Project Golf TDI ARL - PD300 304hp/530NM
09-05-2008, 10:20 AM
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Project Golf TDI ARL - PD300 304hp/530NM
Project PD150
Some of you may know I've been modifying my golf over the years and edited this thread to show a bit up to date information.
I ran the car on a stage 1 remap for approx 2 years. After this I done whole load of work and research to reach a MAX power figure of around 230hp. For anyone that reads this thinking 230hp is obtainable from a hybrid please think again as I had to run a very aggressive/unsafe map to get this figure. A true (and I mean a true power figure) for all VNT 17 based hybrids is around 220hp on stock nozzles.
I have now moved away from VNT 17 hybrids a fitted a bigger turbo unit, bigger nozzles and lots of fabrication work.
Heres the story
March 2008 - Clutch
In addition a new Sachs Dual Mass Flywheel and release bearing were fitted.
April 2008 - EGR Replacement
Before
After
As I have blocked the exhaust manifold end I decided to remove all this (not had any problems with cabin heating):
May 2008 - 312mm Audi TT set up - these might look like scrap metal but they are actually in very good condition
May 2008 - Hybrid turbo based on a VNT17 - with bigger exhast and compressor wheels
May 2008 - Turbo back Milltek exhaust system
May 2008 - New top suspension mounts (plus bearings), ARB bushes and 312mm set up fitted
May 2008 - Exhaust system fitted
May 2008 - Picked up a rear Audi S3 brake set up 256mm vented with calipers & carriers
June 2008 - Alloy boost pipes finally landed
June 2008 - Alloy boost pipes and turbo fitted
Ok let's start off with the turbo first:
Fitted
Next the Allard pipe kit:
First problem no documentation
Second problem tyre rubbing on alloy pancake pipe
Third and forth problem top boost pipe to inlet not correct - the gap is just shocking, so ended up making rubber mounts and then bolted it down.
Bigger rubber mounts fitted to hold top boost pipe and to over come pipe making contact with power steering fluid tank
Problem number 5 the lower boost pipe bracket gap is just too far apart to bolt together.
Ended up making an alloy spacer and drilled another hole for alignment and trimed the extra off
Also note the swarf inside the Allard pipework - this MUST be cleaned before fitting
June 2008 - Upgraded dog mount bushes
August 2008 Audi S3 Rear brakes 256mm
Calipers cleaned up and painted
6mm spacers required
October 2008 After a few development map the Final map is loaded and RR booked
No smoke and running 1.9bar boost
December 2008 - OEM Xenons
Order all the parts needed for the loom:
Loom made up:
Used oem tape for the loom:
April 2009 - More boost and fuel
Now with increased boost and fueling - boost mapped to 32psi. However, map is not as clean as the 220hp map in terms of smoke.
Flywheel figure
August & September 2009 - Water/meth injection
Decided to fit water/meth injection - I ended up buying the Devils own kit stage 1. The kit comes with everything you need. I also went for the dual nozzle set up (pre turbo):
Started work on fitting the nozzles - first started with the inlet manifold
Tapped the 1/8 NPT threads:
Repeated the same process on turbo intake pipe (pre turbo)
Fitted the self sealing bulk head (22mm hole required):
Fitted
Relay and pressure switch:
Custom bracket for the water pump
Been to set up the WMI on a rolling road and below are the outcomes (Red line is the last RR session without WMI and Blue is with WMI on) as you can the peak power is pretty much the same but the power over the same rev range better (holding power). I found having the WMI coming in at 18psi worked best for me. I also ran without the pre turbo nozzle and confirmed it made no difference to power so I'll be disconnecting that. In the future I'll try mounting the nozzle before the map sensor. Looks like if you want more power you'll have to put in more fuel and live with the smoke or get a bigger turbo.
UPDATE - 2010
I've experiemented with having the MAP sensor AFTER nozzle and can confirm it made no difference, since fitting the bigger turbo I have now removed the WMI system as the cylinder pressures are already too high.
Bigger Turbo and larger nozzles - Dec/Jan/Feb & Mar
Nozzles:
Turbo pics:
Note there is a lot of fabrication work that needs to be done such downpipe etc and the nozzle install is not straight forward and a lot of attention needs to be paid at different stages.
Any how the end result is excellent power delivery with a more usable power range over a hybrid. In fact the car is a total animal
Running 2.5 bar boost
With the right mapping this is possible:
April 2010 - Santa Pod
Went for a 1/4 mile run and managed a 13.9 @ 102mph - Its quicker than i was expecting
Video
April 2010 - Car pic's
For sometime I've been asked for pics of the actual car..so here are some:
August 2010 - D24 inlet & TIP
Over the last few months I've been working on the TIP and fitting the D24 inlet
There is def increase in top end top power and smoke has reduced (top end), but I seemed have gained more smoke during spool.
October 2010 - Intercooler
Well the new found power didn't entertain me for long, so I've decided to go further. In preparation for the next step I thought I'd change the intercooler. This is an OEM core (which I think are best) with modified end tanks. I didn't have enough to time to make it perfect as I needed the car back on the road ASAP. Anyways after a lot of grinding, cutting, welding it was on - lets just say the angle grinder was my best friend J
Intercooler:
Stock Set up:
Fitted:
January 2011 - Big valve ported and custom grind cam
Over the Christmas and new years period I've been busy fitted a big valve ported head.
Oversized Valves:
Head:
Head job - new followers, custom grind cam, new cam bearings, head gasket, bolts etc:
Testing:
I wanted to confirm that I have enough fuel pressure for the new power target.
Rolling road result
Pushing the R783's well over the limits I managed this (I'm hoping to replace these in the future):
Flywheel
Wheel
Dyno video
March 2011 - This is how you blow a 2260
In attempt to get smokefree power I tried 2.7 bar - lets just say its not recommended:
April 2011
New 2260 fitted & bigger custom nozzles fitted to newly built injector bodies:
Boost is now set to 2.2 bar (which is the max I recommend for this turbo)
Quick video to show smoke free power
PD300
Cheers
Bobby
Some of you may know I've been modifying my golf over the years and edited this thread to show a bit up to date information.
I ran the car on a stage 1 remap for approx 2 years. After this I done whole load of work and research to reach a MAX power figure of around 230hp. For anyone that reads this thinking 230hp is obtainable from a hybrid please think again as I had to run a very aggressive/unsafe map to get this figure. A true (and I mean a true power figure) for all VNT 17 based hybrids is around 220hp on stock nozzles.
I have now moved away from VNT 17 hybrids a fitted a bigger turbo unit, bigger nozzles and lots of fabrication work.
Heres the story
March 2008 - Clutch
In addition a new Sachs Dual Mass Flywheel and release bearing were fitted.
April 2008 - EGR Replacement
Before
After
As I have blocked the exhaust manifold end I decided to remove all this (not had any problems with cabin heating):
May 2008 - 312mm Audi TT set up - these might look like scrap metal but they are actually in very good condition
May 2008 - Hybrid turbo based on a VNT17 - with bigger exhast and compressor wheels
May 2008 - Turbo back Milltek exhaust system
May 2008 - New top suspension mounts (plus bearings), ARB bushes and 312mm set up fitted
May 2008 - Exhaust system fitted
May 2008 - Picked up a rear Audi S3 brake set up 256mm vented with calipers & carriers
June 2008 - Alloy boost pipes finally landed
June 2008 - Alloy boost pipes and turbo fitted
Ok let's start off with the turbo first:
Fitted
Next the Allard pipe kit:
First problem no documentation
Second problem tyre rubbing on alloy pancake pipe
Third and forth problem top boost pipe to inlet not correct - the gap is just shocking, so ended up making rubber mounts and then bolted it down.
Bigger rubber mounts fitted to hold top boost pipe and to over come pipe making contact with power steering fluid tank
Problem number 5 the lower boost pipe bracket gap is just too far apart to bolt together.
Ended up making an alloy spacer and drilled another hole for alignment and trimed the extra off
Also note the swarf inside the Allard pipework - this MUST be cleaned before fitting
June 2008 - Upgraded dog mount bushes
August 2008 Audi S3 Rear brakes 256mm
Calipers cleaned up and painted
6mm spacers required
October 2008 After a few development map the Final map is loaded and RR booked
No smoke and running 1.9bar boost
December 2008 - OEM Xenons
Order all the parts needed for the loom:
Loom made up:
Used oem tape for the loom:
April 2009 - More boost and fuel
Now with increased boost and fueling - boost mapped to 32psi. However, map is not as clean as the 220hp map in terms of smoke.
Flywheel figure
August & September 2009 - Water/meth injection
Decided to fit water/meth injection - I ended up buying the Devils own kit stage 1. The kit comes with everything you need. I also went for the dual nozzle set up (pre turbo):
Started work on fitting the nozzles - first started with the inlet manifold
Tapped the 1/8 NPT threads:
Repeated the same process on turbo intake pipe (pre turbo)
Fitted the self sealing bulk head (22mm hole required):
Fitted
Relay and pressure switch:
Custom bracket for the water pump
Been to set up the WMI on a rolling road and below are the outcomes (Red line is the last RR session without WMI and Blue is with WMI on) as you can the peak power is pretty much the same but the power over the same rev range better (holding power). I found having the WMI coming in at 18psi worked best for me. I also ran without the pre turbo nozzle and confirmed it made no difference to power so I'll be disconnecting that. In the future I'll try mounting the nozzle before the map sensor. Looks like if you want more power you'll have to put in more fuel and live with the smoke or get a bigger turbo.
UPDATE - 2010
I've experiemented with having the MAP sensor AFTER nozzle and can confirm it made no difference, since fitting the bigger turbo I have now removed the WMI system as the cylinder pressures are already too high.
Bigger Turbo and larger nozzles - Dec/Jan/Feb & Mar
Nozzles:
Turbo pics:
Note there is a lot of fabrication work that needs to be done such downpipe etc and the nozzle install is not straight forward and a lot of attention needs to be paid at different stages.
Any how the end result is excellent power delivery with a more usable power range over a hybrid. In fact the car is a total animal
Running 2.5 bar boostWith the right mapping this is possible:
April 2010 - Santa Pod
Went for a 1/4 mile run and managed a 13.9 @ 102mph - Its quicker than i was expecting
Video
April 2010 - Car pic's
For sometime I've been asked for pics of the actual car..so here are some:
August 2010 - D24 inlet & TIP
Over the last few months I've been working on the TIP and fitting the D24 inlet
There is def increase in top end top power and smoke has reduced (top end), but I seemed have gained more smoke during spool.
October 2010 - Intercooler
Well the new found power didn't entertain me for long, so I've decided to go further. In preparation for the next step I thought I'd change the intercooler. This is an OEM core (which I think are best) with modified end tanks. I didn't have enough to time to make it perfect as I needed the car back on the road ASAP. Anyways after a lot of grinding, cutting, welding it was on - lets just say the angle grinder was my best friend J
Intercooler:
Stock Set up:
Fitted:
January 2011 - Big valve ported and custom grind cam
Over the Christmas and new years period I've been busy fitted a big valve ported head.
Oversized Valves:
Head:
Head job - new followers, custom grind cam, new cam bearings, head gasket, bolts etc:
Testing:
I wanted to confirm that I have enough fuel pressure for the new power target.
Rolling road result
Pushing the R783's well over the limits I managed this (I'm hoping to replace these in the future):
Flywheel
Wheel
Dyno video
March 2011 - This is how you blow a 2260
In attempt to get smokefree power I tried 2.7 bar - lets just say its not recommended:
April 2011
New 2260 fitted & bigger custom nozzles fitted to newly built injector bodies:
Boost is now set to 2.2 bar (which is the max I recommend for this turbo)
Quick video to show smoke free power
PD300
Cheers
Bobby
Last edited by Bobby Singh; 09-09-2011 at 11:27 AM. Reason: PD300
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16-05-2008, 09:51 PM
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16-05-2008, 10:35 PM
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18-05-2008, 12:00 PM
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i remember this lighting up the rollers at PE day a couple of years back!
i was chatting to you VW rallye mate (sanj) on the train the other day!
i was chatting to you VW rallye mate (sanj) on the train the other day!
18-05-2008, 10:00 PM
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Hi - ye its been doing well over the last few years and at PE rollers it recorded 201hp and 315lbft, but to be honest i didnt have much faith in those figures.
Back in the days me and sanj had some good times on the old A40 lol - his Rallye is a very nice car 1.8 20v turbo at the mo.
Cheers
Bobby
Back in the days me and sanj had some good times on the old A40 lol - his Rallye is a very nice car 1.8 20v turbo at the mo.
Cheers
Bobby
13-06-2008, 10:52 PM
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16-06-2008, 08:28 PM
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Why isnt it spooling until 2.5k rpm? The Turbo Dynamics hybrid boosts sooner than that and has been mapped to 247bhp!! It might be worth changing to the latest boost solenoid which is a mk5 golf part and has been known boost quicker. Might also be worth doing a MAF log.
16-06-2008, 09:01 PM
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I thought Allard might have made it fit since they have changed the design and also upped the price!!
Why isnt it spooling until 2.5k rpm? The Turbo Dynamics hybrid boosts sooner than that and has been mapped to 247bhp!! It might be worth changing to the latest boost solenoid which is a mk5 golf part and has been known boost quicker. Might also be worth doing a MAF log.
Why isnt it spooling until 2.5k rpm? The Turbo Dynamics hybrid boosts sooner than that and has been mapped to 247bhp!! It might be worth changing to the latest boost solenoid which is a mk5 golf part and has been known boost quicker. Might also be worth doing a MAF log.
As for the turbo spool up -I can only put it down to size of exhaust wheel, alloy pipe work and obviously mapping.
But remember Im running in the turbo so once done and mapping is complete we'll have a better idea of whats going.
Thanks for the tip about mk5 boost solenoid, you got a part number?
Thanks
Bobby
18-06-2008, 08:13 AM
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I agree with Allard's quality especially at the price - just a shame no one else does a bolt on kit.
Sorry dude - this thread got delelted last time i posted pics of my car from the out side as the mods thought it was a sly advert. Basically my car is signed (got sticker all over) to promote my business.
04-07-2008, 08:48 AM
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I just done a google on Andys Golf he's managed 12.5 1/4 miles run - thats very impressive - but are you sure its 300hp @ wheels?
04-07-2008, 08:56 AM
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AET turbo's where he works has a brand new dynopack
He ran it up at a scooby dyno shootout at work last week with an audience and beat most of the scooby's lol
04-07-2008, 10:41 AM
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WOW - 600ft/lb that must be a missile. I'm afriad mine is not gona be near as powerful - 350ft/lb is my aim with around 200hp @ wheels.
You got a full spec?
You got a full spec?