GTB2260VK, AWIC and SDI intake for my Smyth G3F

[bzeien]

I'm working on some upgrades on the BEW TDI installed in my Smyth Performance G3F Beta #9 (build notes here:http://forums.tdiclub.com/showthread.php?t=367314).

Here are some photos of the turbo/exhaust/intake setup. I'll be mounting it all to the engine to test fit and determine placement of the support bracket for the AWIC. As a mid engined conversion of the MKIV, the G3F has no real space problems to the rear of the engine. Firad +80% injectors have also been installed.

The gtb2260vk is mounted to a Passat manifold ported to a Darkside adapter plate, the AWIC will be supported with a fabricated bracket welded to the SDI intake. The total intake plumbing consisted of only two 180 degree silicone elbows (2.25" and 2.5"). I'm keeping the SDI ASV; there's a thread here somewhere with instructions to convert the wiring to my BEW harness.

Overall a fairly compact package.

 

[JFettig]

Looks good, I increased the size of the pics
Will that 2.25" silicone U seal up on the turbo? I believe the turbo outlet is 2"

 

[Jayg]

I like the compact design of that. What is the ic core rated up to? Looks a tad small for repeated passes unless the aftercooler is huge.

 

[mrchill]

Its the correct size for the use. In fact its larger than the rating...but will be fine regardless. In theory, one could run a much smaller unit and be fine.....but why not one thats a bit larger for the purposes of heat soaking especially when lag isnt an issue.

 

[bzeien]

Looks good, I increased the size of the pics
Will that 2.25" silicone U seal up on the turbo? I believe the turbo outlet is 2"

Thanks! 'Still new at uploading pics, I tried changing resolution, what image size works best?

The turbo outlet measures up at ~2.10", a good t-bolt clamp snugs it up nicely all around.

The intercooler had 2.5" inlet/outlet. I put it on a lathe and cut one side down to 2.25". There was plenty of wall material for the cut.

 

[JFettig]

I like to use 1024x768, your file path was
http://pics.tdiclub.com/data/5723/thumbs/DSCN3192_2_.JPG
I changed it to
http://pics.tdiclub.com/data/5723/medium/DSCN3192_2_.JPG
Could also use this for full size:
http://pics.tdiclub.com/data/5723/DSCN3192_2_.JPG

 

[dieseleux]

Simple and efficient setup!
Intercooler make interference with raintray and freon tube?

http://www.dieseleux.torquedelight.com/ALH%20engine%20rebuilt%20and%20GTB1756VK/Installation%20on%20engine/DSC09425.jpg.php

http://www.dieseleux.torquedelight....756VK/Installation on engine/DSC09428.jpg.php



Dieseleux

 

[manual_tranny]

Looks great, Bob!! I hope that Mark and I can see this build in person soon!

 

[TDIMeister]

Very nice!

 

[greengeeker]

Simple and efficient setup!
Intercooler make interference with raintray and freon tube?

Smith G3F =rear engine

 

[bzeien]

Simple and efficient setup!
Intercooler make interference with raintray and freon tube?
Dieseleux

The engine is in a Smyth Performance G3F: a mid-engine conversion for the MKIV. Plenty of room behind the engine as it's now in the back seat!

2200# mid engined TDI with 250+ hp should be interesting.

 

[bzeien]

Looks great, Bob!! I hope that Mark and I can see this build in person soon!

Thanks Mike, I got a bit sidetracked by that work thing, but making progress!

 

[bzeien]

I cut a mount for the 4-bar MAP in UHMWPE, mounted on the SDI intake

 

[TDIMeister]

I love the integration!!! Very OEM-esque - :thumbup: !!!

 

[dieseleux]

The engine is in a Smyth Performance G3F: a mid-engine conversion for the MKIV. Plenty of room behind the engine as it's now in the back seat!

2200# mid engined TDI with 250+ hp should be interesting.

Oh! my fault!

I see this car at last TDIfest at Ypsilanti.



Dieseleux

 

[timbomfg]

Holy crap that's awesome!

 

[storx]

i love the setup.. but how are you going to control the heat from the turbo bleeding into the intercooler.. since the water inlet/outlet are right above the downpipe.

 

[bzeien]

i love the setup.. but how are you going to control the heat from the turbo bleeding into the intercooler.. since the water inlet/outlet are right above the downpipe.

Thanks. I'll be fabricating a stainless heat shield around the hot side and exhaust pipe.

 

[storx]

Thanks. I'll be fabricating a stainless heat shield around the hot side and exhaust pipe.

Just dont exhuast wrap it. I did this to my car a few years ago and after only 3 years the pipe under the exhuast wrap was rusted to crap...had rusted a hole right through it..

 

[vwmikel]

I cut a mount for the 4-bar MAP in UHMWPE, mounted on the SDI intake

I'm wondering how good of a reading you're going to get with the MAP/IAT sensor mounted there. From what I recall, that port connects to each runner via a small hole. The idea being that it generates a vacuum to draw the exhaust gases into the runners. I would also think the temp readings would lag there. Some of the SDI manifolds did have a map sensor on them, but it was up on the side of the main plenum area.

 

[bzeien]

I'm wondering how good of a reading you're going to get with the MAP/IAT sensor mounted there. From what I recall, that port connects to each runner via a small hole. The idea being that it generates a vacuum to draw the exhaust gases into the runners. I would also think the temp readings would lag there. Some of the SDI manifolds did have a map sensor on them, but it was up on the side of the main plenum area.

Thanks, it's a good point! I'll be running it to verify the signals shortly; simple enough to mill a path to the plenum, or weld a mounting boss elsewhere, if necessary.

 

[JFettig]

You could put it right on the intercooler end tank(cold side).

I have mine on the far end of my plenum. Doesn't seem to care.

 

[A5INKY]

You could put it right on the intercooler end tank(cold side)...

That is basically where it sets OEM on a MKV.

 

[bzeien]

Here are the parts mounted on the BEW, in the chassis. Testing fit and mocking up mounting hardware. Viewed from trunk area.

 

[storx]

i recommend you move the AWIC up as close to the firewall up as you can. I was playing with IR gun with my car after the gtb2263vk install and the part of the cylinder head that was directly by the turbo was 80 degrees warmer then pointing it above the compressor side....if you can move that awic up higher maybe level or slightly higher then the intake you have better results.

 

[vwmikel]

i recommend you move the AWIC up as close to the firewall up as you can. I was playing with IR gun with my car after the gtb2263vk install and the part of the cylinder head that was directly by the turbo was 80 degrees warmer then pointing it above the compressor side....if you can move that awic up higher maybe level or slightly higher then the intake you have better results.

Maybe just ceramic coat the outside of the cooler?

 

[dieseleux]

IR gun on aluminium not work good, when heat source are near, some reflection are made on aluminum and ir gun see wrong.
Contact temp sensor are far better in this case.
Chrome are one of worst IR emit, polished aluminum of intercooler are close to chrome in IR.
Matt surface, better when are dark, manifold, plastic, rubber and silicone tube, engine block and dirty and matt aluminum head make best IR reading,
A simple sheet between manifold and intake block most IR and deflect hot air.



Dieseleux

 

[TheoSweden]

Why not a bigger cooler? Looks realy small to me. Otherwise just awsome setup! Any more info of the car?

Theo

 

[bzeien]

A simple sheet between manifold and intake block most IR and deflect hot air.
Dieseleux

Quite right! A basic thin sheet-type heat shield will block most LWIR and there's plenty of room between the turbo and bottom of the AWIC, I'll cover most of the turbo exhaust outlet pipe as well.

Why not a bigger cooler? Looks realy small to me. Otherwise just awsome setup! Any more info of the car?
Theo

This AWIC is actually rated to 350hp and is plenty for this application.
There are additional build notes about the car on this thread: http://forums.tdiclub.com/showthread.php?t=367314

 

[dieseleux]

http://www.dieseleux.torquedelight.com/ALH%20engine%20rebuilt%20and%20GTB1756VK/Installation%20on%20engine/DSC09379.jpg.php

http://www.dieseleux.torquedelight....756VK/Installation on engine/DSC09389.jpg.php

Wrapping make also a good job!



Dieseleux