DIY turbo guide

[FishWick 21]

I haven't no. It didn't really sound of anything tbh! With a short runner intake the VR6 totally loses it's burble and with the turbo it's very quiet.....dare I say it sounds dull....like a 6 cylinder 1.8T, LOL! :-)

It needs a 3" exhaust to sound good really..

[407BHP VR 2]

I haven't no. It didn't really sound of anything tbh! With a short runner intake the VR6 totally loses it's burble and with the turbo it's very quiet.....dare I say it sounds dull....like a 6 cylinder 1.8T' date=' LOL! :-)

It needs a 3" exhaust to sound good really..

[/quote']

Mine has a full 3" exhaust it to is very quiet .

It has a 3" down pipe that i made my self and a blue flame two box 3" system , I got the lad in blue flame to put my first box where my cat would go on flanges so i can take it off and put a cat on if need be ! But now i think i will put a strait pipe in as my car sounds like its god a standard exhaust on it .

By the way Kev im sorry about the banter !

[407BHP VR 2]

Whats your torque like Kev ?

[FishWick 21]

No worries mate :-)

My torque is much lower than yours :-)

320 - 337lb/ft from 4000 to 6600rpm. It's a big old GT35R and short runner, cams etc causing that. If I can get the turbo to spool sooner with a 0.63 exhaust A/R or a 3" exhaust (or just turn the boost up!), the torque will increase but to be honest it drives superb on the road so I'll stick with the 0.82 exhaust housing. With the 263 cams, at 4000rpm it feels a bit like a VTEC + Turbo, it's quite good fun :-)

So your 3" system is quiet? Does it drone on the motorway when it get's hot? Is it full bore over the rear axle or crimped?

Hmmm, I'm tempted now!

Do you get through the emissions without a cat OK? I've been considering getting a Magnaflow 3" cat from the states as the guys over there rate them.

What turbo are you running? Standard intake etc?

I like the way your torque and power match, nice job mate ;-)

[407BHP VR 2]

No worries mate :-)

My torque is much lower than yours :-)

320 - 337lb/ft from 4000 to 6600rpm. It's a big old GT35R and short runner' date=' cams etc causing that. If I can get the turbo to spool sooner with a 0.63 exhaust A/R or a 3" exhaust (or just turn the boost up!), the torque will increase but to be honest it drives superb on the road so I'll stick with the 0.82 exhaust housing. With the 263 cams, at 4000rpm it feels a bit like a VTEC + Turbo, it's quite good fun :-)

So your 3" system is quiet? Does it drone on the motorway when it get's hot? Is it full bore over the rear axle or crimped?

Hmmm, I'm tempted now!

Do you get through the emissions without a cat OK? I've been considering getting a Magnaflow 3" cat from the states as the guys over there rate them.

What turbo are you running? Standard intake etc?

I like the way your torque and power match, nice job mate ;-)

[/quote']

Exhaust is great on the motorway and is full bore over axle and it aint crimped there is only a coulpe of mil clearance but does not bang or rub what so ever i am very pleased with BLUE FLAMES job ! Not to dear either

My turbo is a GT3076R and it has a short runner inlet but my exhaust housing is a bit small for a vr and spools up a bit hard for me , I should or gone for a GT35 my self but thought a 30 was big at the time little did i know !

Do you live far away from the northwest as pipewerx and blueflame are local to me about £400 from pipewerx

and £500 from blue flame with life time warrenty ! Worth thinking about

[FishWick 21]

That's good to know, cheers. Quiet is what I want!

I'll give Blue flame a look sometime then although I'm in the south east if they have any fitting centres down here?

Hayward & Scott are down the road from me actually, but they are ££££sss..... very good though.

I've tried a GT3071R, GT3076R and a GT3582R - all with 0.82 exhaust housings - and my favourite so far is the GT3582. It doesn't kick in as low as the GT30s but with my other engine mods (83mm pistons, BV head, 263 cams etc) it does pull nicely at low rpms, but is mental from 3500rpm. The 3582 will do 40psi aswell, so loads of potential :-)

I'll need 4WD and a stronger gearbox before exploring the big power though, which is why I've limited myself to under a bar of boost so far. I don't trust the 02A gearbox, especially not 3rd. Not that I hammer it over bumps or anything.....but I just cringe everytime it comes on boost in 3rd, LOL!

[407BHP VR 2]

That's good to know' date=' cheers. Quiet is what I want!

I'll give Blue flame a look sometime then although I'm in the south east if they have any fitting centres down here?

Hayward & Scott are down the road from me actually, but they are ££££sss..... very good though.

I've tried a GT3071R, GT3076R and a GT3582R - all with 0.82 exhaust housings - and my favourite so far is the GT3582. It doesn't kick in as low as the GT30s but with my other engine mods (83mm pistons, BV head, 263 cams etc) it does pull nicely at low rpms, but is mental from 3500rpm. The 3582 will do 40psi aswell, so loads of potential :-)

I'll need 4WD and a stronger gearbox before exploring the big power though, which is why I've limited myself to under a bar of boost so far. I don't trust the 02A gearbox, especially not 3rd. Not that I hammer it over bumps or anything.....but I just cringe everytime it comes on boost in 3rd, LOL!

[/quote']

Blue Flames job is as good as you get as is pipe werx the only reason i went to blue flame is that pipewerx was booked up for two weeks and inters was 10 days away !

Pipewerx said they would do me a one box 3" system for £370 and blue flame done mine trade for £450 with two boxes so its not bad !

As for turbo's i wanted quick spool up as im not a fan of big lag but would of liked mine to be a bit smoother !

Before my golf i had a vauxhall corsa c20let that done just shy of 290bhp with a boost leak and a missfire it was

crazy quick !

My friend has a escort cosworth doing about 330-350 bhp and the corsa would pull away from him if he was in third gear and i was in fifth at 60mph thats how i wanted my golf !

And as for 02a gearboxes i broke mine on the motorway on a nice smooth section !

So dont beleive that about cracks when its gona go it will go .lol

[antonio_b12 1]

[blockquote]Before my golf i had a vauxhall corsa c20let that done just shy of 290bhp with a boost leak and a missfire it was

crazy quick !

My friend has a escort cosworth doing about 330-350 bhp and the corsa would pull away from him if he was in third gear and i was in fifth at 60mph thats how i wanted my golf ![/blockquote]

Hi mate,

One thing that impresses me about the LET, is the F28 Gearbox. i understand you had the engine in a corsa, but how does it compare overall now with your vr6t?

my friend has 1 in his Astra and im just curious how much difference there is...

[407BHP VR 2]

[blockquote]Before my golf i had a vauxhall corsa c20let that done just shy of 290bhp with a boost leak and a missfire it was

crazy quick !

My friend has a escort cosworth doing about 330-350 bhp and the corsa would pull away from him if he was in third gear and i was in fifth at 60mph thats how i wanted my golf ![/blockquote]

Hi mate' date='

One thing that impresses me about the LET, is the F28 Gearbox. i understand you had the engine in a corsa, but how does it compare overall now with your vr6t?

my friend has 1 in his Astra and im just curious how much difference there is...

[/quote']

Mine only had an F20 in it but would do about 160mph and it broke one every two weeks piss take !

I must say i wish i had not sold the corsa and when it comes down to price it must be one of the fastest cars you can build for £2000 .

It cost me about £300 to go from 200bhp to 300bhp

It drove better than my VR6 handled better and could even be faster but at the end of the day it was a corsa and i was fed up of people looking down at me when i was driving it and it pissed me off !

[antonio_b12 1]

well they wont be looking down at you now with the amount of torque you have

[kcw 1]

About the whole VRT's distroying 3rd gears, what is it about 3rd thats particularly weak?

Also what can be done to strengthen the box? Would it be possible to uphrade the internals to stronger or possible straight cut cogs?

Ken

[Phat VR6 3]

http://images.google.co.uk/imgres?imgurl=http://dutchdub.com/images/Forumpics/hal2.jpg&imgrefurl=http://forums.vwvortex.com/zerothread%3Fid%3D1891426&h=600&w=800&sz=149&hl=en&start=4&um=1&tbnid=d5fOSHeG0ZoewM:&tbnh=107&tbnw=143&prev=/images%3Fq%3Dgolf%2B4motion%2Brear%2Bdiff%26svnum%3D10%26um%3D1%26hl%3Den%26client%3Dfirefox-a%26rls%3Dorg.mozilla:en-GB:official%26sa%3DG

How to put a 02M box in MK3/ Rado ect, Including how to mod syncro rear axal to put haldex diff ect. Ive hurd these boxs take 600bhp reliably

[xyber 1]

407BHP VR - I know what you mean about it being a corsa, I was on the verge of buying an Astra coupe turbo as they can be made into animals for not much £££. But the same thing kept niggling in the back of my mind, ITS A VAUXHALL!! So I bought my VR instead

[FishWick 21]

The only Vauxhall I've owned is a 2.0 GLi Cavalier, so I'll declare myself out of the Vauxhall chat :-)

3rd gear breaking. Not sure why that gear breaks first. Physically it doesn't "look" any less robust than the other 4 cogs but it's hard to say for sure.

I have a theory though because 3rd gear breaking is common to other powerful FWD cars too....

....1st and 2nd gears are very short, low vehicle speed, low engine loads, the power spins away.

3rd gear on the other hand......vehicle speed not much faster and 3rd is taller which increases engine load and therefore the boost rockets and you get a big loading on the gearbox.

4th and 5th - The car already has good momentum so there's less transient load on the gearbox.

That's my theory at least anyway :-)

The other gears can and do break aswell, but 3rd is usually always the first to bite the dust.

You can get a straight cut gear set from a Czech firm for the 02A that's been proven to take 800whp.....but the whole trans case buckled and shattered under the strain. The gears were perfect though :-)

Good shout on the 02M link, I've been trying to find some info on that.

407BHP VR - Yep, I was the same when I first did my VRT, I wanted minimal lag but the the 3071 bit the dust (sucked something through it), then I got a 3076, was OK but it was faulty so had to go back. At that point I though F'ck it, I'm going GT35R! Glad I did because it seems to tick all the boxes. Good spool up and savage top end :-)

[407BHP VR 2]

407BHP VR - I know what you mean about it being a corsa' date=' I was on the verge of buying an Astra coupe turbo as they can be made into animals for not much £££. But the same thing kept niggling in the back of my mind, ITS A VAUXHALL!! So I bought my VR instead

[/quote']

Now an astra coupe turbo has a z20let and aint half as easy to tune as the c20let !

My friend has a astra mk4 gsi thats has had all work done by regal and is 400bhp which makes it the most powerful astra gsi in britain !

And let me say if he had spent that much on a vr6 it would be about 800bhp and thats just what he spent this year !

[rodney 17]

Remember it's the point at which the tyres bite that causes the gears to go. So once you turbo you'll spin all the way to 3rd which is when you bite. That's why typically that gear breaks. Though as said others can go to.

You can get the gears anealed/hardened to take the power BUT it will make the metal more brittle. So a chicken and egg thing on that....

You can always look at companies like elite racing transmissions, Sellholm Tuning (DMMR) etc who, whilst they specialise in other brands of car, can make to order to take real big BHP... Also get sequential systems if you want....

Sequential 6 speed with LSD Mmmmmmm

[jon@vagworx 0]

The only Vauxhall I've owned is a 2.0 GLi Cavalier' date=' so I'll declare myself out of the Vauxhall chat :-)

3rd gear breaking. Not sure why that gear breaks first. Physically it doesn't "look" any less robust than the other 4 cogs but it's hard to say for sure.

I have a theory though because 3rd gear breaking is common to other powerful FWD cars too....

....1st and 2nd gears are very short, low vehicle speed, low engine loads, the power spins away.

3rd gear on the other hand......vehicle speed not much faster and 3rd is taller which increases engine load and therefore the boost rockets and you get a big loading on the gearbox.

4th and 5th - The car already has good momentum so there's less transient load on the gearbox.

That's my theory at least anyway :-)

The other gears can and do break aswell, but 3rd is usually always the first to bite the dust.

You can get a straight cut gear set from a Czech firm for the 02A that's been proven to take 800whp.....but the whole trans case buckled and shattered under the strain. The gears were perfect though :-)

Good shout on the 02M link, I've been trying to find some info on that.

407BHP VR - Yep, I was the same when I first did my VRT, I wanted minimal lag but the the 3071 bit the dust (sucked something through it), then I got a 3076, was OK but it was faulty so had to go back. At that point I though F'ck it, I'm going GT35R! Glad I did because it seems to tick all the boxes. Good spool up and savage top end :-)

[/quote']

Lol, pretty close theory.

1st/2nd puts the stress through traction, ie tyres (wheelspin) drive shafts, hubs etc.

4/5th the load is on the engine as the gearing is above 1:1

So, third is when the gearbox is most loaded. Will also be the gear that gets the most prolonged use of full load/ throttle on the road.

Also, its in the middle

Please don't bother with straight cut gears in the 02a, waste of money as the gearset isn't its only weakness.

[407BHP VR 2]

Remember it's the point at which the tyres bite that causes the gears to go. So once you turbo you'll spin all the way to 3rd which is when you bite. That's why typically that gear breaks. Though as said others can go to.

You can get the gears anealed/hardened to take the power BUT it will make the metal more brittle. So a chicken and egg thing on that....

You can always look at companies like elite racing transmissions' date=' Sellholm Tuning (DMMR) etc who, whilst they specialise in other brands of car, can make to order to take real big BHP... Also get sequential systems if you want....

Sequential 6 speed with LSD Mmmmmmm

[/quote']

RCF Whats with the frazer nash ?

[Dent Reform 0]

Can i be dumb and ask for a link to this "Bill Schimmel" site please

never heard of the chap and interested in what he has to offer

THANKS

Andy

AWESOME write up by the was and i am doing my 24V Turbo soon lol

[Phat VR6 3]

http://spturbo.com/ there you go...and 24v turbo will be nice

[FishWick 21]

Thought I'd wake this thread up again. I've fixed all the dead image links, so it's a proper guide (of sorts) again!

I'll throw in some updates too whilst I'm here as it's been a while!

When my 2.9 and a bit block was built, I decided to return the oil to the block, rather than the sump. It's a more direct, shorter path back and is above the driveshaft level, so acres of clearance.

Here's how you do it. Start of with a 23/32" drill and you'll need a 1/2" pipe tap to cut the thread. The fitting is a 1/2" NPT to -10 JIC/AN 45 degree.

Life in the turbo lane isn't without it's faults. I've had my fair share of bad luck!! First casualty was the JE pistoned block. No 6 piston scratched it's bore and wrote the whole lump off. So the second attempt used Wossner pistons and was built by Stealth. I've done around 20K on this second engine and here's how it looked recently.....perfect!

Second casualty was the turbo. The original GT30 I started out with ingested some debris and damaged the compressor wheel. What and how is still a mystery to this day.

Good excuse to upgrade to a GT35R though :-) Mr 35 on the left, and Mr 30 on the right for comparison....

Then I had a weird problem with the tappets not turning in their bores, which wrecked them and the cams :-(

Still, nevermind, good excuse for more upgrades.... Schimmel big valve head and 263 cams :-)

The cams on their own are superb, but together with the head, bloomin awesome!! Highly recommended. Mpre torque and power everywhere.

So yeah, then I started playing with various toys to make it run a bit better....

MSD coils...

Schimmel throttle elbow...

Audi 1.8T air intake sensor (instant update) in custom stealth throttle elbow....

Stock regulator holder.....

And so it continues really. It's an endless cycle of experimentation and constant development and here's how the car looks as of July 08....

And the most recent dyno plots from December 07....

Power....

Torque...

Tis all for now :-)

[sparkz 0]

Can you give me some more info on the msd coils kev? How much? advantages, etc???

[FishWick 21]

They give a stronger spark than than the standard coilpack, which means you can open up the plug gaps and get a better burn on boost.

There's nothing wrong with the stock coilpack though. It's been proven to handle 25+psi of boost no trouble.

The MSDs just make it run (and idle) a bit smoother and crisper, but they're not essential.

Cost with the Gruven parts bracket etc was close to that of a replacement stock coilpack from VW! But the coils themselves aren't that expensive, about £30 each.

They can be a bit unreliable though, so I'd only recommend them if you run into spark related problems on boost.

[Junior VR6 0]

Hello kevhaywire!

I did read all 20 pages and i was surpresed that you use a manifold from Brazil in your project!

More details here:

http://www.spaturbo.com.br/

http://www.spaturbo.com.br/html/vw/golf02.php

http://www.spaturbo.com.br/html/vw/golf02b.htm

http://www.spaturbo.com.br/html/produtos_avulsos/coletores_turbo10b.htm

Regards!

[FishWick 21]

Hey there!

Yes we use the SPA one here because it's the best manifold for right hand drive applications.

I'm not convinced the manifolds we get here in the UK are genuine SPA ones because the lettering is ground off and the port alignment is shockingly bad.

I would like to try a proper one from SPA one day.