darrenjlobb's M-TDI/16 Twin Turbo 306 Project

Vlog part 9

2012-09-30T16:25:00.001+01:00

Vlog Part 8

2012-09-29T21:36:00.000+01:00

Sorry for the editing fail!

Tearing it out again!

2012-09-29T20:41:00.000+01:00

So the time has come to tear the motor out again....I have really hit the limits of the standard 16v head now in many respects...the exhaust ports are very restrictive, the valve springs are so weak that im floating valves at any more than 30psi, and the hydro lifters are just poop, so its time to tear it off and beef it up!

The stripdown...

Now time to strip the motor down!

We Have Thermostat!

2012-08-29T22:00:00.001+01:00

Well ever since the motor went in the car, it has been running without a stat, so constant flow to the radiator...the original HDI stat housing was frankly a total pisstake / took up half the engine bay, which space was IMO much better used for turbos than holding water for no reason at all!

So the engine went in with a simple homemade flange to allow the rad hose to connect to the head...which is all well and good, but obviously no stat, means serious over cooling of the coolant, and in turn, meant the thing runs at like 40deg / 60 flat out, which is far from ideal, so after re arranging the boost pipes a bit the other day, I have now fitted my external stat housing just down in the front...

The housing with stock PSA stack inside (83deg):

And in position, there is a bypass pipe thats out of view, that routes the water back to the water pump until the stat opens, allowing the engine to circulate water / warm up evenly.

In position:

Now holds its temp perfectly at 83deg, yet to drive as front end is still missing!

Thanks for reading :)

Vlog7

2012-08-28T11:47:00.002+01:00

More Fuel!

2012-08-27T11:43:00.004+01:00

Despite the current restriction of air / boost, as the car stood, with everything maxed out, the injectors could only really move enough fuel for 140-150hp at most, which although was all very well and good to run it in, was really starting to get rather boring by this point, so it was time to start playing...

I have already built a VE pump capable of moving some fairly serious ammounts of fuel, which on an IDI would be all I needed due to the nozzles being so free flowing as stock...but with DI, its a very different kettle of fish, which nozzles in the injectors always being the next big fueling restriction, so I needed to find / modify some to fit!

A few emails / phone calls later, and a 3 weeks wait all the way from Texas USA, these turned up at my door:

So after some brief prayers for the poor DW10, it was time to make them fit...as with everything in this build, its not just a case of bolting them in, despite being fairly custom made anyway, they simply dont fit my current nozzle holders without "modifications", so, out with the grinder on one of the most precision parts of the entire injection system....

Then was time to test them / shim up the springs to get them popping off at the correct pressure, notice the rather chronic amount of fuel exiting the nozzle!!!

So for all the people wondering, that's what the delivery from the states was all about!

Now we need more air, badly!!

Changing Things Around!

2012-08-26T18:20:00.001+01:00

Well times have been a bit busy just recently on the farm with harvest and what not, so progress has been very slow / non existent with the bus just recently, but small things have been going on / some big changes taking place!

I've been having an issue with the manifold / turbos melting the reverse cable, which with a gti'6 box, can lead to some VERY embarrassing situations in the local village of meva with single row streets, and no reverse....your imagination can do the rest...long story short, 2 way traffic jam, oiley haze passing down the street, racket coming from hunting DI motor running plenty of timing, and me looking like a right idiot getting out asking for a push wearing a Deere boiler suit and covered in WMO!

The melted section of cable (plastic inner layer fused with plastic lining on steel cable!):

So after having a good hard think about it, there were two options, A was to bodge it, and have bit of fencing wire thro the bulkhead that you simply yank on to use reverse, simple, effective, and would do the job....but messy / just not going to happen...So came up with something a little more interesting involving a boot popper, some wiring, a relay, and a switch! Basically ended up mounting the solenoid well away from the head, and then with clear line of site, a single solid steel wire back to the tranny, with a oem switch in the right hand trim area which you can activate with your right hand while dropping the tranny into reverse with left hand as normal, works like a charm, and shouldn't suffer from heat issues! Also means I can loose the spasticated gti6 gearlever that feels the need to be half a meter up into the cabin?!

Picture of the solenoid semi in position:

As tuning is now under way, some teething problems have become apparent, and need dealing with....The original plan was to run the two turbos sequentially, and then compound with the supercharger to long term give me some decent pressure / flow to work with... But after being on the road a few weeks with the VNT, its become very apparent that the supercharger is really just not needed anymore, and being one of the most problematic / un reliable components, other than the noise, im more than happy to see it go!

So I made the decision to sack off the charger, and then run the blowers in compound instead, midrange torque / daily driveability is all good fun, but after a couple weeks it soon gets boring, and its never what the cars been about, so chronic top end boost wins for me anyway!

Long term the VNT is really a little small for the compound arrangement I have going on here, but will work for the time being with external gate allowing excess exhaust to bypass the VNT to save cooking it! but upgrading the smaller turbo is certainly on the books for the future.

But anyway for now, it was time to go ahead and plumb it up / remove all the bypass valves (that took ages to make / get working!!) and simplify things a bit, as well as at the same time inverting the gas flow through the intercooler, and relocating the oil cooler to somewhere it didnt look to tragic!

This is the arrangement I've ended up coming up with, again as normal, its a constant fight with making it physically fit under the bonnet, and perform the job in hand without rubbing / fouling anything else!

There are many other things I've no doubt forgot to mension / photograph, but I think that's covered some of it!

The next big thing is really going to be a case of beefing up the head, as the stock head is fitted with valve springs that float at a mere 35psi of boost (hence my serious limitation right now) and also very restrictive exhaust ports...so lots to get busy with!

Thanks for reading :)

Time to start getting serious...

2012-07-18T20:41:00.000+01:00

Well now that FCS is out the way, and ive got some miles on the motor, its time to start getting serious with the motor, as afterall, I didnt build it to run a reliable 150hp all day long!!

First step is to beef up the injector pump some, only small modifications for now, but will be getting the drill out soon enough!

Anyway pulled the pump off this evening:

Vlog 6

2012-06-23T20:26:00.002+01:00

Vlog Part 5

2012-06-23T18:25:00.003+01:00

Tacho Sensor

2012-06-09T20:22:00.001+01:00

Little boring update, still waiting for stuff to be sorted out so cant really make any serious progress, so started work on a few side lines, one of which being getting the tacho to work, as the DW10 has no pickup point for the old XUD style pickup, as they use the ecu / 42-2 sensor, which would be very hard to get working with a ph1 dash.

So just mounted the original XUD tacho sensor in the bell housing cover, and hey presto we have a tacho!

Pump Timing and Charger Woes

2012-06-09T20:20:00.004+01:00

Ok so progress has been pretty slow, I'm having serious headaches with the ongoing crank pulley saga, but have possibly found a new person to do it (many thanks to Scott) so we will see how that one goes.

In the meantime have been sorting out some other issues, timed up the pump to get a base timing figure, which will make tuning much easier in the future, seems going by "knock" is very much impossible with DI as the window for engine to run is absulutly tiny in comparison to the idi which seems to run even if pumps 180deg out!!

As some people have no doubt noticed on my facebook, have had another fail in that the charger I bought (old one got broke on last engine) has turned out to be dud, basically on the eaton chargers one end of rotors is oil filled, so generally fine, but other end runs in sealed needle bearings, which often fail if not rebuild / greased, turns out some **** fooked me over on ebay and sold me a screwed one, sadly bought it months ago and only just got around to digging it out, so no way to get refund now, so will have to order up another!
But basically the bearings have been gone a while / rotors have been rubbing the casing / screwed it totally, either way, I repacked the buggered bearings with grease / re built the blower just so as I can still start the car in the workshop etc as without it the belt dosnt fit and decomp isnt happy!

Few photos of the rather pointless rebuild:

Other than these fails, not much to report sadly!

Some bits and pieces

2012-06-09T20:19:00.002+01:00

Have been waiting for a part for a while now and sadly the guy who was making it has got mechanical issues with his lathe, so is unable to complete it for me, which has left me with no time to sort anything out in time now, not helped by the stupid insurance problem which is still an ongoing saga as of the moment.

Due to not being able to get the car up and running / ive been working on silly little things, so got the cooling system piped up as far as I could without the front end on, mounted the accuators on the VNT, and big turbo, and also made my homemade boost bypass valve, doesn't look like much, but surprising what time it takes welding up little brackets / stripping actuators to reverse spring movement etc...

VNT Can: (ignore solid oil line as have now replaced with homebrew flexis) (this was a bit of a tight sqeeze!)

Wastegate on the big blower (clears clutch arm by 2mm, altho have since moved it due to pipe route issue):

And the bypass valve, its made from a petrol throttle body which i modified to close fully, welded up some brackets to hold a boost can, then welded wastegate lever to the butterfly shaft,and reversed the spring inside the boost can, hey presto:

And a bit of a mock up of how im going to sqeeze the sequential setup in the bay, hence having to re clock the blower:

Oil Feeds

2012-06-09T20:15:00.004+01:00

Not much to update sadly as stuck atm waiting for parts to move it on, but did get turbo oil feeds half sorted the other day, although waiting for some inline filters to turn up atm so cant even finish that.

Made up my own hoses with AN fittings, if anyone is doing custom turbo jobs, this is by far the easiest way of doing this that ive found, fittings for anything in the world are easily avalible, and easy to do yourself...

Manifold Wrapping

2012-06-09T20:14:00.003+01:00

Well due to a fairly epic cock up on my behalf with photobucket, I figured I had better update this anyways, havent been posting much recently as been busy trying to sort this out as still lots to do and think only 6 weeks left till my "deadline", but seen as though the photos got uploaded publicly by accident anyways, I might as well write about it to!

Still got some cambelt issues, but waiting on a pulley which should resolve that, fingers crossed, but has meant very little progress on engine side of things as unable to run it now until ive got the pulley back...

So have used the last week or so focusing on blower mounting, which has frankly been a total ballache, but starting to get there now.

Got my manifold back from tigg'ing last week, which meant my most loved job....not....heat wrapping! Everytime this stupid stuff piss's me off / gets all itchy and horrible, but had to be done, so set about doing it in a couple evenings to get it out the way:

Was really fidly / tight, but got there in the end, its no pro job, but its good enough for me

Then set about bolting up the blowers / bypass, and heatwrapping that also:

Then got it mounted in the car, and sorted out the oil feeds / returns, still waiting on some fittings for the return on the VNT as dont have anything suitable, but got the big'un plumbed in.

Also got the supercharger re mounted on the new mounting face, which *fingers crossed* will be the final location, but cant test as cant run it up yet with no belt setup etc, but should be with me soon

Fan Update!

2012-06-09T20:12:00.005+01:00

The fans before mounted, much as the last ones only these acaully blow some air, last one were suck only running in reverse, which was just total air flow fail!

Also got oil cooler plate mounted / new gauge senders into plate and all mounted up:

Tidying inside up

2012-06-09T20:09:00.005+01:00

Spent some time today putting the interior back together, as never really did after changing the heater matrix as got my interested in doing the engine!

Ended up gutting all the old wiring out, and re doing it all, using a multicore from cabin to bay as fed up with a thousand cables thro the bulkhead!

The mess:

IPP gauge / various switchs (ive given up on making things look clean / tidy inside now)

Wiring is obviously covered up though in attempt to look tidy...

Almost back together :

Notice the glove box top box has been converted into a wiring center, as its useless for anythig else anyway, so just removed the box part, attached hinges to dash and lots of room now for wiring!

The new third boost gauge to monitor manifold boost levels, the most win gauge ever, acquired from james's work, win for many reasons, A because it goes to 100psi not just 60, but mainly because the green area is between 40 - 60psi...WIN?!!?

Have also wired up elec pas again / new relay, and same for rad fans. Has also been a breakthrough with regard to the bonnet fail, and with some carefull (not pretty) injector line adjustments / other modifications, the bonnet SHOULD now close / not foul the engine. Lines arnt pretty, and will be replaced at some point, but should be functional for now.

Thanks for reading

First Start!!

2012-06-09T20:06:00.002+01:00

Another little video update, including the first start, although there was a camera fail involving the battery going flat on the tripod, and me not realising, so sadly it cut off after priming oil system, but video of it running was taken the day after when I moved it about a bit. Some of you with a well trained ear will probs notice a sticky injector on number two which is causing the thump thump thump you can hear from a single cylinder, which has now been resolved.

Supercharger mounts,

2012-06-09T20:04:00.005+01:00

Well a bit of an overdue update, but sadly not a very interesting one,

Have pretty much been sorting out some campatibility issues over last few days, as nothing bolts up as I had hoped, so have been having to re make just about everything to make it fit / work right.

Tonight has been sorting out the charger, as it used to bolt to the alternator bracket / block / pump, and all 3 are out of sync / different now, so had to start over, also added a steel plate to make the mount rigid to stop stress being put across the charger itself, which last time resulted in a mounting lug snapping off.

Other bits and bobs werent really worth bothering to take photos of, have also sorted out a lower tensioner, so just need to measure up for belt and get one, and charger should be finished bar painting up the brackets.

Uh oh, wiring!

2012-06-09T20:03:00.003+01:00

So I figured id sit down quiet yesterday (regret it today!) and carry on with a little job that needed doing on the car, stripped the XUD loom down, and removed all the crap I didnt need / re taped it all, amazing how much crap pug put in the loom thats totally pointless tbh!

Old loom: (has already been pruned once before for last rebuild)

After a "prune"

Video Update 3

2012-06-09T20:01:00.002+01:00

General Update

2012-06-09T20:00:00.002+01:00

Another update....

Been a **** of a week / weekend, but did manage to get some stuff done, been having issues with missing bits / bits not fitting as hoped / having to make stuff up etcetc, just loads of lame time consuming shabang that isnt worth talking about!

Anyway, sealed up the rear crank cover:

Also had to machine the lower cambelt pulley, as I need to run an XUD one to fit my uber charger pulley, but the hdi ones are a different style, and the oil pump retainer is also different, meaning you cant just run the complete DT setup with narrowing the pulley...another fail that I had to end up dropping a main bearing to get over which took time.

Then got around to finishing building the injector pump, the first pump ive built is a pretty mild / tame" pump, as just want it to run oemish / easy to setup to start with until I work the niggles out, but just doing that has caused to much grief, due to incompatibility between IDI housings and DI parts, etc.
Also tapped out the IPP gauge fitting: (please ignore the shear state of the bench, things were not going well this day lol....)

So then had to abandon the pump as was missing a bit I needed, so went ahead and mounted the motor in the car for the first time SO I could measure head to bulkhead clearances etc, and also check it fitted ok / mod the top engine mount to fit.

So then once that was sorted, pulled it back out again, and set about mounting up the pump, fixing up injectors into head, and making injector lines up to join the two things together, ended up bending a set up myself as buying ones made to a design is $$$, Will see how it goes, do the same on field cars all the time, and has always worked well, ive tried to keep them tidy on here though obviously, kinda oemISH

Also realised that some bolt holes I thought were the same arnt, so my supercharger brackets on left side / crazy idler system wont fit, so going to have to make a new one...think this must be going to be S/C belt setup mk6 by now!

Thanks for reading!

Heater Matrix Woes

2012-06-09T19:57:00.000+01:00

Removed the heater matrix this afternoon, so waiting for new one to turn up now, did few other little bits and bobs, but nothing major as spend day fixing other things really.

Almost had a very expensive disaster yesterday with the new engine, but luckily my toe was just quick enough to take the crunch instead of the engine!

Video Update 2

2012-06-09T19:55:00.002+01:00

Video Update 1

2012-06-09T19:55:00.000+01:00