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TDI Power Enhancements Discussions about increasing the power of your TDI engine. i.e. chips, injectors, powerboxes, clutches, etc. Handling, suspensions, wheels, type discussion should be put into the "Upgrades (non TDI Engine related)" forum. Non TDI vehicle related postings will be moved or removed. Please note the Performance Disclaimer.

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Old September 12th, 2017, 04:02   #916
TDIsyncro
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I think they got 40x hp on diesel only which is a great result anyway.
This is a 2.0 pd with new turbo testing now, did 394hp on a reputable dyno
Car ran 11.6s on diesel only, 10.6s with nos
With little tweaking of the turbo it should be good for 400+hp
See dyno
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Nice numbers on Pd!
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Old September 12th, 2017, 04:24   #917
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Consider this is not insane big turbo.. gtb2365vk with some good stuff inside, 7+7 mfs point milling cw etc.

Hope you are going for 4x4 configuration otherwise youre wasting your time on big power

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Old September 12th, 2017, 06:01   #918
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Consider this is not insane big turbo.. gtb2365vk with some good stuff inside, 7+7 mfs point milling cw etc.

Hope you are going for 4x4 configuration otherwise youre wasting your time on big power

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Mid engine platform can easily put down more than what 2.0 tdi can produce without being 4x4. I have good weight distribution and currently 315 rubber. I can easily fit 335 if more is needed but I doubt it. If I have front wheels driving in future it will be additional power through YASA drive not power sent forward with exotic R8 or Porche transmission.
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Old September 12th, 2017, 07:58   #919
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It's my understanding that the big torque numbers are only out the rear output on Quattro configuration. Running just fwd configuration is much less rating based on strength of front differential. This can be somewhat enhanced by installation of a wavetrac.
Hard to say how much the diff takes but the box internals are the same excluding torsen. And it seems its fine on turbo gt40s and some porsche applications where they have those. And since i had past 800nm without problems ... although engine mounts got destroyed. It's really not the weakest link
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Old September 12th, 2017, 13:46   #920
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Glad that the "secret" is finally out, Louis! Amazing design and fabrication skills! Looking forward to first startup of the engine and first drive of the car. Saskatoon is within a day's drive from me, I'll have to plan another visit!

PS : exhaust manifold and bypassed biturbo system are badass!
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Old September 12th, 2017, 19:09   #921
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Glad that the "secret" is finally out, Louis! Amazing design and fabrication skills! Looking forward to first startup of the engine and first drive of the car. Saskatoon is within a day's drive from me, I'll have to plan another visit!

PS : exhaust manifold and bypassed biturbo system are badass!
Thank you Dave. I appreciate your comments. Perhaps next summer things will align and we can do a first test drive or at least some testing and tinkering on turbo control.
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Old September 14th, 2017, 07:36   #922
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Thank you Dave. I appreciate your comments. Perhaps next summer things will align and we can do a first test drive or at least some testing and tinkering on turbo control.
Glad to see you are back on track with this project Louis
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Old September 14th, 2017, 07:54   #923
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I know of 4 builds aiming for 400+ hp on 2.0CR this winter, curious how it ends.
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Old September 15th, 2017, 10:38   #924
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Glad to see you are back on track with this project Louis
Thank you Geir. Your support over the years has been much appreciated.
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Old September 15th, 2017, 10:42   #925
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I know of 4 builds aiming for 400+ hp on 2.0CR this winter, curious how it ends.
That is great! Hopefully everyone gets there. I just hope there will be some continued knowledge sharing on the details of these paths. This thread has always been about sharing information and experience.
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Old September 17th, 2017, 01:32   #926
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We had measured all springs available (stock, b8, bsr, DS) on the 2.0CR platform and custom made them, specific for exhaust and intake.
I'll try them as soon as i finish the 3.0 engine.
Plan is fuel upgrade, springs, BB turbo with lighter tw, 2.6-2.7 boost.
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Old September 17th, 2017, 04:29   #927
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We had measured all springs available (stock, b8, bsr, DS) on the 2.0CR platform and custom made them, specific for exhaust and intake.
I'll try them as soon as i finish the 3.0 engine.
Plan is fuel upgrade, springs, BB turbo with lighter tw, 2.6-2.7 boost.
Mac how did you measure my springs? You never bought a set.
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Old September 19th, 2017, 20:30   #928
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Awesome to see pics of your project Louis ! How do you plan on controlling that 7.3 exhaust back pressure valve ? Electric actuator or mechanical boost
?

Would the OE powerstroke/IC way of controlling that valve would be too slow responding ? It might be kind of handy to use the powerstroke/IC turbo pedestal system as it looks like you have room.Mabye one could tune something like the EGR or intake flapper system to operate that PWM regulator on the pedastal ?

Edit:One thing to add though is that the powerstroke/IC uses an exhaust manifold pressure sensor as a main input to controlling the EBPV.Perhaps a standalone controller would be better to control the valve if going this route.

Last edited by andy2; September 19th, 2017 at 20:46.
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Old September 20th, 2017, 12:00   #929
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Awesome to see pics of your project Louis ! How do you plan on controlling that 7.3 exhaust back pressure valve ? Electric actuator or mechanical boost
?

Would the OE powerstroke/IC way of controlling that valve would be too slow responding ? It might be kind of handy to use the powerstroke/IC turbo pedestal system as it looks like you have room.Mabye one could tune something like the EGR or intake flapper system to operate that PWM regulator on the pedastal ?

Edit:One thing to add though is that the powerstroke/IC uses an exhaust manifold pressure sensor as a main input to controlling the EBPV.Perhaps a standalone controller would be better to control the valve if going this route.
Thanks Andy.

I think the Power Stroke actuator would be too slow responding. I am planning on using a vacuum actuator. I will uses a solenoid valve to control the vacuum source. If I use the SCS Delta ECU, then there is probably an output I can configure for the job. If not, I have considered setting up my own micro controller to run all the junk.
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Last edited by TDIsyncro; September 20th, 2017 at 12:50.
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Old October 8th, 2017, 13:23   #930
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A little bit of a progress update. All the exhaust manifold welding is compete. I do have to remove one of the v-band flanges and re-weld after I machine flanges and install gaskets. I realized this would be a problem on final fitment late last week. I also have to add some sensor ports.

This is the EBV valve and flange for LP turbo. I cut the EBV valve down shorter on one end just to make things as compact as possible. The big tab on one end of the LP turbo flange will be one of my mounting points.




This is the modified HP hot-side. Very happy with how this turned out. Welds on casting went really well. Housing was preheated to 550F, held above 550F for welding; post heating was also continued.




Picture of the beautiful HP compressor wheel



Test fitting manifold parts and full HP turbo assembly. Clearance over valve cover and injector lines looks perfect. Removed clocking pin from compressor backing plate (this was also done on hot-side) and have arrived at a good angle. I will weld a nipple onto the compressor housing. I am also thinking I will add an RPM sensor to the HP compressor housing.



LP installed. Compressor housing still needs to be rotated. I am very happy with fitment. It does not interfere with the rear door at all. There is good height and angle to accommodate a gravity drain back to oil sump! There is good position for the custom motor mount/turbo mount bracket.
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Last edited by TDIsyncro; October 8th, 2017 at 13:26.
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