507hp TDi. 423hp without NOS, Anyone got any bigger numbers?

ATR · Sep 29, 2015

ryanp said:
I like to stick to OEM ECU's just so we are improving the skills that can be carried over to customers cars, plus standalone is expensive!!

We stripped the teeth off 4th for the 2nd time, must be a casing flex issue.

Check out SQS Racing. They do some great work on gear sets and gearbox reinforcement.

There was a member here that went big turbo on his common rail a couple years back that had issues blowing out syncros in 4th & 5th. More info in post #133:
http://forums.tdiclub.com/showthread.php?t=367577&page=9

SQS Racing's site:
http://www.sqsracing.com

ryanp · Sep 29, 2015

They wont make the ratio's we need so thats a no go!

chapelhill · Sep 29, 2015

Had a quick look at their web site and these were their comments on high torque VW boxes:

"02Q casing – especialy Mk5 casings hase more material around bearings and are better for high torque engines."

Not sure if you can use 02Q casing with O2M internals as starting point before further case support is added.

ryanp · Sep 29, 2015

I have such a gearbox coming to me on Saturday, not sure if that gives enough time to have the car ready for Sunday but we will try!

Video from the trackside:

https://www.youtube.com/watch?v=lMtcQw3OOz8

[486] · Sep 29, 2015

chapelhill said:
We would need to find some methods of improving engine efficiency to justify reving higher as torque drop off by 5200rpm is quite steep and gets below 500 ftlb.

If you can shift the powerband up higher in the revs and limit peak torque it'll help your gearbox life. All the trans and clutch sees is torque load, easiest way to sneak more power through it is to spin it faster. Won't help with anything after the final drive gearset though.

Layerz · Sep 30, 2015

Stand alone ECU wise part of my thought Haltech as seens the stuff they've done with the MCM guys.

Then looked at the cost...ouch! Looks like $1500-$2k+ before harnesses etc... so where you are staying on the PD for easier ECU changes makes sense.

It's a shame as someone will work out homebrew ECU's in the next few years as long as they don't chase £££

numbnuts · Sep 30, 2015

How about a dsg gearbox? I see adrenalin tunings mk1 golf with 700hp has one working very well

Scott_DeWitt · Sep 30, 2015

bhodgkiss said:
Which gearbox will take 600ft.lbs?
Wowsers

Under racing conditions none. I have several R32 twin turbo customers that can strip first gear with a part throttle launch at 3000 rpm. You can perfect your driving and shifting to maximize gearbox life but there is only so much you can do within the stock gearbox housings.

ryanp · Oct 2, 2015

I'd like to keep a manual gearbox just so its not a point and squirt car.

devonutopia · Oct 2, 2015

All this talk of 4th gear is getting me concerned, but I am never going to be in these realms of power. Still wondering about that little brace though.....

mrchill · Oct 3, 2015

The german guys have a reinforcement for that flex issue...but if you make enough power, even that may not be enough. I would consider moving the power band a bit.

jos_br · Oct 4, 2015

ryanp said:
Jos, MQ500? Just found one with suitable ratios about an hour ago! Haha this in your TT?

Any info for install? Email if you like ;b

Not in our TT, just the Golf V,

With these results,

And the 02M gearbox, als with some modifications,

And the Tiguan gearbox below the airbox. I have no other foto's,

Jos.

ATR · Oct 4, 2015

Wow! Nice torque numbers!

I can see why the stock gears said "see ya!"

jos_br · Oct 24, 2015

Tomorrow we will try the Golf V on the circuit (TT in Assen). I will try to make some footage.

Jos.

jos_br · Nov 29, 2015

The Golf V in action,

https://www.youtube.com/watch?v=q-rfIPhqLl8

Jos.

mk1-83 · Nov 30, 2015

nice to have fun Jos, whats in the middle gauge egt ?

gloaming · Dec 1, 2015

mk1-83 said:
nice to have fun Jos, whats in the middle gauge egt ?

Looks like KPH

jos_br · Dec 1, 2015

mk1-83 said:
nice to have fun Jos, whats in the middle gauge egt ?

Km/u......EGT is about 750gr but this is not visible.

Jos.

ryanp · Jan 14, 2016

Recently we did 10.14 @ 148.8mph on a bad track with a suspension issue (lots of wheelspin) and a bad 2nd-3rd gear change. Low 9s speed if we had the traction but my right foot is all i have to control power, plus i'm a bad driver! haha

I still have 50% more NOS but we are out of fuel now.

Current spec list:
http://www.darksidedevelopments.co.uk/arosa-mk2-2-0-16v-bkd/

Fastest run: https://www.youtube.com/watch?v=_VPOsB9If9g

This one i killed another gearbox (listen out for it @ 11s) : https://www.youtube.com/watch?v=lMtcQw3OOz8

New season mods: New gearbox, 100psi (yes 100psi!!) MAP Sensor, clean, paint inside and maybe race with Compound turbo's if they test out OK.

mk1-83 · Jan 14, 2016

Nice job Ryan

ATR · Jan 14, 2016

Wow!

So are you guys using dog gears on these transmissions?

andy2 · Jan 14, 2016

I have the Kalmar 02a/02j drag 4spd dog gearset (3.294) ready to install into mine for this year.I'll have to update my thread sometime.

Ryan,I'm currently using your facebook compound turbo picture as my windows background

https://www.facebook.com/darksidede...413180442923/1263603453657219/?type=3&theater

[486] · Jan 14, 2016

T4 HX40 atmospheric?

andy2 · Jan 14, 2016

[486] said:
T4 HX40 atmospheric?

Looks like t3.

My high pressure wastegated s300 has a 65mm turbine exducer and 58mm compressor inducer.My low pressure turbo is an s366.

ryanp · Jan 15, 2016

Thats funny Andy, I usually have someone elses stuff on my background too! haha

Hope the 4sp works out, what top speed you looking at?

We just run normal synchro gearbox, we would be faster with Dog engagement and maybe Seq shifter but like to keep it simple and as close to 'road' spec as possible so we are better positioned to advise customers what breaks first.

Turbo is a T3 Twinscroll (knife edged) 10cm HX35, we have a larger compressor available should we not make more power.

ryanjames170 · Jan 15, 2016

damn.. i got to see a video of this that is just nuts

[486] · Jan 16, 2016

ryanp said:
... we would be faster with Dog engagement and maybe Seq shifter ...

Turbo is a T3 Twinscroll (knife edged) 10cm HX35, we have a larger compressor available should we not make more power.

the dog engagement (when properly done with new gears rather than welded on stock gears) allows wider face width on the gears, meaning more strength, unless the case is truly the weak point.

Hm, smaller than I'd have expected given the output.
I was just comparing the look of it to the 16cm T3 hx40 that was on my desk for a while. On that one the flange bolts have corresponding bumps inside the inlet ports they're so close, smaller volute on that one. Watching with interest for sure.

m1ketdi · Jan 16, 2016

andy2 said:
I have the Kalmar 02a/02j drag 4spd dog gearset (3.294) ready to install into mine for this year.I'll have to update my thread sometime.

Ryan,I'm currently using your facebook compound turbo picture as my windows background

https://www.facebook.com/darksidede...413180442923/1263603453657219/?type=3&theater

Where is the HP turbine bypass on that Ryan?

andy2 · Jan 17, 2016

ryanp said:
Hope the 4sp works out, what top speed you looking at?

I'm hoping for 130-135mph.

ryanp · Jan 18, 2016

m1ketdi said:
Where is the HP turbine bypass on that Ryan?

We are using the internal gate, should work now we have it ported out to twice stock size, If EMP's are high i have a Tial V-Band gate that will take a few hours to install

andy2 said:
I'm hoping for 130-135mph.

That should be plenty if you are not running NOS, we get to just over 150mph @ 5700rpm.

[486] said:
the dog engagement (when properly done with new gears rather than welded on stock gears) allows wider face width on the gears, meaning more strength, unless the case is truly the weak point.

The casing does seem to be the weakpoint, we upgraded the forks and made as many supports as we could but still stripped 4th quite a number of times.

[486] said:
Hm, smaller than I'd have expected given the output.
I was just comparing the look of it to the 16cm T3 hx40 that was on my desk for a while. On that one the flange bolts have corresponding bumps inside the inlet ports they're so close, smaller volute on that one. Watching with interest for sure.

We tried a compound setup before with a 12cm housing, the WG never opened and still not enough boost from the LP turbo to make 400hp.

It seems on these 'small' engines that you need to keep EMP high to keep the larger turbo spinning. The big truck guys seem to get away with an overly large turbo setup with big housings.

507hp TDi. 423hp without NOS, Anyone got any bigger numbers?

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