K-Jet turbo setup

[DaBeeterEater]

dam nice build man looks great

[John Milner]

Quote, originally posted by Southcross »

Dual (or tripple) cold start valves???????????? I'm super lost well... I don't know exactly what it will do... if its copper based it might stand up to the temps *shrug* Just be prepared that it might burn up and turn into a giant cloud of nasty smoke the first time the turbo gets hot. I don't know if you have a CAT or anything right down stream from it, but burning chunks may wind up going through your exhaust its a very interesting build... and way overdone on the photos, way to go!

I'm starting off with twin cold start valves but as I said, if its not enough, there is another mounting point for a 3rd cold start valve in the weber throttle body.

This is a MY76, so I don't have to run a CAT. or any kind of pollution gear here in OZ

Sorry about all the pics. I'm just trying to help people see what goes into a build project like this or any kind of build, instead of a before & after shot & alot of kept secrets.

If it's too many, I'll cut it right back & just give you a before & after shot & keep all the little helpful bit's of info to myself.

[Southcross]

Quote, originally posted by Mk1-20V »

I'm starting off with twin cold start valves but as I said, if its not enough, there is another mounting point for a 3rd cold start valve in the weber throttle body.

is that for fuel enrichment under boost??

[John Milner]

Quote, originally posted by Southcross »

is that for fuel enrichment under boost??

Yeah. It will be set off by an adjustable Hobb's Switch.

I'll set it at 7psi initially & see how it all goes with the tune. I may have to bring it in sooner, or may leave it later. But I just need a starting point.

[John Milner]

Well this weekend was alittle disappointing & not really happy with the progress. Crappy weather put a stop to painting & a so called dash -4 fitting decided to strip an oil supply adapter! Mmmmmmm.

But I did get some stuff done.

I finished welding all the pipe work, smooth & blended everything which took quite some time. Especially around the BOV. But the extra effort was worth it

All the piping ready for paint tomorrow

Dropped the sump & fitting the oil drain fitting

I also decided to fit a VW Motorsport Windage tray I've had here for a long time. What better time to use it than now.

Made up the oil return line & oil supply line For interest sake the supply is dash -4 & return is dash -10

I also got time to modify the wastegate mounting bracket, due to how the turbo housing's are clocked, the original bracket jammed the wastegate pot against the intake manifold. I also had to mod the swing/push rod end too.

So out came some scrap metal, the hacksaw, linisher & welder.

My welds are slowly getting better.

I'll be ordering some more part's tomorrow which broke, painting the piping & hopefully start reassembly tomorrow night!

[John Milner]

Got another good day in of work today.

Decided to set up a makeshift booth in the shed as it was crap weather all day again & line it with old massive blanket's & got the patio heater going! Crap I know, but it all didn't turn out half bad.

Managed to etch & spray all component's & then fit everything up.

Just waiting on an oil supply fitting & then onto the wiring which shouldn't take all that long & then brake booster pipe, exhaust & aux. injector fuel line

On with the pics. Very pleased with the final product. Almost look's factory apart from the Tial BOV.

[John Milner]

Before & after shot's.

Engine look's alittle cleaner now with all the aux. air valve supply hoses deleted & the Warm up reg hoses/pressure gauge tucked away too.

[John Milner]

Got a chance when I got home to wire up the A/F meter, calibrate it & fit the boost gauge. These will only be fitted temporarily for tuning. Once I'm happy with it all, it will all get removed & back to stock interior.

Anyway I can safely say it runs!

Cranked over on the 2nd revolution & fired into life. Although alittle noisey & once all the gasket goo & exhaust paint had settled, it idled perfectly as before at 1000rpm.

I'll get a chance tomorrow arvo to drive it & see how it all goes.

[Holden McNeil]

Fantastic job!!! I love all the hands-on fab work you did!

Something about this photo makes me want to turbocharge a lawnmower

[John Milner]

Well with the car still without an exhaust, test driving has been kept to a minimum.

I did get a chance to drive it though & initially boost was kept as 5psi. The turbo isn't even working!

The A/F ratio is spot on at idle & cruise. approx 14.6-14.9:1, but under boost it richen's upto low 10's:1! That's without the Extra injectors even hooked up!

But after a few goes & alittle bit of playing around, I wound it up to 10-12psi & the surge starts to come in. Its still running rich as under boost, so there is sill some playing around to do yet with adjustment's etc.

I'll get more tuning in, once the exhaust is fitted which should be tomorrow.

But it's slowly getting there.

No leak's, no fires & everything is smooth.

[LA7VJetta]

thats surprising, good to know that i wont really need do any manifold modifying when i get to turboing mine

[John Milner]

Quote, originally posted by nickzom »

thats surprising, good to know that i wont really need do any manifold modifying when i get to turboing mine

You may still have to clearance the intake & exhaust manifolds to fit flush.

[DaBeeterEater]

a/f in the 10's, man crank that boost up lol your good to go lol, crank that baby up t0 20 lol

[John Milner]

Quote, originally posted by DaBeeterEater »

a/f in the 10's, man crank that boost up lol your good to go lol, crank that baby up t0 20 lol

Haha.

Yeah tried that already. spiked at over 15psi & popped & farted!

It's looks like it's going to be a juggling act of boost & timing.

I was surprised about the A/F. I thought it would lean out. That's why I installed the extra injectors. Haven't even hooked then up yet!

[DaBeeterEater]

what plugs you have in there and what are they gapped at??

that could be why its popping,

this is not much of a comparrison but my 600 hp car i run iridium plugs in it and we run it rich like 10.2's in boost to keep it safe and it does not brake up, i was very very supprised at the iridium plugs

[booested4door]

it might be smart to make your valve cover vent go back to the air box. also you should try running a dv instead of a bov. both are releasing metered air, causing issues. she might run better!!!!!!!!

[Southcross]

Quote, originally posted by booested4door »

it might be smart to make your valve cover vent

it will only vent metered air if connected to the manifold (like the NA engine)

[booested4door]

ya.... i realized that after i sad it...duh!!!!

[John Milner]

Well fella's, the full exhaust is now on which is a 2.5" full mandrel system with a resonator & high flow rear muffler.

The car is now nice & quiet to drive, idles nice & after a few runs, I'm seeing better increases.

I've since increased the ignition timing & set boost at approx 10-12psi & now it's taking off!

This would eat my old 135hp NA setup for breakfast!

The plug's are mk4 GTI (AGU) plug's. You don't gap them, as they are 3 prong plugs.

I've alway's ran my valve cover breather into catch can's. It prevent's the buildup of crap in the intake system. I see this in new VW's all day everyday!

So far the BOV hasn't given me any trouble with unmetered air, or causing running rough.

At the moment I'm getting closer & closer to the tune. It's just timing & boost. Fuel is spot on!

[DaBeeterEater]

id try some nkg iridium plugs man they are the shiz lol, bkr8eix,
id be very curious to see what this thing makes on the dyno lol, looks awsome man btw where you located at ?

[LA7VJetta]

i am surprised you got it running good with the stock fuel disto. thats what makes me happy.

i have a Audi manifold, turbo, wastegate, and downpipe, Audi Intercooler, and Audi oilcooler.

so all I need is a WUR then.

[John Milner]

Quote, originally posted by DaBeeterEater »

id try some nkg iridium plugs man they are the shiz lol, bkr8eix, id be very curious to see what this thing makes on the dyno lol, looks awsome man btw where you located at ?

Might try those plugs later on. At the moment it's all working out pretty good. It's turning the tyres through the first 2 gears, so I'm slowly getting there. More tuning over the weekend.

Just a pain in the arse procedure!. Floor it, diagnose what it may be, stop, adjust boost, timing or fuel & try again. Only touch one thing at a time though, as it's easier to workout what does & doesn't improve.

Right now the timing & boost seem to be getting closer, now I need to richen it up some more. It's starting to lean off in the higher gears under full throttle at high rpm's, due to increased boost & timing.

I'm located over an hour out of Melbourne, Australia

Quote, originally posted by nickzom »

i am surprised you got it running good with the stock fuel disto. thats what makes me happy. i have a Audi manifold, turbo, wastegate, and downpipe, Audi Intercooler, and Audi oilcooler. so all I need is a WUR then.

The fuel dizzy/airflap assy I've got is off an NA Volvo 2.2L from 1983 I think. The air flow sensor plate is larger & lifts up more than the stock VW one. This is how I ran it with the slightly modded NA 1.8L & it provides better throttle response & better fueling over the stock GTI setup. It also improves bottom end torque as well, but seem's to be upto the task of FI too.

The only mod I've done so far to the fueling system over a stock setup so far is fit an Audi 5000T warm up reg with the vacuum/boost supply to the large fitting above the barbed fitting. Not the barbed fitting!

I'm yet to adjust the system pressure with the shim's.

Modified by Mk1-20V at 12:39 AM 10-2-2009


Modified by Mk1-20V at 12:47 AM 10-2-2009

[LA7VJetta]

is that compared to the MK1 Airflap? I have a MK2 so I think I will be good

[John Milner]

Quote, originally posted by nickzom »

is that compared to the MK1 Airflap? I have a MK2 so I think I will be good

Yeah it comparing to the mk1 airflap. But I think the mk1 & 2's are the same.

I'm using the complete Volvo 2.2L assy. Airflap & fuel dizzy.

[LA7VJetta]

MK1 is 60mm right? my car has a 80MM flap.

[John Milner]

Quote, originally posted by nickzom »

MK1 is 60mm right? my car has a 80MM flap.

I'll be honest & say I'm not sure. I haven't' seen a stock GTI setup in years.

Some more pics for the sake of it

Innovate Motorsports Air/Fuel meter. Awesome bit of gear & should be on everyone's list for the home tuner!

Happily idling away at 14.5-.14.9:2

Fitted the LC-1 in the rain tray. The oxy. sensor lead isn't long enough to reach into the car

Callaway boost gauge

The matching pair of tuners tool's!

I'm still slowly honing in on the tune, but I'm now running out of fuel up top in the higher gear's/load, so the car is booked in next Fri. to have the aux. injector hosing made.

I took a friend for a spin on the light setting & he reckons it's alittle bit faster than a lightly modded WRX. Not sure on that though. It's scrabbling for traction in the first 2 gears, but it's still slow to me!

[John Milner]

Got some more work done this arvo & also getting to the end of the part's list.

The faster I get this done, the sooner I can move onto other projects.

Fitted up my new ATE Powerdisc's & Pagid brake pads front & rear

I also decided to give the underneath a pressure wash, due to the weekend away bush bashing a few weeks ago.

Fronts are Corrado 280mm discs & stock Mk1 GTI style pads.

Rears are just standard size Mk2 16V rear disc's & pads

[zcxerxes]

keep up the good work

[John Milner]

Well I finally broke something today.

My old ABD short throw shifter. The top relay lever broke clean off the shaft!

Stopped,opened the bonnet & manually selected 2nd gear on the gearbox & drove back to a mates house for some repairs too.

Other than that, its been smooth sailing. the car is performing without fault. Mixture's are good, fuel economy is the same as before if not better.

I've removed the tuning gear out of it, till I get my next upgrade which will be a MSD 6BTM. Boost retard ignition

The aux. injector fuel hose will be going on the Fri & I'll have some wiring to do as well.

[ShaggysGTI]

What bolt pattern are those adapters to on your hub?

[echassin]

Subscribed, nice workmanship!

[John Milner]

Quote, originally posted by ShaggysGTI »

What bolt pattern are those adapters to on your hub?

They are H&R adapter's 25mm thick 4x100 to 5x130 Porsche stud pattern.

[John Milner]

I'm not planning anytime soon on dragging it or dynoing it just yet. There is still some little bits & pieces I'd like to do to make it more consistant in power delivery.

At the moment, I'm driving it 200km a day round trip for work & more than happy to drive it, as it's nice & smooth & alittle quieter than before. Although with the 13b style idle & weber throttle body, it's a pain in traffic!

I can now see why VW/Audi used a twin style progressive throttle, as a large single is just too sensitive on take off

I did manage to get in a drag race last night against my brothers mid 13sec 6L V8 family wagon just for interest sake.

On low boost (10psi) & rolling along in 1st we nailed it & it was pretty even steven till about 110km & he started to pull away.
Then we tried the 80km roll on. In 3rd I pulled a car length & stayed in front till 140!

I had no expectation's of how fast it would be or how much power it would make & I was alittle suprised how fast it goes.

I honestly didn't think it would be this fast.

Hopefully soon I can turn it up some & be consistent, once I get a few more upgraded component's incl. a MSD 6BTM

[John Milner]

Well not much has been going on apart from driving the car everyday & no problem's have arose since getting it going.

I managed to get in some time to get the Aux. injector fuel hose made & then wire it all up today. I also tested the system to see if it would all work

System all up & running

The cold start valve outlet

With the Hobbs switch bridged out

I'm yet to hook up the A/F meter & see what's going on. I'll do that once the MSD 6BTM has been fitted & then see how it all goes.


Modified by Mk1-20V at 7:54 PM 10-11-2009

[ShaggysGTI]

That last pic is awesome!