Darkside Developments CR140 GTB2260 turbo kit

[bhutchins]

only codes thown are expected from "change" of equipment. I'll just have to wait for the tune

 

[bhutchins]

Had some problems tuning at first... apparently all CR processors are not equal. the later revisions in the CJAA (2010+) are harder to unlock than the CBEA 2009. the ECU wouldnt take the program to be able to prrogram through the OBD2 port, and we had to send it out over thanksgiving to unlock it again.
after the first bench tune it keeps the torque of a diesel and keeps pulling to higher RPMs like a gasser (so far up to 25psi). in moderate traffic MFD read 46mpg. Will tune further to match boost and fuel/air ratio before putting back on the dyno

 

[TheHolyCobra]

You only planning on running 25 psi max? I thought someone said somewhere these engines are capable of 260hp (NOT wheel horsepower) and 35 psi...and stock-ish mpg figures.

Please correct me if I am wrong.

 

[storx]

You only planning on running 25 psi max? I thought someone said somewhere these engines are capable of 260hp (NOT wheel horsepower) and 35 psi...and stock-ish mpg figures.

Please correct me if I am wrong.

noone has really walked the path yet... so baby steps.. heck we been trying things out to see how far the GTB turbos can be pushed.. just not going WOT on our first try...

PS... Im sure Brian can agree with me.. the GTB22 turbo is extremely streetable on the commonrail.. almost as streetable as the stock turbo.. just not instant torque off the line.. but once your rolling *Drool*

 

[JFettig]

How are those stock boost pipes holding up?

 

[bhutchins]

How are those stock boost pipes holding up?

so far my logs are only up to 2601 mBar ie. 1.6 Bar boost (23.5 psi) / about 5 psi over factory with no problems, but have clamped connections to the aftermarket FMIC. the S3 cooler is probably a better choice. I know Storx has had the clips blow off the factory IC

 

[m1ketdi]

so far my logs are only up to 2601 mBar ie. 1.6 Bar boost (23.5 psi) / about 5 psi over factory with no problems, but have clamped connections to the aftermarket FMIC. the S3 cooler is probably a better choice. I know Storx has had the clips blow off the factory IC

2601mbar sounds like it hits a diagnostic limit....

 

[bhutchins]

2601mbar sounds like it hits a diagnostic limit....

You are correct. Mark is trying to figure out how to modify this on the EDC17
He already knows how on the earlier models.

 

[storx]

I'm sure he will figure it out... Our engines are still new territory so bugs were bound to pop up

 

[bhutchins]

I had the GTB flange welded onto the existing aftermarket down pipe that was fitted to the stock Turbo, and the location was amazingly the same. Pulls down low is similar to the little stock turbo, but doesnt surge as bad as a tuned stock turbo. Cant wait to get the 2601 Bar diagnostics limit removed

 

[devonutopia]

At least go for 2.0 bar + atmos next time.

 

[bhutchins]

At least go for 2.0 bar + atmos next time.

Eventually I will
the GTB2260VK is a 35psi compressor, and the bottom end is stock
I am trying for 2.2 Bar (32 psi gauge) and 1.5 Bar (22psi) by 2000 rpm

 

[bhutchins]

I see Ryan has the kit for sale on his site now

 

[ryanp]

Yeah manifold is up and the full kit will be up shortly.

Can't wait till you are hitting full boost Brian, you won't believe the difference, trust me

Ry

 

[Butt-Roc]

Hey Brian. Are you using the engine I sold you for this build?
If so, wow! Great progress!

 

[bhutchins]

Hey Brian. Are you using the engine I sold you for this build?
If so, wow! Great progress!

original block so far.
Pistons are removed from the block I picked up from you and getting ceramic dome and anti-friction skirt coated right now at Brooks. Rosten rods already in hand. a "Just in case" something happens. I dont imagine it will, the CR's run lower comresion ratio than the PD's. Ryan thinks 260HP will be fine with 32psi boost on bottom end

 

[storx]

well we will see.. i plan to push 35-37psi daily

 

[bhutchins]

ok, while the tuning is being worked out, here's a little car porn:

Rostens obviously on the left. Geir confirmed that the CR140 are the same rods as the PD150

and some high temp ceramic coated dome and anti friction coated side skirt CJAA pistons

 

[bhutchins]

The factory hose clamps could not be tightened enough to hold 30+ psi. McMaster-Carr caries the Mikalor t-bolt clamps. McMaster-Carr part numbers begin with 5462k##, where ## are numers for different sizes.

Some air does escape through the crankcase ventilation hose during the pressure test (only 16,125 miles on the car currently)

Sent from my GT-P3113 using Tapatalk 2

 

[bhutchins]

it looks like Ryan has the kit on his web site now

 

[Jeffbucc]

Hutch, can you take a picture of your FMIC setup? How'd it fit and what cutting/drilling needed to be done? Excited for you to get this dialed up and get some video of this beast running! Glad you guys are doing the leg work for me when I do this down the road...

 

[bhutchins]

skip the FMIC, and get the european S3 IC with aluminum end caps, much larger. my FMIC only had about half the cooling volume of the S3

 

[Jeffbucc]

skip the FMIC, and get the european S3 IC with aluminum end caps, much larger. my FMIC only had about half the cooling volume of the S3

Sweetness! Didn't know that the end caps matched up since it was for TSI/FSI, for $300 those things are cheap considering how much bigger they are.

Now to find a DIY on changing out intercoolers. I'm taking my mods incrementally harder to ease my way into the more technical stuff...

 

[bhutchins]

Cat "test pipe" on, now actuator adjustment responds!

Sweetness! Didn't know that the end caps matched up since it was for TSI/FSI, for $300 those things are cheap considering how much bigger they are.

Now to find a DIY on changing out intercoolers. I'm taking my mods incrementally harder to ease my way into the more technical stuff...

RyanP (darksidedevelopments.co.uk) who made my Turbo Kit, also has the euro IC for £250.00 (~$400USD)(the U.S. S3 IC has plastic end caps), and Ryan referances this guide http://www.vagfans.com/forum/viewtopic.php?f=4&t=290

Storx said he had to make custom hoses, he couldnt just cut off the clips. AWE-tuning says they make TDI S3 hoses, but I cant find them alone.

If you dont upgrade at least your clutch first, you shouldnt try the turbo upgrade! It will not hold. Pelequin LSD recomended

 

[Jeffbucc]

No, not planning on jumping straight to the turbo without the supporting mods. Planning on a Stage 3 clutch w/pelequin and the S3 euro intercooler before I even approach purchasing the turbo kit.
Already worried about my clutch with the stage 2.

 

[bhutchins]

a little dash view video
you can see the stability control come on, even with the limited slip and a really rough surface
http://youtu.be/HOepkyvcJyc
I'll try to modify the camera mount to be over the left shoulder s the gauges have better visibility

need to get rid of the plastic IC pipes!

 

[bhutchins]

IC Pipes from DarksideDevelopments

more toys from the Dark Side

 

[ryanp]

they look familiar

 

[2bitthugs]

Is the turbo in the same position as a BRM? If so one of those pipes might work on a BRM.

Pat

 

[Jeffbucc]

Hutch, I'm not sure if I'm just not that smart but a couple of the hardpipe kits look similar, mind linking me the correct one for the 2260? Also, can the pipes be used in conjunction with the stock turbo until I purchase the turbo kit? Doing my upgrades incrementally.