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    Thread: G60 to Xflow turbo build

    1. Member Svedka's Avatar
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      10-09-2010 03:03 PM #1


      My g60 to X-flow turbo (goal is 180-220 WHP daily)

      I had rebuilt a G60 to stage 4 or 5 or whatever it had every possible bolt on and some mild head work and it was a fun car but after blowing up 2 gladders in the same year I regretted my decision to make my daily GLI a g60 so I ripped the g60 out and installed a new obd1 Xflow for the family car...


      So I decided to make a hybrid Xflow pg turbo and throw it in the coupe that was sitting on the side of my house, because I did not feel there was a kit that would meet my needs for the price I was willing to pay I spent roughly 8 months piecing the parts I would need and have mostly completed the mock up stages.




      I’m looking to make 200 WHP or somewhere in that area with the parts I have. I figure my g60 was around 160-170 WHP on a good day so a little bump in HP and the ease of changing the parts and availability is well worth it in my opinion.


      parts list I used
      Bottom end PG from g60 1.8
      x-flow obd1 head welded surfaced then drilled
      BBM 268/260 cam
      Autotech adjustable cam gear (no longer sold they make a newer lighter one now)
      Arp head studs
      G60 head gasket
      BFI turbo oil pan
      Oil catch can (ebay)
      Innovative wideband for tuning
      VDO boost gauge
      Oil feed line to turbo is 24in from oil filter flange
      Oil return line I used SS braided line to the BFI oil pan
      V belt alt custom mounting 940mm vbelt
      V belt crank and water pump gear
      Beetle valve cover breather oil cap
      MK4 intake manifold
      Mk4 valve cover
      g60 injectors
      Adapter from mk4 manifold to g60 throttle body
      Adapter from throttle body to 3in round
      Solid IC piping from TB to IC (this was a bbm tube refit)
      Forge BOV
      Forge manual boost controller
      Spearco FMIC
      Solid pipe from IC to turbo
      CAI (this was a refit from BBM no longer on there site)
      Kinetics cast 8v turbo manifold with external waste gate
      Tial 38mm waste gate
      Garrett t3 .42 (baby turbo)
      Alot of custom sized silicone couplers (ebay)
      2in header wrap with black sealer paint
      T3 4bolt down pipe 2.5in with 2 o2 bungs (custom refit from ATP)
      Waste gate dump tube (ebay)
      2-¼ Euro sport exhaust with cat delete
      16v Passat duel fan shroud on a factory mk2 radiator capped the end
      Factory mk3 cross flow hoses route the cooling (exception I used mk2 water pump to oil cooler and mk2 heater hose to metal line)
      Digi 1 ecu and harness with custom chip
      lightened flywheel 16v pressure plate 020 trans with shift kit
      Mostly painted with cr@p ceramic paint

      So this is how the test fit went this week as I received parts to put on =)





      So I'm waiting on some pieces to come in from UPS this week and hopefully next few weekend's I will be able to start it So during the next few week's I will sand the tubing if there is a nice day to paint and I need to get some header wrap for the down-pipe and put the wiring harnesses back into it

      Some info I have came across while doing the build.
      G60 injectors are 26lb
      Adding more than a 3.5 bar fpr could make your injectors not fire or over-spray
      Digi 1 ecu with factory map can only handle 15psi (some people push the bar to 18psi)
      SNS has the best ability to custom burn a chip
      Stock clutch and 020 is good for 150-170ish WHP
      MK4 manifolds need support made when installing without the factory heat shield
      To do V-belt on a pg bottom end you need to customize your alt bracktery
      To do aba xflow alt on pg bottom end you need vr6 water pump pulley g60 crank pulley and to make a adapter for the alt to bolt to


      If any information is incorrect please let me know.
      Last edited by Svedka; 11-16-2010 at 10:30 AM.

    2. Member Svedka's Avatar
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      10-14-2010 12:34 AM #2
      Update:

      finished lower manifold and bosch injectors in the mk4 manifold and got it painted up also got the manifold turbo and waste-gate all painted along with the boost tubes and TB




      really just need to finish the down pipe
      Last edited by Svedka; 11-16-2010 at 10:31 AM.

    3. Member Svedka's Avatar
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      10-16-2010 03:21 PM #3
      Lunchtime



      got some of the wiring installed just waiting for a few more parts I ended up with a 940mm V belt and had to modify the alt bracket finished up the cold air intake and boost tubes also got my BFI oil pan and my wide-band so after lunch it will be more work

    4. Member Svedka's Avatar
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      10-24-2010 07:46 PM #4
      Got the down pipe pieces this week now I just need to wrap it and put it in

      Down pipe work



    5. Member Svedka's Avatar
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      10-25-2010 12:04 PM #5
      Wrapped and mounted with both o2 sensors in place


      Also got my eurosport wires and did a rear disc conversion whiel I was waiting for a few more parts to show up

    6. Member pendulum's Avatar
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      10-25-2010 03:42 PM #6
      subscribed

      I like the work you're doing, especially with coating & wrapping the tubing. Looks clean

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      10-26-2010 11:25 AM #7
      2 door jetta <3

      really awesome project.. wouldnt mind driving up some day and buying your cam and turbo mani off ya, and to see your projects..


    8. Member Svedka's Avatar
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      10-26-2010 12:20 PM #9
      So I have been testing a New south power gasket for the X-flow head on my family car and I can say they work.

      Redneck Test #1 went car came home from 1hr drive and I cant put my hand on the intake manifold and hold it there its just to hot

      So off it all came and ceramic painted wrapped the mk4 tubular manifold and added a new south performance gasket

      Redneck test #2 went drove around for an hr I immediately noticed my wide-band was reading differently at WOT it was slightly leaner than before without the gasket so pulling over every so often to check and see if I can tell a difference in the manifold temps I was simply amazed in how cool to the touch it was.

      Conclusion: I felt a power difference it smoothed out my idle increased my gas mileage smoothed out my cruising AFR and WOT AFR, now I don't have a dyno or a datalog because it is a AEM wide-band on OBD1 and dyno time just isn't in this cars future

      Now to order another one for the turbo build

      And pics or it didn't happen

    9. Member pendulum's Avatar
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      10-26-2010 12:47 PM #10
      interesting.

      why does a gasket affect driveability? did you use a thicker one to lower compression or something?


    10. Member Svedka's Avatar
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      10-26-2010 12:50 PM #12
      you can barely see it in my pic but if you look closely at the head/manifold the gasket is about the thickness of 2-3 quarters stacked up

    11. Member pendulum's Avatar
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      10-26-2010 12:52 PM #13
      How does that add power though? (reading the link it shows a dyno graph of a 10 hp gain just from a gasket)

    12. Member Svedka's Avatar
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      10-26-2010 12:54 PM #14
      There is also this style which I have on my ITB counterflow car and it is alot thicker not sure if it works any better it also uses 2 gaskets and longer studs.

      no picture is available of the 8v counterflow one
      http://www.evolutiontuning.com/evohe...ds18SOHC8V.htm

      this link has picture of the xflow showing the 2 gaskets and hardware
      http://www.evolutiontuning.com/evohe...ds20SOHC8V.htm

    13. Member Svedka's Avatar
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      10-26-2010 12:56 PM #15
      Quote Originally Posted by pendulum View Post
      How does that add power though? (reading the link it shows a dyno graph of a 10 hp gain just from a gasket)
      Better explanation from there web site
      NewSouth Performance has designed an insulating gasket that radically reduces the heat transfer from the cylinder head to the intake manifold.

      PowerGasket Plus™ gives you up to 5% more power from your engine by reducing the temperature of the incoming air to your engine. This gives you cooler, denser air for more horsepower and performance from your engine.

      The PowerGasket Plus™ is made from a purpose-built high performance composite material. It conducts on average less than 1/500th of the heat of the steel gasket that it replaces. Your intake manifold will stay 30-50° F cooler and your incoming air will stay 20-30° F cooler.

      Cooler air, denser air, means more oxygen. Your engine sensors register these changes and will inject more fuel to give you more power. Cooler air also reduces detonation, so you can turn up the boost or advance your engine timing for even more performance gains.
      http://www.newsouthperformance.com/gasket.htm

    14. Member pendulum's Avatar
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      10-26-2010 03:48 PM #16
      Quote Originally Posted by Svedka View Post
      Better explanation from there web site
      NewSouth Performance has designed an insulating gasket that radically reduces the heat transfer from the cylinder head to the intake manifold.

      PowerGasket Plus™ gives you up to 5% more power from your engine by reducing the temperature of the incoming air to your engine. This gives you cooler, denser air for more horsepower and performance from your engine.

      The PowerGasket Plus™ is made from a purpose-built high performance composite material. It conducts on average less than 1/500th of the heat of the steel gasket that it replaces. Your intake manifold will stay 30-50° F cooler and your incoming air will stay 20-30° F cooler.

      Cooler air, denser air, means more oxygen. Your engine sensors register these changes and will inject more fuel to give you more power. Cooler air also reduces detonation, so you can turn up the boost or advance your engine timing for even more performance gains.
      http://www.newsouthperformance.com/gasket.htm
      interesting, thanks!

      edit: doh! don't have them for the 16v
      Last edited by pendulum; 10-26-2010 at 03:55 PM.


    15. Member pendulum's Avatar
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      10-27-2010 01:09 PM #18

    16. Member papo98jetta's Avatar
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      10-27-2010 01:44 PM #19
      Nice
      ABA Turbo Club

      228hp 271tq at 14psi with pte GT3561E

    17. Junior Member
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      10-30-2010 02:05 PM #20
      I'm in the middle of the same project. I'm hoping for around 200hp using a very small turbo. Can you give me more info on what chip your using? and are you sticking with the stock fpr?

    18. Member Svedka's Avatar
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      10-30-2010 02:55 PM #21
      stock fpr with a custom burnt chip similar to the SNS one

    19. Member Svedka's Avatar
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      11-07-2010 03:39 PM #22
      Update: Got a few things sorted out

      got my alt stuff finished up vbelt with 940mm belt


      Also took my dump tube back off and painted/wrapped it


      finished my SS oil return line ended up about $60. If I was to do it again I would weld my own bung onto a pan and have a custom line made to fit with less fitting's. I did not like the fact that most just drape around the axel so well see if mine works ok or if I have to drape it around the axel. Had to make a bracket to hold it to the block.


      Just a few little details to finish up

    20. Member Svedka's Avatar
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      11-11-2010 09:09 PM #23
      Gauges installed just need the boost controller to mount in there somewhere now


    21. 11-11-2010 09:21 PM #24
      looks great now if only i could get my wiring done


    22. Member STEALTHCORRADO's Avatar
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      11-16-2010 12:09 AM #26
      did you decide not to use the mk4 intake i see in one of your pics you have the mk3 intake

    23. Member Svedka's Avatar
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      11-16-2010 09:54 AM #27
      That's the family car with the mk3 aba full swap.

      I am using the mk4 manifold on the turbo coupe, finishing the last few miscellaneous mods to it. Had to make a heat shield for the throttle body and tap and reroute the brake booster line as well as make a mounting bracket for the back side of the intake manifold.

    24. Member Dave926's Avatar
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      11-17-2010 10:21 PM #28
      Quote Originally Posted by Svedka View Post
      finished my SS oil return line ended up about $60. If I was to do it again I would weld my own bung onto a pan and have a custom line made to fit with less fitting's. I did not like the fact that most just drape around the axel so well see if mine works ok or if I have to drape it around the axel. Had to make a bracket to hold it to the block.


      Just a few little details to finish up
      Same here about the bfi pan. Its ****ing junk were they put the bung. Plus the threads are on the inside of the bung, so by time you get all the adapters in there with a too small -10 you have a drain line in the 0.4xx range.

      I blocked mine off and ran a -16 an line for a turbo drain, and had a bung welded over about an inch to the passenger side.

      There is some stuff out there so you can tune the digifart yourself too.
      Last edited by Dave926; 11-17-2010 at 10:23 PM.

    25. Member Svedka's Avatar
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      11-19-2010 12:12 PM #29
      Quote Originally Posted by Dave926 View Post
      Same here about the bfi pan. Its ****ing junk were they put the bung. Plus the threads are on the inside of the bung, so by time you get all the adapters in there with a too small -10 you have a drain line in the 0.4xx range.

      I blocked mine off and ran a -16 an line for a turbo drain, and had a bung welded over about an inch to the passenger side.

      There is some stuff out there so you can tune the digifart yourself too.
      Although I said i would weld my own bung to the oil pan in no way am I saying the BFI pan is junk in all reality it was a bolt on piece and does work I would just do it differently if I was to do this again.

      You can tune the digifart yourself if you have the programs but in my case buying theses programs would cost as much as setting this up on MS so I only used the digifart to get it going because I had it and had a chip maybe next fall/winter I'll do the swap to SEMS.

    26. Member Svedka's Avatar
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      11-19-2010 12:32 PM #30
      Update:

      Last mock up for BOV wastegate lines and vac lines


      Finished manifold


      My oil return bracket


      My new lighter


      Not alot of time to work on the project this week but maybe this weekend I can put a few more hours into it


    27. Member B4S's Avatar
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      11-21-2010 04:32 PM #32
      Quote Originally Posted by Svedka View Post
      Although I said i would weld my own bung to the oil pan in no way am I saying the BFI pan is junk in all reality it was a bolt on piece and does work I would just do it differently if I was to do this again.

      You can tune the digifart yourself if you have the programs but in my case buying theses programs would cost as much as setting this up on MS so I only used the digifart to get it going because I had it and had a chip maybe next fall/winter I'll do the swap to SEMS.
      I got my chip burner off ebay for $16, and the programs are freeware. If you click the red in my sig, there is a document that I wrote on self-chipping digi-1. It's completely mappable, like megasquirt.

    28. Member Svedka's Avatar
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      11-29-2010 04:04 PM #33
      Got it fired up and running this weekend so I will be test driving and tuning this coming up weekend

    29. Member Svedka's Avatar
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      12-02-2010 08:23 PM #34
      Runs


      Under side throttle cable pull


      How it started


      How it looks now just need to wrap and finish some wiring


      I also decided I would buy another digi 1 ecu and the burner so I can attempt to tune it myself it shall be a learning experience if nothing else


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