www.tdiclub.com

Economy - Longevity - Performance
The #1 Source of TDI Information on the Web!
Forums Articles Links Meets
Orders TDI Club Cards TDIFest 2016 Gone, but not forgotten VAG-Com List Unit Conversions TDIClub Chat Thank You




Go Back   TDIClub Forums > VW TDI Discussion Areas > TDI Power Enhancements

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.

Reply
 
Thread Tools
Old March 11th, 2015, 18:26   #61
[486]
Veteran Member
 
Join Date: Mar 2014
Location: St.Paul, MN
TDI(s): 02 golf ALH
Fuel Economy: 42 stock, 47-49 now
Default

So, back on this, still smokes at 25:1 smokemaps at low RPM, still working on that slowly. Got a 3" maf housing in it and the proper programming changes for something nutty like 3000 mg/str of measured airflow.

Now, back to the turbos, my gauges read 40-50 PSI of EMP and 24 PSI IMP. Bad juju.

I've got a few ideas rattling around in my head,
First idea, a K03-005, it's laying around, in fact I've got three laying around. All dimensions are slightly larger than a gt1749VC, so I think it should flow more through the exhaust side. Would eliminate the VNT, though.
Second idea, big wastegate on the 1749v. Got a spare manifold to set it up on.
Third idea, get a chinese CHRA from a 1749vc and do the needed machine work to the spare 1749v manifold laying about. Don't know if the VC uses a different VNT mech with taller vanes for more flow, though. Then get the thing properly balanced, because the chinese probably never did.

I... don't know which way to proceed.
Leaning toward option C.
[486] is offline   Reply With Quote
Old March 12th, 2015, 07:08   #62
Markus L
Member
 
Join Date: Feb 2015
Location: Finland
Default

VNT mech of VC is like in GTB-series turbos. Vanes might be higher. In my setup GTB1752V's exhaust side (same as VC) chocked in ~4000 rpm with 30 PSI. Fueling wasn't maxed but it was enough for ~240 bhp.

With external wastegate and VNT it could be hard to make function right with EDC15.
Markus L is offline   Reply With Quote
Old March 12th, 2015, 09:12   #63
[486]
Veteran Member
 
Join Date: Mar 2014
Location: St.Paul, MN
TDI(s): 02 golf ALH
Fuel Economy: 42 stock, 47-49 now
Default

Quote:
Originally Posted by Markus L View Post
VNT mech of VC is like in GTB-series turbos. Vanes might be higher. In my setup GTB1752V's exhaust side (same as VC) chocked in ~4000 rpm with 30 PSI. Fueling wasn't maxed but it was enough for ~240 bhp.

With external wastegate and VNT it could be hard to make function right with EDC15.
I'd think the vanes would be taller, being that the tip height was something like 2mm wider.
Never know, though.

Another idea would be to fix the vanes in one position and mill out slots in the vane housing such that it'd be as though the vanes were taller.
Then I'd need the wastegate for sure.

Fixed vanes would let me stuff in the CHRA from anything with minimal hassle from the vanes., like maybe a td04-09B outta a volvo. The 1749V's attached exhaust manifold looks to be a very free flowing unit. Might not clear the block, though.
[486] is offline   Reply With Quote
Old March 14th, 2015, 19:09   #64
[486]
Veteran Member
 
Join Date: Mar 2014
Location: St.Paul, MN
TDI(s): 02 golf ALH
Fuel Economy: 42 stock, 47-49 now
Default

So I took the 1749v manifold and bored a nice big 1.5" hole where the EGR port was.
Gonna try my hand at using the tig with silicon bronze rod tomorrow to join some stainless pipe to it.

The idea is going to be to use an external wastegate to bypass the 1749V's turbine. Got an external wastegate and modified it a bit (cut some vent passages into the stem guide so that the backpressure from the TD04 doesn't cook the diaphragm blowing exhaust past the valve guide in there).

After some testing it cracks open at about 40 PSI of pressure differential, and has something like a 2" diameter diaphragm, so it should open under diaphragm pressure of something like 6-7 PSI. Figure I'll hook up the diaphragm to the TD04's boost signal, as it makes around 7 PSI when really on it, see what it does. Might have to get more spring in it and hook it up to intake manifold pressure. Maybe with the TD04's pressure on the other side of the diaphragm acting against the opening? It'll get played with.

Any advice on an interstage wastegate to share?

Jon, you were running a BV43 HP in yours, that's a vane turbo I think, what kind of springs and pressure reference are you using?
[486] is offline   Reply With Quote
Old March 21st, 2015, 09:52   #65
[486]
Veteran Member
 
Join Date: Mar 2014
Location: St.Paul, MN
TDI(s): 02 golf ALH
Fuel Economy: 42 stock, 47-49 now
Default




Bored out the EGR port on a spare manifold big enough for a proper 38mm wastegate. Welded it in with 316 stainless rod and the tig in the first usable result I've gotten from the tig yet. Kinda glad I didn't take pictures, they may have been better than these and you'd be able to see how much the welds were just bits of broken off tungsten smooshed into the bead.

So, after I did this I got a GT1752 out of a saab 2.3 at the junkyard.
Wonder if I can use that turbine and compressor on my VNT center housing and machine out the turbine housing for the larger turbine.

Well, going to go off to get the datsun off the f350 so that I can drive the F350 while this is apart as I don't have a spare VNT center housing, even a blown up one, to see how deep I've gotta make the radiused bit in the cut on the turbine housing.

Last edited by [486]; March 21st, 2015 at 09:54.
[486] is offline   Reply With Quote
Old June 11th, 2015, 21:37   #66
[486]
Veteran Member
 
Join Date: Mar 2014
Location: St.Paul, MN
TDI(s): 02 golf ALH
Fuel Economy: 42 stock, 47-49 now
Default

Lots of time with no updates.
Well, in the interim I've got the GT1752's rotating bits into a center housing to fit the VNT exhaust housing. Cut the 'gated 1752 turbine housing apart to grind a form tool to flycut the same radius profile in the turbine bore in the 1749's turbine housing.

Bored out the 1749v's exhaust housing and profiled it to fit, with a good 1/16" of clearance all around the turbine wheel. That seemed to be how much was in there on the 1752's stock turbine housing, so I rolled with it.

Then it got interesting with the VNT mechanism, the stock vane travel limit stop on the "open vanes" side was too small, the vanes would hit the turbine wheel when full open!, so I made a new stop pin with a .250" working diameter (stock is .19", thanks AndyBees) and that leaves enough clearance that I'm comfortable.

Getting close to putting it in, finally got some 1.5" mandrel bends and an expansion joint. A subaru came in with a dead catalyst, and it's part of the mandrel bent stainless tubular manifold. Whoo.

Oh, and the spring I added on the TD04's wastegate broke, so it is just putting along making 1 psi or so (don't ground the welding lead on the can and weld on the actuator rod, it grounds through the spring, haha) meaning that the 1749V's making the bulk of the 24 PSI I was running for the last day or two. Oops. Shaft play is still minimal so far though.

tl;dr, I'm not dead yet, the stupid volksmobile isn't either.
[486] is offline   Reply With Quote
Old June 11th, 2015, 21:57   #67
turbovan+tdi
Veteran Member
 
turbovan+tdi's Avatar
Default

Crap, more stuff to read. Very cool, only read page one so far.
__________________
1984 6.2 Diesel Get A Way van, remote turbo setup designed/installed by me, burning anything that burns.
2003 GSW, 2.0L ALH, Stage 2 Colt Cam, 1756 turbo, auto, silver, 380k-Wife's.
2004 GSW TDI, blue, 5 speed-DD-Malone stage 2, no kitty, aeroturbine muffler, PD150's.
2003 JSW 1.8T, silver-parting out. 2006 JSW, TDI 5 speed, blue.
turbovan+tdi is offline   Reply With Quote
Old July 2nd, 2015, 13:55   #68
GOFAST
Member
 
GOFAST's Avatar
 
Join Date: Oct 2014
Location: nederland
TDI(s): vento afn
Default

read your topic, like how you try to make it low budged in the beginning.
going to follow this thread.
GOFAST is offline   Reply With Quote
Old August 25th, 2015, 22:16   #69
GOFAST
Member
 
GOFAST's Avatar
 
Join Date: Oct 2014
Location: nederland
TDI(s): vento afn
Default

how is your new set up doing ?
__________________
-----KEEP ON MODIFYING-----
GOFAST is offline   Reply With Quote
Old August 25th, 2015, 22:25   #70
[486]
Veteran Member
 
Join Date: Mar 2014
Location: St.Paul, MN
TDI(s): 02 golf ALH
Fuel Economy: 42 stock, 47-49 now
Default

Quote:
Originally Posted by GOFAST View Post
how is your new set up doing ?
hm?
the 1752 hybrid sorta thing is still sitting on the shelf, still DDing it until it gets cold enough out that I get tired of not having heat

TD04 has a new spring on the wastegate and is making 6-7 PSI again.
Tore the aluminum exhaust off running over a truck tire on the freeway.
Welded the aluminum exhaust back together and put it back on.
Started dripping oil recently, so might have to actually look at it rather than just driving it.
Looking at the spare head I've got, a compression release brake is doable, and could even be a bolt-on affair.

ETA: Been working on a fox body ford with an HX40 a lot lately. Hope to drive that over the winter while I work on this.

Last edited by [486]; August 25th, 2015 at 22:30.
[486] is offline   Reply With Quote
Old November 12th, 2015, 18:50   #71
[486]
Veteran Member
 
Join Date: Mar 2014
Location: St.Paul, MN
TDI(s): 02 golf ALH
Fuel Economy: 42 stock, 47-49 now
Default

Quote:
Originally Posted by [486] View Post
ETA: Been working on a fox body ford with an HX40 a lot lately. Hope to drive that over the winter while I work on this.
To the point where I'm more or less done with this one, and will be driving it over the winter.

That means the VW's getting tore down for a bit of a refit again.

I've got te high pressure side figured out (gt1752 from a saab 93 LPT stuck in a VNT bearing housing and the gt1749V turbine housing machined to suit), a TD04HL-15t-5cm from a saab 93 HPT, and various volvo TD04 parts (a td04-12t-8.5cm, and an HL 7cm turbine housing)

The TD04HL-15t-5cm turbine caught something, but otherwise looks great after a little dremel work to remove any stress risers from the damaged area, so I was thinking I'd fit a cheapo 19t compressor wheel since it needs a balance anyways. Then toss on the 7cm turbine housing for a little less restriction at cruise than my current 6cm subaru housing. Maybe go with one of those 20t billet wheels that have been showing up lately, but that's more than twice the price of a cast 19t wheel for one extra mm of inducer diameter (the ones I see don't even have extended exducer tips).

So, I'm hoping for some info from those smarter than me on what I should do with the atmospheric turbo. That's all up in the air at this point, could go any way.

Alcaid, can you get a cast 20t wheel? If it would be a good direction to go, that is. I hear they came on dodge caliber SRT4s.
[486] is offline   Reply With Quote
Old November 12th, 2015, 21:01   #72
[486]
Veteran Member
 
Join Date: Mar 2014
Location: St.Paul, MN
TDI(s): 02 golf ALH
Fuel Economy: 42 stock, 47-49 now
Default

Looking at the maps, the MHI 19t map overlaps with the gt2052 map (nobody seems to have a 1752 map, but the 52 trim 2052 has the same compressor dimensions as mine) somewhat, and extends it off to the right and up well past the gt2052




I did the conversion on the MHI map myself, so it might be off. it was in cubic meters per second, I used 1.204 kg/cubic meter as the conversion because it says 20 degrees c up at the top

I'm moderately uneducated, it feels like it'd be a good matchup. But I'd really like a second opinion, as I don't really trust my knowledge here.

Last edited by [486]; November 12th, 2015 at 21:06.
[486] is offline   Reply With Quote
Old November 13th, 2015, 01:16   #73
Alcaid
Veteran Member
 
Alcaid's Avatar
 
Join Date: Sep 2006
Location: Norway
Default

The SAAB GT1752S has a 52.0mm 55Trim comp wheel (52.0/38.6mm) so based on dimensions it should flow slightly more than the GT2052S.

I have a used, in good shape, 16T compressor wheel if interested, took it off a Volvo turbo when I converted it to 11-blade GTX style comp wheel with extended tips. It's yours if you cover the sending cost. I also have an extra 16T "GTX" billet comp wheel if the 16T flows enough for you, we'll find a bargain price

I don't buy cast wheels so only have supplier for billet wheels. No 19T or 20T in my shelf right now an no orders happening anytime soon so you would have to shop those on ebay.
__________________
'03 VW Golf PD130 4Motion Highline - GTB2056VL, 4 bar map, FMIC - 191whp/320wft-lbs @ 4x4 Dynapack
'10 VW Passat 1.6TDI Highline - 2.5" DP (DPF/Cat delete), DP built and software by VVT - 145bhp/229ft-lbs
'83 VW Jetta 1.6TTD - Holset HE200WG-5cm + Custom Holset HX30W-12cm compound, 12mm Dieselmeken pump, Rosten rods, girdle, Ported AAZ head with custom valves, valve springs, Ti retainers, camshaft +++ WIP
Alcaid is offline   Reply With Quote
Old November 13th, 2015, 08:14   #74
[486]
Veteran Member
 
Join Date: Mar 2014
Location: St.Paul, MN
TDI(s): 02 golf ALH
Fuel Economy: 42 stock, 47-49 now
Default

Quote:
Originally Posted by Alcaid View Post
The SAAB GT1752S has a 52.0mm 55Trim comp wheel (52.0/38.6mm) so based on dimensions it should flow slightly more than the GT2052S.

I have a used, in good shape, 16T compressor wheel if interested, took it off a Volvo turbo when I converted it to 11-blade GTX style comp wheel with extended tips. It's yours if you cover the sending cost. I also have an extra 16T "GTX" billet comp wheel if the 16T flows enough for you, we'll find a bargain price

I don't buy cast wheels so only have supplier for billet wheels. No 19T or 20T in my shelf right now an no orders happening anytime soon so you would have to shop those on ebay.
I remember one dimension being slightly off, but didn't want to take the compressor cover off to measure. It's cold outside.

The 16t map overlaps the 2052 map a lot more than the 19t.
Going off my peak MAF readings with the current choked up setup I'm only moving something like 9 lb/min of air (1300 mg/stroke at 3k RPM) which is more or less in the middle of the map on my current 13t... The 19t has a lot more room to grow, I think while I'm cutting the cover and getting it balanced I should just go all the way once, and then if my motor's needs outgrow it I can just move onto a different frame size all together.

On reading the HP compressor map, would it still be accurate as it's getting (hot) compressed gas in, so maybe I just multiply the X-axis data by the difference in density?

I was really hoping to give you some money, with how helpful you've been. Maybe got a gt17 turbine wheel with the full diameter shaft? You've no doubt got the dimensions on the one I'm running, but I can always cut the turbine housing further. I'm kinda hesitant to use the necked down one that's currently in mine as when it lets go it takes the other turbo with it.
[486] is offline   Reply With Quote
Old November 26th, 2015, 18:24   #75
[486]
Veteran Member
 
Join Date: Mar 2014
Location: St.Paul, MN
TDI(s): 02 golf ALH
Fuel Economy: 42 stock, 47-49 now
Default

Tearing it down and before I got too far into it I remembered to stuff a decent camera in there and take a bunch of pics, so all the fancy "junk, radiator hose and pvc" charge piping is out and you'll notice missing nuts everywhere. Oh well.
Anyways, picdump time.


the tee is EMP on the odd leg and a water heater thermocouple for my pyro probe

the EMP tube breaks off every once in a while, so I reanneal it and pop it back in

almost fits like the car was designed for this kinda stupid

rotated the actuator can's heat shield a little bit because of where the downpipe is, chinese actuator anyways

lots of pics, lots of 1 star thread ratings? I know I vote all my own threads 1 star.

Lookit those ugly ports, mostly adding a comment between pics so the forum software doesn't mash them all together and make them hard to distinguish where one starts and the next ends

1749v may have ingested some poop, when I got the car the CCV hose was broken off, so it was eating unfiltered air.

TD04 hasn't eaten much poop, despite being PO'd by a ricer-type person

the thermo vacuum switch was from a previous experiment using the EGR cooler routed past the turbo to heat the coolant without pooping in the intake manifold, it worked sorta okay, but more turbos was more important to me. May incorporate a coolant loop into a muffler later on down the road.

more pics in a second, forum software's set up for only 10 pics per post for whatever dumb reason
[486] is offline   Reply With Quote
Reply


Currently Active Users Viewing This Thread: 1 (0 members and 1 guests)
 
Thread Tools

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off

Forum Jump

Similar Threads
Thread Thread Starter Forum Replies Last Post
Trying out a compound setup 17/22-hy35 Jonamond TDI Power Enhancements 59 July 1st, 2016 19:36
Compressor compound turbo setup storx TDI Power Enhancements 16 October 22nd, 2014 20:54
AEL compound setup suggestions? A.Dutsov TDI Power Enhancements 17 December 30th, 2012 07:51
GT1749V with GT3880 compound setup? Golden Dub TDI Power Enhancements 77 May 20th, 2010 23:42
Twin Turbo Setup (Not compound) Piranha TDI Power Enhancements 25 August 23rd, 2007 09:31


All times are GMT -7. The time now is 19:34.


Powered by vBulletin® Version 3.8.5
Copyright ©2000 - 2018, Jelsoft Enterprises Ltd.
Copyright - TDIClub Online LTD - 2017
Contact Us | Privacy Statement | Forum Rules | Disclaimer
TDIClub Online Ltd (TDIClub.com) is not affiliated with the VWoA or VWAG and is supported by contributions from viewers like you.
1996 - 2017, All Rights Reserved
Page generated in 0.17234 seconds with 11 queries
[Output: 143.62 Kb. compressed to 121.84 Kb. by saving 21.78 Kb. (15.16%)]