]Large[/URL]
Cyl 3 exhaust final		[URL="http://mobrienphoto.com/Misc-Pics/TDI-Pics/Strengthening/Head/_OB_9637-low.jpg"]Small[/URL]	[URL="http://mobrienphoto.com/Misc-Pics/TDI-Pics/Strengthening/Head/_OB_9637-hi.jpg"]Large[/URL]
Cyl 4 exhaust final		[URL="http://mobrienphoto.com/Misc-Pics/TDI-Pics/Strengthening/Head/_OB_9638-low.jpg"]Small[/URL]	[URL="http://mobrienphoto.com/Misc-Pics/TDI-Pics/Strengthening/Head/_OB_9638-hi.jpg"]Large[/URL]
Nitride coated VW lifters	[URL="http://mobrienphoto.com/Misc-Pics/TDI-Pics/Strengthening/Head/_OB_9318-low.jpg"]Small[/URL]	[URL="http://mobrienphoto.com/Misc-Pics/TDI-Pics/Strengthening/Head/_OB_9318-hi.jpg"]Large[/URL]	[URL="https://forums.tdiclub.com/showpost.php?p=4342262&postcount=82"]Post[/URL]	[URL="https://forums.tdiclub.com/showthread.php?p=4342262#post4342262"]Post in Thread[/URL]
Transmission Modification
Code:
[URL="https://forums.tdiclub.com/showpost.php?p=4699679&postcount=271"]Post[/URL]	[URL="https://forums.tdiclub.com/showthread.php?p=4699679#post4699679"]Post in Thread[/URL]
5th gear holes			[URL="http://mobrienphotography.com/Misc-Pics/TDI-Pics/Strengthening/Assembly/_OB_9965---enfuse-0.3-0.35-low.jpg"]Small[/URL]	[URL="http://mobrienphotography.com/Misc-Pics/TDI-Pics/Strengthening/Assembly/_OB_9965---enfuse-0.3-0.35-hi.jpg"]Large[/URL]
Reinforced clutch release	[URL="http://mobrienphotography.com/Misc-Pics/TDI-Pics/Turbo/GTB1756/_OB_7924-low.jpg"]Small[/URL]	[URL="http://mobrienphotography.com/Misc-Pics/TDI-Pics/Turbo/GTB1756/_OB_7924-hi.jpg"]Large[/URL]
Pinion brace			[URL="http://mobrienphotography.com/Misc-Pics/TDI-Pics/Turbo/GTB1756/_OB_7943%20-%20enfuse%202-low.jpg"]Small[/URL]	[URL="http://mobrienphotography.com/Misc-Pics/TDI-Pics/Turbo/GTB1756/_OB_7943%20-%20enfuse%202-hi.jpg"]Large[/URL]
Additional Modifications
Code:
Coming soon			
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Vacuum layout			
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	[URL=""]Post in Thread[/URL]
Mini racepipe & 2-stroke downpipe
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	[URL=""]Post in Thread[/URL]
2-stroke downpipe		
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Mini racepipe w/ JB weld lip	
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Digital Corpus

Top Post Dawg
Joined
Mar 14, 2008
Location
Ontario, California
TDI
'97 B4 w/ 236K mi body, 46K mi soul
That protruding dent if from the turbine of the old turbo








<BREAK!!!>​

Forgot about these glory shots of the exhaust manifold after I baked it to remove any moisture before painting it. Mind you I wire-wheeled the whole thing to remove all the rust I could. Anyone know enough to know why it was shiny as a result? If memory serves, It was in the over for ~3 hrs @ ~300˚F.


Part number shot:






 
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Digital Corpus

Top Post Dawg
Joined
Mar 14, 2008
Location
Ontario, California
TDI
'97 B4 w/ 236K mi body, 46K mi soul
Preview cell phone pics:




Before everything was welded up


Look at the picture above, needed Dry ice to get the collar on the left-most pipe:


This be my new baby:


Installed!


Firewall clearance (I'll update with a better focused photo soon):


Steering rack clearance is now easily adjustable:
 
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Digital Corpus

Top Post Dawg
Joined
Mar 14, 2008
Location
Ontario, California
TDI
'97 B4 w/ 236K mi body, 46K mi soul
At the time I was looking into this, about 2 years ago, the only options I had for upgrades that were bolt on were the K03/K04 turbos or maybe the occasional 17/22. In order to use something different, I'd have to use a different manifold. Based on placement of the turbo and not wanting to go with a tubular manifold, I came across the AFN one. It was cheaper, $180, than the any of those motor mounts, $250, and I had no problem taking my time to get a hold of one. Also meant that I wouldn't have to worry about it's structural integrity of the mount at all.
 

swtlowtdi

Well-known member
Joined
Apr 10, 2012
Location
Mira Loma, California
TDI
2013 Golf 6M
Im waiting for pics michael. Comon man. Dont keep us waiting. Lol. :). I kinda like the EM you chose. But i want a tube EM. But i like the outcome of the car. Need to get the exhaust finished. Lol
 

mrchill

TDIClub Enthusiast, Super Secret Diesel Ninja Vend
Joined
Sep 16, 2003
Location
MASS! home of THE WORLD SERIES CHAMPION RED SOX! x
TDI
96 B4v red \ 98 Mk3 green\98 Mk3 Jetta black\ 99 Mk4 Jetta green x2\ 99 Mk4 Golf silver x2\ 99 Mk4 Jetta black\ 97 B4 sedan green\04 JSW gold\03 JSW silver
The mounts are fine when modified. But anyway...the choice you made was still good. Although the AFN manifold is a little restrictive...it works ok.
 

ryanp

Vendor
Joined
Jun 22, 2008
Location
Barnsley, South Yorkshire, UK
TDI
Arosa CR - 550hp - 9.7 @ 150mph 1/4 Mile, Citigo 4x4 CR TDi - 340hp, Caddy 2.0 CR 4x4 TDI - 300+hp, Golf Mk2 Van 1.9 TDI - was 290hp, Mk5 Ibiza 2.0 FR TDi - 270hp, BMW 135d - 360hp, BMW 330d - 335hp, BMW 335d - 380hp + a few more ........
I'd get shut of the boost valve and let a tune do the work, if its set up properly (which it should be by now) its another thing to mess up!

If anyone needs the wiring connectors and a pig tail for the N75 i have lots of TDI looms to chop them from.

Will be nice once you have an excess of fuel and see what it will do!
 

Digital Corpus

Top Post Dawg
Joined
Mar 14, 2008
Location
Ontario, California
TDI
'97 B4 w/ 236K mi body, 46K mi soul
Yeah, I'm late on photos. It took me 4 days to get logs to my tuner :\. Sorry all, but vacation has beckoned and I've been trying to relax, but also fix a bit of an overboost problem on the sister-in-law's '01 Jetta. I've 'donated' my valve to the cause actually and was actually planning on doing just that Ryan ;). A replacement BV should arrive on the 31st or the 1st with any luck.

I'll have a Win7 compatible, native USB, PLCC32 programmer in my hands in about a week and a half and will start up the tweaking of the tune as long as schedules align.
 
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Digital Corpus

Top Post Dawg
Joined
Mar 14, 2008
Location
Ontario, California
TDI
'97 B4 w/ 236K mi body, 46K mi soul
For the record, I'm a bit of a nerd/technologist as well as a photographer. After talking about it for several years I finally picked up a Canon 7D. If anyone here knows of indie DSLR video, then you've most likely heard of Magic Lantern. Back in October, an alpha build was released for the 7D. Back on Sunday, the 2nd alpha was released. Especially because it's not exclusively for video, I've been digging around with with which takes up a bit of my time.

Who was it who said that there is only room in life for one great passion? For the past 2 years I've had TDI's, photography, videography, PCB design, and product design all happening in some form or another. I wish I didn't need sleep :D
 

Digital Corpus

Top Post Dawg
Joined
Mar 14, 2008
Location
Ontario, California
TDI
'97 B4 w/ 236K mi body, 46K mi soul
No. The top part of the flange has 2 bolt holes. But only 1 of them gets used. All 3 studs are in.
<image snip>
Two comments:

Hex bolts from the turbo to the manifold is asking for grief - change them out before they rust.

Is the topmost downpipe stud missing?
Thanks for the like on the photos. I'm loving new tech to make things easier to see. Except the entire engine bay shot, I only used the shop light in the photos for illumination, which means I had very little light.

I'll check on the hardware since it was supplied with the adapter plate. Any suggestions on hardness and finish?

As swtlowtdi noted, that is an extra hole. It was a flange that fits more than one turbo. Tonight I believe I have time to remove some piping and get cleaner/clearer shots.

It's not fully apparent from the above shots, but the clearence on the downpipe with the firewall and with the heatshield is not completely acceptable to me. Don't get me wrong, that DP works **really** well. However, it's not in a position that I'd consider is good for long term maintainability. I'm bumping this up to my #1 priority to fix, and engine mounts & IC piping a close second. There is room in the egine bay for this, look at the under the turbo shot, and I have the tools to work on cutting and fine tuning the parts. Just need the time.

I also noticed that I missed 2 parts in my list: The pipe from the air box is not stock for the B4, and the TIP is from a PD 130 is memory serves. I'll pull part numbers after getting home.
 
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BioChoppers

Vendor
Joined
Aug 8, 2007
Location
Whittier, California
TDI
2003 jetta 5spd wagon
Digital Corpus said:
It's not fully apparent from the above shots, but the clearence on the downpipe with the firewall and with the heatshield is not completely acceptable to me. Don't get me wrong, that DP works **really** well. However, it's not in a position that I'd consider is good for long term maintainability.
It was never meant to be permanent Michael you know that…

http://forums.tdiclub.com/showthread.php?t=334460&page=5

Digital Corpus said:
Okay, based on what we're seeing right now my peak boost is about 25 PSI @ 2700 RPM. Injection pump timing is slightly below center line with adaption set to be a bit retarded to avoid just that, bent internals.

Running a 4 Bar sensor as JFettig had mentioned. The clutch was upped to a DC Stage iV with a 14 lb flywheel which has absolutely no chatter in idle. The downpipe is currently a prototype but holding together very well and it's design will continue on into the final setup once we hammer everything out. I don't know the precise OD it goes to but is flares out to 4-4.5" and then comes back to 3", does a 90˚ bend, and have about 6-8 " of 3" pipe before dumping to atmo. Currently we're a little crazy with the IC piping, but It Works. Except for tuning, I won't be lashing it else I will be getting speeding tickets left and right.

I made from a Yamaha YX80 exhaust. I’ve wanted to try it for a while now. An accelerated down pipe inspired me a-long time ago by StingrayRT.
http://forums.tdiclub.com/showthread.php?t=186239&highlight=accelerated&page=4

It's actually 4.2 " at the largest diameter.




It even still has the federal off road motorcycle disclaimer LOL!


Digital Corpus said:
Scott, Jeremy, and Greg spent a massive amount of work, culmination of about 3.5 days to get everything built and together and running. For two days we had a bit of rain. Sprinkles to light rain by what the rest of the nation knows, but working in the cold while raining is still unpleasant to say the least. If it wasn't for their dedication, we wouldn't have gotten it together. There are variations of stock IC piping are used, but it's not final and things are holding together very well. Everything was down to the line and we barely got the car together and to the shop and GTG on time.

Thanks for your guys help on this. Jeremy [FONT=&quot](kooyajerms) [/FONT]was up all night and installed the clutch. Greg [FONT=&quot](swtlowtdi) [/FONT]helped me with the turbo from 8p.m. until 10:00a.m. the next morning of the dyno…

john.jackson9213 said:
For a car you just got running about 1:00 p.m. to be pushing out that much power two hours later on the dyno is FANTASTIC.
Thanks John!


Digital Corpus said:
I ditched the 17/22 (just shipped it out today) in favor of a 1756vk. Couple reasons why, my builder convinced me to is one. It requires a bit less work to get it ready to go on the car with the downpipe and such. It's specs according to ryanp's site put the full boost in at a lower RPM range which is closer to where I drive, and I was able to get it at a reasonable price as well.
BTW Hey Ryan, I owe you a major apology….
 
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Digital Corpus

Top Post Dawg
Joined
Mar 14, 2008
Location
Ontario, California
TDI
'97 B4 w/ 236K mi body, 46K mi soul
I think I've found the components I need to setting up the new DP. It'll be a partial corkscrew in order to maintain clearance. I will re-do it with a small 1/2" to 1" strait pipe coming off the flange and then go into a cone or V-Band mount into a cone flaring out to 4", moving then towards the engine and angling to the passenger's side, and continuing the spiral to point it to the rear of the car and out the middle. I've only been looking at fab parts for about an hour, but that's the rough plan. I know I'll have to taper it back to 2.5", but that's a part of letting the plan simmer while I work on other stuff...

I'll need:
1.5" to 3" transition
3" to 5" transition
Maybe 2 of these:60˚ Mandrel bent 4" OD, 5" radius
90˚ Mandrel bent 4" OD, 4" radius

I'm open to suggestions if you guys know fo better parts.
 

Fix_Until_Broke

Top Post Dawg
Joined
Aug 8, 2004
Location
Menomonee Falls, Wisconsin, USA
TDI
03 Jetta, 03 TT TDI
I saw that and figured they were trying to do some sort of 2 stroke expansion chamber or something like that.

From someone who has put a 3" downpipe and 4" from the dp all the way back - don't do it unless you like a challange.

A 3" will be more than big enough and much easier to fit/fabricate.
 

Digital Corpus

Top Post Dawg
Joined
Mar 14, 2008
Location
Ontario, California
TDI
'97 B4 w/ 236K mi body, 46K mi soul
The premise was just for an expansion chamber. If that provides no benefit, though I understand how it can help, then I'll keep it simple and just do 2.5" on the rebuild. The rest of the exhaust will be 2.5"
 

vwmikel

Vendor , w/Business number
Joined
May 5, 2005
Location
Las Vegas, NV
TDI
'94 Golf Sport TDI
Using the cone for the downpipe would be great, but there's no way you're going to get a tight enough radius. That dirtbike pipe is actually a good idea as it's two stamped pieces welded together to form that radius. I'd just cut it and reweld it to fit. Should be simple enough.
 

Digital Corpus

Top Post Dawg
Joined
Mar 14, 2008
Location
Ontario, California
TDI
'97 B4 w/ 236K mi body, 46K mi soul
Thanks for the tips guys. I have a cutoff wheel so we'll see.

My next concern is the IC piping. Would it be simpler to by aluminum pipe with a bead, or find a local shop with a mandrel to bead the pipe that I cut to length?
 

storx

Veteran Member
Joined
Jan 16, 2006
Location
Earth!!
TDI
2009 Jetta CR140, 2010 Corvette Z06
i bought all my pipe from siliconeintakesystems.com ... i get everything at wholesale from them so it makes for a cheap custom exhuast
 

Digital Corpus

Top Post Dawg
Joined
Mar 14, 2008
Location
Ontario, California
TDI
'97 B4 w/ 236K mi body, 46K mi soul
Okay, so cones/transisions, have been a difficult one to find. After re-examining the existing DP, I'm going to have to put a new cone on because there isn't enough material after I cut it. I've tried locating them, but they are hard to come by for an inexpensive price.

I've tried woolf aircraft, mandrel-bends, jegs, amazon, and google. Any other places I can have a look at?
 
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