Project GTB1756VK, tubular manifold and water to air intercooler!

[dieseleux]

Two years ago, I started to buy pieces to put together this project.
I finally after all this time to do something functional!
There is still work to do to complete the system to start.
Here are some images and links photo server that contains many.

This picture is to see how fit the piping.






Height of new setup


Height of PD150 intake


My water intercooler kit, i buy just another intercooler with vertical flow to weld on intake manifold.
Intercooler in this picture have horizontal flow and i dont use.


Intercooler weld on intake, i do only weld between intercooler and intake, all other aluminium weld is already on intercooler when i buy.



This is the link of picture server, you see the rebuilt engine and many stage of intercooler built.
http://www.dieseleux.torquedelight.com/ALH engine rebuilt and GTB1756VK/




Dieseleux

 

[GTiTDi]

Luc! I am so glad you started a thread for this! Your intake had to be one of the most innovative and cool things I saw at Fest! I was very impressed with your fabrication work!

 

[Bczuk]

Really cool

 

[Growler]

Luc! I am so glad you started a thread for this! Your intake had to be one of the most innovative and cool things I saw at Fest! I was very impressed with your fabrication work!

I couldn't have said it better myself.

Awesome work, as usual.

 

[dieseleux]

Luc! I am so glad you started a thread for this! Your intake had to be one of the most innovative and cool things I saw at Fest! I was very impressed with your fabrication work!

Thanks you!
Me, it's your car that gives me a twinge in my heart, I love this model!




Dieseleux

 

[TDIMeister]

Tellement bon travail Luc!

 

[GTiTDi]

Thanks you!
Me, it's your car that gives me a twinge in my heart, I love this model!
Dieseleux

Thanks Luc!

 

[Alcaid]

Watching

 

[jimbote]

this is a sweet setup ....when are you going to start building kits ?

 

[JFettig]

I do like it.

How does the MAP sensor respond so close to an intake port?

 

[dieseleux]

I do like it.

How does the MAP sensor respond so close to an intake port?

This is one of my interogation...
For now, no trouble, no signe of wrong reading.
I put 2.5bar MAP on intake only for IAT sensor, later i put custom 4 bar MAP on inlet pipe of intercooler.




Dieseleux

 

[Alcaid]

Any updates?

 

[dieseleux]

No...!
In few week i prepare swap and final installation.



Dieseleux

 

[GTiTDi]

No...!
In few week i prepare swap and final installation.



Dieseleux

Keep us posted!

 

[X-Man]

did you complete the project ? I'm really interested how does the water intercooler performs

 

[dieseleux]

All work without water... i have lot of work and a golf (the friend car) to swap engine in my garage!
When i put the water and see how performe, i write here...




Dieseleux

 

[Alcaid]

Did you figure out a solution for a gasket between intake manifold and cylinder head to isolate from heat transfer?

 

[dieseleux]

Not for now, my garage too cold to work in and engine head heat in intercooler work great in winter!
When spring will arrive I'll test some materials.
Glassfiber of electronic pcb seems to be good for this job, is mecanical hard and easy to seal.
Now i work on my CNC project... great tools to make my own intake gasket!



Dieseleux

 

[A5INKY]

Bump for updates please. I'm fascinated by your intake manifold/intercooler design.

 

[dieseleux]

Engine swap done last weekend...
I install thermal isolator between head and intake.
Water pump and pipe install in few days, max 2 week!
I have some question about air flow between firts and last cylinder, i need some flow bench test.

Photo here
http://www.dieseleux.torquedelight.com/ALH%20engine%20rebuilt%20and%20GTB1756VK/Plan%20C/





Dieseleux

 

[A5INKY]

Excellent!

...I have some question about air flow between firts and last cylinder, i need some flow bench test...

I have this question too. I am thinking that the IC core might act as an effective diffuser and actually help even out charge air distribution between cylinders. Flow bench data will tell for sure though.

I have manifold envy

 

[dieseleux]

I have this question too. I am thinking that the IC core might act as an effective diffuser and actually help even out charge air distribution between cylinders. Flow bench data will tell for sure though.

I have manifold envy

On my work bench, with air gun, cyl 4 have lot more air flow than cyl 1!!!
Because high velociter of air rush to the end of top reservoir and than pass truth the intercooler.
This simple test do with all 4 port open.




Dieseleux

 

[A5INKY]

Wonder if that might change some with increased (boost) pressure. Perhaps test by measuring output volume of each port with significant but equal restrictions at the head flange of each port to better mimic in situ conditions? Not normal flow bench strategy but might give more real-world result.

 

[dieseleux]

Wonder if that might change some with increased (boost) pressure. Perhaps test by measuring output volume of each port with significant but equal restrictions at the head flange of each port to better mimic in situ conditions? Not normal flow bench strategy but might give more real-world result.

Yes i know!
When i install my water pump and i see if i have some gain on smoke.
I think installing an air deflector in the entrance of the intercooler to properly feed the number one cylinder.

Dieseleux

 

[jimbote]

the spacer to stop heat transfer is called a "phenolic" spacer ...great project btw~!...can't wait to see the results !

 

[dieseleux]

Yes, is phenolic, made for 8v diesel.
I see some gain now without water in intercooler, my IAT follow more turbo pressure and less engine temp!



Dieseleux

 

[GTiTDi]

the spacer to stop heat transfer is called a "phenolic" spacer ...great project btw~!...can't wait to see the results !

beat me to it!

Yes, is phenolic, made for 8v diesel.
I see some gain now without water in intercooler, my IAT follow more turbo pressure and less engine temp!
Dieseleux

Where did you get this gasket Luc?

 

[moivw]

the difference betwin 1-4 will be huge, you would have to re- do the upper part of your manifold to have first an equal separation of gazs-air from left to right... even though not many tend to do it...

 

[TDIMeister]

Engines do not breathe through two cylinders at once to matter too much.

 

[dieseleux]

One of my friend follow me and do same intercooler project, he modify intake for the Audi A4 TDI quattro GTB1756VK turbo.
I explain my possible flow distribution problem and he follow my explanation in how to do better flow distribution in top of intercooler on Audi A4 engine location.

This is my friend do...










Dieseleux