MK1 2.0 16v Turbo

fuel_slut · Apr 23, 2009

Looking good.

From experience you are going to have sooo many problems with the manifold. I garentee those welds will crack after time. Log type manifold is better but even these seem to warp and crack.

Justin_16vT · Apr 24, 2009

yeah im aware its going to crack

one of the biggest pain jobs to do aswell, as im going to have to remove the head/engine to get the manifold off

fuel_slut · Apr 24, 2009

Naples_16v said:
yeah im aware its going to crack one of the biggest pain jobs to do aswell, as im going to have to remove the head/engine to get the manifold off

If you can somehow re-enforce those welds, then try to. I replaced all my exhaust mounts and tried giving the system more support just to take abit of stress off the manifold. But its difficult to stop warping and expansion.

Some manifolds have a cut on the mating face of the manifold to allow for expansion.

I have had to remove and weld mine twice now!! lol

Justin_16vT · Apr 24, 2009

ah right, well i've got to fit all new rubber mounts on the system anyway. plus im looking into a mani/turbo brace to the block to take a bit of weight strain off of it

Justin_16vT · May 7, 2009

Exhaust is finally all put together and worked out after much hassle!! Found a nice section of flexi piping

Also put my battery box in

Tomorrow is D-Day (decision day) on rear brakes wether i mod them or keep standard as i'll be hearing from/visiting the machinist

f0xy · May 7, 2009

where is the battery box from mate? looks pretty tidy

Justin_16vT · May 8, 2009

ebay, listed as a caravan battery box lol

f0xy · May 8, 2009

cool! does the lid 'attach', or just sit on top?

Justin_16vT · May 8, 2009

ive a strap to go over/around it that came with it

f0xy · May 8, 2009

nice one, cheers for the info. Cars looking good too

Justin_16vT · May 8, 2009

no problem and cheers

Rob · May 8, 2009

Just read all 13 pages and it was well worth it!!!! Great project, like how you've just picked up bits off ebay and tried to make it all work! Amazingly impressed considering your not a mechanic! Good work! Can't wait til i have an income that means i can try things like this!

Justin_16vT · May 8, 2009

Thanks for the kind words

and yeah, 90% of things are from eBay lol

k1ano · May 8, 2009

fuel_slut said:
Looking good.

From experience you are going to have sooo many problems with the manifold. I garentee those welds will crack after time. Log type manifold is better but even these seem to warp and crack.

I concur with some of the above ...

I just saw this thread and read the first couple of pages (will finish the rest in a bit) and my immediate thought was the manifold and turbo - it is in clear need of a turbo stay IMHO to prevent cracking/failure of the manifold which I would say will occur otherwise. I have had a fair bit of experience with turbo installations on various cars and have had tubular manifolds made before and have experienced issues with no stays.

It shouldn't be too hard to make a stay up to support the turbo though if you haven't already.

I also hope all the welds have been cleaned up inside the exhaust manifold too but that should be a given and it looks like a comprehensive job ...

Looks a great project though and I love turbochargers

Martin

172Ben · May 8, 2009

The turbo has no support? And is just effectively hanging off the manifold and connected to the exhaust?

Mark One · May 8, 2009

it's a T3 isnt it? weighty bugger is gonna want some support?!

Justin_16vT · May 9, 2009

its getting support

Fred@BTM · May 9, 2009

no need to run the earth the length of the car fella!

Justin_16vT · May 9, 2009

cable and connectors cost me nothing

Fred@BTM · May 9, 2009

apart from time! it does nothing and costs extra weight! add at least 3psi to compensate

Topgeartom · May 9, 2009

this is cocking fantastic.

Think i saw the start of this on c16v then managed to forget about it.

Just read through the lot and i'm massively impressed with all the fabrication. I just wouldnt know where to start with everything!

Justin_16vT · May 9, 2009

Cheers tom

Fred said:
apart from time! it does nothing and costs extra weight! add at least 3psi to compensate

haha

kevin.s · May 9, 2009

this is a great build mate. your a skilled man.

ric1.4 · May 9, 2009

sweet build dude

DH_GTI · May 9, 2009

just read all 14 pages,
Great project and car now get it finished lol

sideways danny · May 9, 2009

Mark One said:
it's a T3 isnt it? weighty bugger is gonna want some support?!

my GT28RS doesn't have any support, done close to 40k on it like that now. Mild steel steam pipe

Justin_16vT · May 16, 2009

Wrapped the downpipe today. Bought 100ft of exhaust wrap and still have miles left :lol: so going to wrap the decat aswell lol doesn't look to bad, sprayed it with some silicon stuff for heat wrap ?

Andy GDI · May 16, 2009

looking good

Justin_16vT · Jun 6, 2009

http://www.youtube.com/watch?v=YuihMXf5xws

exhaust blows STILL and need a different dump valve i think. not sure why else im getting comp stall

Adey. · Jun 6, 2009

softer spring in the dump valve but big turbos have big blades that seem to chop the air more if you know what i mean

Mark One · Jun 6, 2009

I'd leave it. You've got the DV in there to protect the compressor from really high pressures, It's just stalling a bit when it builds real boost up. I'd leave it for the noises tbqfh!