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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 18th, 2012, 09:52   #46
Fix_Until_Broke
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How do you do a VE for a cylinder head itself?

What do you compare it to?
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Old September 18th, 2012, 09:59   #47
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How? I'm not sure, I sure would be interested in learning.

What I'd use it for is calculating flow on compressor maps for sizing turbos.
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Old September 18th, 2012, 10:49   #48
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Well, lets see...

1) You could evaluate the VE of an engine, then port the head and re-evaluate the VE. You'd have to insure that cam timing was identical before/after though.

2) You could have a valve that seats on a tube the same diameter as the valve seat that is 20+ diameters long (for established flow). Evaluate the pressure drop vs flow at the same length as the runner in the actual head. The thought being that this would be the ideal port - no bends, no swirl, constant area, etc. This gets a bit messy though because you want swirl and the ports are not constant area and the flow is not steady state.

3) The typical that I've seen is a comparison to a stock head on a flow bench - % increase/decrease in flow/swirl/tumble over stock.

These are just a couple ideas off the top of my head...For it to be an efficiency, you need something to compare it to - what is 100%? Also, putting the RPM component in adds another few dimensions of complexity.
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Old September 19th, 2012, 23:56   #49
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I see people here keep asking about hogging out ports go check out motoman.com good information there, last time i checked the the 1.9 tdi's etc. are small bore 4 cylinder motors large ports are for large motors and top end HP. if you make these ports much larger you can loose power everywhere else

here is some information for porting the 1.9 alh > EXHAUST PORT as viewed mounted on the motor > the top only of the exit area of the exhaust port runner where it meets the manifold to about one inch in only remove about one mm or so there. 2 smooth the ridge in the bowl clean up under the seat where the bowl hog from the factory ended maintain a circle in the bowl go for the consistent radius 3 short side very slight rounding of the sharp edge.

intake port its a large runner and port don't enlarge it anywhere 1 clean up just under seat where the bowl hog from the factory ended> maintain a circle in the bowl go for the consistent radius. 2 short side very slight rounding of the sharp edge.
make that the end all of the porting its only a 4 cylinder > if you only care about hp. and top end only power open the exhaust port like above but more. i would avoid at all cost excessive rounding of the short side areas.all.

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Old September 21st, 2012, 11:32   #50
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5-years old pictures, but still valid =)
Not actually molds of ported heads, but good view about what we are talking here about:







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Old September 21st, 2012, 11:44   #51
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Marco, your contributions are much appreciated!

I'm assuming in your last pic that most of the bump in the swirl port on a PD must be left alone?
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Old September 21st, 2012, 11:51   #52
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Quote:
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I'm assuming in your last pic that most of the bump in the swirl port on a PD must be left alone?
It depends what are the goals, but I have ad more luck with swirl than no swirl.
7-years ago I ported one with swirl removed and it made extremely smoky 295hp.. of course injectors and turbos are improved, but now days I can make same or more flow and more power without smoke and that's enough for most.

PD and VE intake ports are the same and they also flow the same.
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Old September 21st, 2012, 12:00   #53
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Marko - The bump I'm speaking of is the extra material in the PD bowl that allows clearance for the injector, its 5 oclock to the valve guide.

So you have removed swirl all together in a port? Thats interesting and good to know someone has done it
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Old September 21st, 2012, 12:04   #54
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If you remove injector hump completely, you might end to injector hole, or at least really close.

We made some trials without swirl, but I made another head later for that engine with swirl.
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Old September 21st, 2012, 13:39   #55
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Injector bump on pd. I rounded port to follow the natural curve as if the bump had never been there and then ground away at the point to see how much material was left. Unless you are going to go to bigger valves I don't think there was much risk of breaking through. I am sure I saw some pictures of a ported head somewhere where it looked like it had broken through. I think the cylinder is sealed by the copper washer and the fuel channels by the seals on the injector, so in theory it might no be an issue, but I don't know if there are other considerations.


I have some moulds of pre and post porting for my cylinder head but not much time, but since I am a DIY porter I have no idea if they are any good. I also have a mould of the area between inlet manifold and inlet port for about an inch each way. I will try to get it done in the next week or so.
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Old July 2nd, 2015, 03:07   #56
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Old August 14th, 2015, 16:16   #57
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wow that looks really nice.
wish mine was like that.
how many hours of work did you spend on it ?
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Old August 15th, 2015, 23:10   #58
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Quote:
Originally Posted by GOFAST View Post
wow that looks really nice.
wish mine was like that.
how many hours of work did you spend on it ?
it goes reasonably quick, long as you've got a coarse tooth die grinder burr that's made for aluminum
ETA: and enough air compressor to run it for a while, hah
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Old September 10th, 2015, 07:49   #59
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I just finished on my CJAA head and there doesn't appear to be many places to improve on stock other than casting/machine marks and polishing. I removed so little material, I thought I was on season 1 of Gold Rush . The effort feels like a waste of time but now I know what things look like in there. Time to get it buttoned back up and get this part of the project reassembled. This mod. Brought to you by red bull.
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Old September 23rd, 2015, 16:51   #60
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Just wondering why people touching inlets and changin geometry of them???
That not good idea, there is just nothing to do with inlets. They can be just smoothed what not changing any thing.
You can do exhaust for mearly 10mm bigger and deeper and thats all.
+ ofcourse polish it up.

Il upload picture if some one tell me how
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