A start of a new "project" IMG_20170305_150102_zpszaskgw6e by Milos Balunovic, on Flickr you wonder what happend... 1st - I drive a turbo car, that has the most sensitive turbocharger probably there is. and the fact once I drowe 600km with broken intake pipe from IC to intake ) didn't notice it as I wasn't pushing the car on the highway and I drowe on cruise control I think you know what happened. my turbo gave up at 200km/h 20170310_172646_zpspnqy6mgd by Milos Balunovic, on Flickr the shaft broke to 3 peices, puncturing the intake pipe from the airbox. god thing that at same time the exhaust part got out and blocked most of the exhaust flow. 20170310_173608_zpscrzhjgvf by Milos Balunovic, on Flickr 20170311_120930_zpsnrkoctte by Milos Balunovic, on Flickr 20170311_120940_zpsp8nn3ltf by Milos Balunovic, on Flickr aprox 1/3rd of oil from the IC 20170311_123953_zpsjvj4ged2 by Milos Balunovic, on Flickr I suppose there was 1 to 2 L of oil in IC. there is just enough oil in the engine to touch the oil stick.
So I decided I wont mount that turbocharger again. 20170312_135808_zpsubydhzq2 by Milos Balunovic, on Flickr 20170312_135818_zpsnhuhs5zk by Milos Balunovic, on Flickr 20170312_135824_zpspedlfquj by Milos Balunovic, on Flickr the VNT mechanism has been rusted, the turbocharger wasnt on a car for few years, so I cleaned that and now it looks like this 20170313_183605_zpscxpbfgnf by Milos Balunovic, on Flickr vnt mechanism. [ 20170313_183626_zpsr1kwskzi by Milos Balunovic, on Flickr Open position, low boost 20170313_190800_zpsqghhz274 by Milos Balunovic, on Flickr Cloased position - max boost 20170315_164736_zpsekrg957u by Milos Balunovic, on Flickr intake 20170313_184409_zpsxuwqng5n by Milos Balunovic, on Flickr 20170313_184414_zps3ezpqctz by Milos Balunovic, on Flickr Go BIG or go home stock one is GT1749V (1st gen.) this one is GTB2260VK (3rd gen.) plus the size difrence. (top one stock, bottom one new one) FILE001_zpsybvkhsir by Milos Balunovic, on Flickr exhaust housing diference 20170314_162237_zps5jehxaal by Milos Balunovic, on Flickr 20170314_162345_zpsnup6vcon by Milos Balunovic, on Flickr
made an adopter plate to check if everything will fit 20170317_190952_zpsz0jda4g0 by Milos Balunovic, on Flickr 20170317_191013_zpsodryuwe7 by Milos Balunovic, on Flickr 20170318_110532_zpsrqrryf3j by Milos Balunovic, on Flickr 20170318_110537_zps4uxh7egw by Milos Balunovic, on Flickr 20170318_110541_zpsj5ey1kol by Milos Balunovic, on Flickr 20170318_110545_zpszniue0wz by Milos Balunovic, on Flickr ill need to reroute the cabin heating pipe 20170318_110626_zpsfc4goiwq by Milos Balunovic, on Flickr vacuum VNT actuator fitted, (stock one is electronic) 20170318_194248_zps2m06o1op by Milos Balunovic, on Flickr 20170318_194303_zpsu7bph2yo by Milos Balunovic, on Flickr rechecked if it will clear the starter motor, etc. 20170324_152803_zps6z3ukpuo by Milos Balunovic, on Flickr 20170324_152819_zpsc2hhc9y9 by Milos Balunovic, on Flickr
no more eco man from me talk about EGR delete Intake side: received_10212350964668134_zpsdzybfgtx by Milos Balunovic, on Flickr received_10212350964628133_zpsrmfkqvvy by Milos Balunovic, on Flickr received_10212350964708135_zps4owgjepe by Milos Balunovic, on Flickr received_10210642218984934_zps6eujnqe1 by Milos Balunovic, on Flickr exhaust side: 20170325_114944_zpsiabzqskr by Milos Balunovic, on Flickr 20170401_105510_zps8cc78blq by Milos Balunovic, on Flickr the original complete part looked like this: received_10209350792385702_zpsqnxvdwwg by Milos Balunovic, on Flickr
bought some steel angle pipes (bigger ones are OD 76mm ID 70mm),smaller ones are for my friend. 20170330_131706_zpsv9pmnbz7 by Milos Balunovic, on Flickr Wellded 20170401_194928_zpsg7oqskge by Milos Balunovic, on Flickr Full penetration: 20170401_195228_zps9fss3nf2 by Milos Balunovic, on Flickr that's now on halt until my adapter plate, and downpipe flanges arrive so I can cut the pipe to size and weld on the last angle.
got these from my friend. one pipe is for the turbo - IC pipe part I missed that was just short, now I have enough piping to replace the pipe from IC to the intake manifold, also got a huge oil cooler- 20170403_154649_zpsqcv00v3b by Milos Balunovic, on Flickr ordered this boost gauge, as I dont want to have one more failed turbo because I didn't notice something was wrong. and I don't want to run my torque pro all the time received_10212435605424100_zpstm20ryau by Milos Balunovic, on Flickr I will mount it like this fella relocated my engine breather pipe connection, 20170402_155015_zpsmv0xbb4k by Milos Balunovic, on Flickr 20170402_155029_zpsdhmh2l1w by Milos Balunovic, on Flickr So I can make room for bigger intake pipe as the stock turbo feed pipe is 40mm ID, and the turbo needs an 55mm pipe: here you can see the new intake pipe and the new relocated cabin heater pipe. 20170401_141539_zpszbbscsn3 by Milos Balunovic, on Flickr 20170401_144110_zps3q9mcdxf by Milos Balunovic, on Flickr the old turbo oil feed line fits, the oil return does not fit so well so I cut it in half and used the beginning and the end and the rest will be replaced with a silicone hose.
Im waiting my cnc machinist for adapter plate and 2 flanges for diwnpipe they should arrive in a week or so. Sent from my LG-D855 using Tapatalk
made an silicon-alu pipe from the IC to the intake manifold, which was plastic OEM. I only have to flare the pipe to ensure the silicone pipe wont slip off 20170408_133510_zpsraby6pya by Milos Balunovic, on Flickr 20170408_133514_zpsaqulmzx9 by Milos Balunovic, on Flickr 20170408_133522_zpsccv3sjtx by Milos Balunovic, on Flickr
some goodies arrived 20170409_085325_zpssihud7xz by Milos Balunovic, on Flickr 20170409_085328_zpswieffviw by Milos Balunovic, on Flickr RS250 DMF/Clutch plate/Pressure plate
the most important parts after the turbo have arrived ie the ex.manifold to turbo adapter plate, and downpipe flanges designed/received: image-0-02-05-c2487ed0cc101dded5db3a6c123ffa71cf2520906d3fb06b594069712083f7f7-V_zps9hovxwwj by Milos Balunovic, on Flickr IMG_20170413_100301_zpsprtqzumi by Milos Balunovic, on Flickr received_10212340544527637_zpsiewa6ugq by Milos Balunovic, on Flickr IMG_20170413_100221_zpskd9a3jv7 by Milos Balunovic, on Flickr received_10212340549807769_zps7bbwzwv4 by Milos Balunovic, on Flickr here we changed a design in the mean time a bit, for smaller screw heads etc IMG_20170413_100251_zpsyeie0j0k by Milos Balunovic, on Flickr
almost done me and my wife started at 3pm and finished at 9pm when the car started gosh, how much smoke came out of the car, it was unbelievable. but lets start from the beginning. from the part which took most of my time. I put the welded part of the downpipe and the turbo flange, and hey, there was a nasty surprise. downpipe is 10cm beneath the exhaust, and that is the minimal distance that could be achieved because of the downpipe had to clear the turbo. 20170414_164654_zpsdttaom8v by Milos Balunovic, on Flickr figured out the solution. 20170414_171243_zpsf15ywtb6 by Milos Balunovic, on Flickr 20170414_180323_zpswlzbvx6x by Milos Balunovic, on Flickr only part left to do is to see why is there an oil leak on the oil supply line to the turbo. and to bee clear, this is my workshop received_10212878328699192_zpssakth633 by Milos Balunovic, on Flickr 20170414_161505_zpsbqinbpgz by Milos Balunovic, on Flickr
thats the fun part of it. now i have to make a big service (cam belt, water pump etc, big end bearings, dmf/clutch upgrade) and then gather some money for the remap, to fit the oil cooler, and maaybe make an water methanol injection
Well done - that mega - total dedication and drafting the wife in too, top marks The welds do look, er.. not great though
Some hoses to tidy up the engine bay 20170419_200433_zpsjfrgcz8r by Milos Balunovic, on Flickr Sent from my LG-D855 using Tapatalk
updates slowly to come my old vs my new (used) dmf, (please like and share the video on YT). I managed to fit the RS250 DMF + clutch plus pressure plate, tho one thing that disappointed me way that the clutch plate is same diameter as the 1.9dci tho they are specified as 240 for 1.9dci and 250 for RS mk3. tho I can feel the new pressure plate being stiffer more on what was needed to fit the RS250 clutch to the 1.9dci later on
the light on the gauge turns on as the headlights do 20170502_171935_zpsyfzpn8g8 by Milos Balunovic, on Flickr
lets explain how the rs250 dmf set fit the 1.9dci the oem has 60 teeth crank position profile, 58 teeth's + 2 missing one the rs250 has the same 60 teeth position profile but 57 single teeths, one double teeth and one missing one. and is rotated compared to the oem. the work need to perform the conversion was to cut off the 2 teeth's at corresponding position, cut the double teeth to two single ones, and weld on a missing teeth.
as the full brightness of the boost gauge irritated me at night driving I decided to make it adjustable. using 1k ohm potentiometer, the backlight can be adjusted from max brightness to turned of as seen on the video. the pot is "click" type so i have 4 positions: 1-max 2-dimmer 3-even more dimmer 4-turned off
I got to participate in a drag event held at Grobnik airstrip in Croatia. Sadly i had trouble with the car. and in the end I won the 3rd place in 16s class 19648252_10213411043129433_1952010940_o by Milos Balunovic, on Flickr The problem I had was actually the intake pipe between the air filter and the turbo collapsing, and taking all of the pressure/flow down to minimum.
in the mean time we are slowly raising the power. here are few boost logs in the process. 1.55bar (very low boost for this turbo) Log - 2.55boost map 1st iteration._zpspb3ndv1v by Milos Balunovic, on Flickr but the boost was very stable. then we upped the "game" and raised the boost to 2.3bar Log 2.3bar_zpscdsmtvqr by Milos Balunovic, on Flickr , the redline is at 5000Rpm but I had to brake I need to adjust the VNT actuation a bit and that should be it. the second run was done with open airbox and no air filter. I thought of making an intake like this made by Steven878 shown in this thread Steven878's r26 build thread: 8db4a8c9dcdd230c8718c8aa2cde2fd8_zpsbfbt6gmm by Milos Balunovic, on Flickr will see what ill accomplish
the photobucket pulled the plug on me only yesterday, so now I have to re-upload every image and re organise. will do asap (probably tomorrow) very shitty move from photobucket...
Photobucket has really gone down hill. So slow and full of adverts Sent from my SM-G935F using Tapatalk
this (rubber pipe that goes on turbo) is the pipe that has been collapsing on me during the drag event. 20170401_141539_zpszbbscsn3 by Milos Balunovic, on Flickr I figured it out when I removed the intake pipe to the turbo, and the turbo and the power of it emerged. Then I figured I will use it to test out what is also restricting in the pre turbo intake system. removed the filter and filter holder (ie open airbox) and the problem was gone. it was then time to figure out if the filter it self is the flow limiter, or the airbox it self. I put the filter holder back in without the filter, and the problem is still present. so I think to my self, this must be because of the restriced airbox, so I cut it open and ised it with the filter 20251101_10213630446894390_2406417_o by Milos Balunovic, on Flickr this was ok for a small period, but on hot days the pipe would collapse on me anyway. so I replaces the rubber pipe with a plastic one from another cars turbo air feed line and its "OK" ish, but im definitely planing on running a CAI system. just have to figure out how exactly.
what do you guys think, is 50mm sufficient or should I use a 76mm ID pipes for turbo feed pipe (from air filter to turbo)? the 76mm is much harder to route to the front-fender like shown above the 76ID has 2.25times grater surface then the 50mm id one.. I ordered this RAMAIR filter Thanks in advance for the help/advice.
Fitted a CAI And got my self an rs225 front and back bumper. Still unbiased abaut the rear. I dont know if I like it or not.
I love all the work and fabrication that had gone into this car.love individual build threads like this,makes for a great read.well done and keep up awesome modifying
described latest upgrade as mentioned before the intake to the turbo is very restrictive, and there isnt to much space either to fit a higher flow one. hence I decided to go with a Cold Air Intake - CAI and put a big sponge filter there (an 170mm OD 170mm long Ram Air cone) only god place for such is the front bumper underneath the headlight, but to get there, its a long road the stock airbox feed pie is 60mm OD and i desperately wanted to run at least 70mm ID which was an 76mm OD pipe as long as I could and only taper it on the very end to the 55mm ID (same as the OD on the turbo inlet) first thing first, this channel that the OEM feed pipe towards the airbox need to be widened. 20170814_185142 by Milos Balunovic, on Flickr the easiest way was to bend it. 20170814_191448 by Milos Balunovic, on Flickr and woila, the 76OD pipe fits 20170814_190722 by Milos Balunovic, on Flickr in the end i had to cut out a part of the bent piece to be able to route the 90deg bend down under the headlight as I have hid headlights, and they occupy more space behind them 20170816_111019_HDR by Milos Balunovic, on Flickr 20170816_111022_HDR by Milos Balunovic, on Flickr 20170816_111151 by Milos Balunovic, on Flickr and it fits 20170816_114031 by Milos Balunovic, on Flickr I created a support that mounts to the body to stop any potential vibrations but I forgot to take photos battery trey was cut, and pipe is routed 20170816_172428 by Milos Balunovic, on Flickr MAF retained (the plastic hose , with white strips was changed for a rubber one) 20170816_172430 by Milos Balunovic, on Flickr I ran the feed underneath the master brake cylinder to lower the need/number of the bends. I know I need to sand the welding marks, but I assure you on the inside, everything is clean. The IAT temps are now only a degree to two degrees higher than ambient temp which is huge improvement
