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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 August 8th, 2009, 21:07   #1
TDIinTexas
 
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Default gtb2260vk build: stateside, aiming for the masses

Alright guys here we go!

I have spent many months in preparation for this build, and I am very excited to finally be making some progress with a grinder and welder.

I am developing a turbo system for the masses. When I mean system, I am trying to provide a bolt-on big turbo, with all the trimmings for us. For a long time I have been under the impression that we as a niche group are capable of using larger turbos, to take us to a higher standard of performance TDI.

I want to see more large turbo TDIs running around here. I think the biggest hurdle has been sourcing manifolds and other plumbing parts reliably. That is what I hope to accomplish.

I am going to focus on Audi's gtb2260vk. Many guys in Europe are using this turbo with great results.... Its time for some of them here stateside! It does require modification to convert it to vacuum actuation, from the factory it is electronically controlled.

So without delay, lets get started.

Car: 2002 Jetta TDI

Here is what I have come up with in CAD. You can't see the hood, firewall, K-frame, or steering. It is in the drawing, just turned off for the picture. All should fit.



The manifold is 1.5" .065 stainless tube with all equal volume runners. Flanges are .5" stainless. The flange on the block is port matched to the exhaust gasket, and extra material given to accommodate the welds for the pipe. Intake manifold will have the plenum up by the injection pump, I'm trying to get the volume and length of the SDI manifold, still needs minor touches. The turbo drain sits perpendicular to the ground, without clocking the exhaust side at all (both the compressor and exhaust sides of this turbo can be clocked in any position 360 degrees for those who do not know this). The actuator bracket is incorporated into the oil drain flange, making it dependent to the chra and nothing else . There are 2 actuators in the picture, but it is the one on the left that is correct, the one on the right shows the offset, you'll understand later when it is pictured mounted. Exhaust is 3" with v-band clamps. The flex is shown in the picture.

I have played with the manifold alot, and have ideas for a smaller volume version in the future.

I started work today, going with the intentions of following my drawings as carefully as possible. Here is what I got done:

I want to thank Steve Glover for lending me a bad head to mock-up on. I build a frame that holds it at the 12.5 degrees that my engine sits at in the car.



Here are some goodies:



and I welded up the collector too..



This system is going to consist of: gtb2260vk (new, not re-mann), stainless exhaust and aluminum intake manifold, 3" aluminum turbo inlet pipe, stainless oil supply and drain lines, 3" stainless downpipe, intercooler & piping. This should be everything unique to installing this turbo. We will see what the future holds for supplying tuning. I am working on a website and vendor status.

What do you think?

David
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Old August 8th, 2009, 21:27   #2
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umm wow...that collector looks clean. can't wait to see more.
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Old August 8th, 2009, 22:52   #3
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David, where did you get that rendering of the block and head? Did you mock those up from your bad head? What are you using for your cad? I use SolidWorks everyday at work. I love to see others work with 3D renderings.

Keep up the goos work. Looks like you will have a great end product.
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Old August 9th, 2009, 03:44   #4
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interesting... cant wait to see more...
and I know this is a crappy question. but do you have a ballpark(high side estimate) of what the finished price would be... so I can save up and budget it...
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Old August 9th, 2009, 04:02   #5
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Wow, the primaries look exceptionally long.

Edit: be that as it may, I'm not criticizing. However, may I suggest you consider welding in a divider plate to separate the exhaust pulses between the 1-4 and 2-3 cylinders.
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Last edited by TDIMeister; August 9th, 2009 at 04:11.
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Old August 9th, 2009, 04:57   #6
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Looks good! subscribed!
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Old August 9th, 2009, 05:40   #7
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Quote:
Originally Posted by 79TA7.6
David, where did you get that rendering of the block and head? Did you mock those up from your bad head? What are you using for your cad? I use SolidWorks everyday at work. I love to see others work with 3D renderings.

Keep up the goos work. Looks like you will have a great end product.
I started from scratch, I rendered the head from measurements taken from the head on the stand. Its Autocad2009, that is what I work with all day at work. I wish they would let me play with Solidworks or Catia.

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Old August 9th, 2009, 05:45   #8
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Quote:
Originally Posted by TDIMeister
Wow, the primaries look exceptionally long.

Edit: be that as it may, I'm not criticizing. However, may I suggest you consider welding in a divider plate to separate the exhaust pulses between the 1-4 and 2-3 cylinders.
Yes, I battled with the pulses, and could not come up with a clean, cost efficient, equal volume primary setup. Instead I went with what I could get, equal volume. I work with cnc tube benders, and have layed this out to be bent, after the prototyping, this will drop labor time.

I could weld in the divider, which means I need to cut that collector open , we'll see. Probably.

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Old August 9th, 2009, 05:47   #9
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Quote:
Originally Posted by TDikook
interesting... cant wait to see more...
and I know this is a crappy question. but do you have a ballpark(high side estimate) of what the finished price would be... so I can save up and budget it...
We will have to see how much labor is invested. It will be in the ballpark of similar kits for gassers.

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Old August 9th, 2009, 05:47   #10
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Quote:
Originally Posted by TDIinTexas
I could weld in the divider, which means I need to cut that collector open , we'll see. Probably.
No no, don't do that then. Maybe something to consider in another header build.
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Old August 9th, 2009, 10:29   #11
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Quote:
Originally Posted by TDIinTexas
I started from scratch, I rendered the head from measurements taken from the head on the stand. Its Autocad2009, that is what I work with all day at work. I wish they would let me play with Solidworks or Catia.

David
I think that is the first rendering from AutoCAD that I have seen. It looks pretty good. I have not heard very many good things from people who have worked with AutoCAD and other 3D CAD programs. They say AC is harder to work with. But that is a different thread topic. Keep up the good work. Hope everything goes good with this project.
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Old August 9th, 2009, 11:07   #12
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for the easyness I work with Inventor, and for finite elements NX with Nastran solver.. Catia with Fluent pluging can do nice trings for CFD but I don't have the skill

as for the intake manifold, I'd make it so that it also fit a PD head, so it will not go to low in the IP area, this will be better for many people with more recent cars

with the exh manifold like that does it have enough clearance for the driveshaft?
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Old August 9th, 2009, 11:53   #13
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Quote:
Originally Posted by Rub87
for the easyness I work with Inventor, and for finite elements NX with Nastran solver.. Catia with Fluent pluging can do nice trings for CFD but I don't have the skill

as for the intake manifold, I'd make it so that it also fit a PD head, so it will not go to low in the IP area, this will be better for many people with more recent cars

with the exh manifold like that does it have enough clearance for the driveshaft?
Good idea Ruben. If possible, the design would be best suited for both ALH and BEW customers...
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Old August 9th, 2009, 12:03   #14
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Yes, good point, as I am trying to accommodate both ALH's and PD's with this. I need to measure up a PD head with valve cover on.

Will the SDI manifold fit the PD's, or better yet... Is it made for the PD's? I don't know alot about the SDI.

David
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Old August 9th, 2009, 12:12   #15
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the plastic sdi one I don't think it will fit PD, altough there are PD sdi's in caddy IIRC but don't know what intake they use

the actuator like you have it there is very handy to adjust
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