Mr_Diesel
03-30-2006, 09:09 PM
This topic will be a "from start to finish" thread detailing and documenting my whole project of turbocharging the 2.0L ABA crossflow engine in my 94 Jetta. Feel free to ask questions and post opinions and ideas... I could use them for this project!
As the story begins about 2 months ago...
--------------
I had a local junkyard yank the manifold and turbo from an audi 5000... It's the k26 turbo, and the 5 cyl manifold... I'll have to block off the last port, but it should be good...
Anyway, just a heads up : )
http://www.dubnetworks.net/vbulletin/images/newbits/DSCF0826.JPG
http://www.dubnetworks.net/images/newbits/DSCF0825.JPG
---------------
Allright... I finally broke down and decided to see what I could do with this manifold... It's been sitting in my basement for a month now, so yeah.. like I said, I decided to see what could be done.
First, I took it to my favorite custom exhaust shop, and asked him what he could do... He said he didnt even want to touch it. He didnt have a welder anywhere near the power that he needed to weld that thick steel cast iron! He said... "Ya gotta go to one of thems high dollar welding shops". He sent me to a place called "Barber's Welding" in Spanish Fork, Utah. I took it to them and tried to figure out what he could do... He said that he could try, but from what he has seen in the past, he hasnt had much luck... I was pretty desperate at this point, so I asked him if he would give it a shot. He decided to practice on one of the bits of scrap that was going to be cut off.
He used a high power helium / argon arc welder with a nickel welding rod, and that weld was sooo strong it was amazing... He finally decided to give the project a shot.
I came back today, and sitting on the table was my manifold. Welded to perfection! He did a freaking awesome job. I would recommend that man and welding shop to anybody!
The actual work is better described with pictures... here is the manifold in all it's glory. A few of the whole setup on a spare cross flow head I had sitting around too.
http://www.dubnetworks.net/images/modmani/DSCF0828.JPG
http://www.dubnetworks.net/images/modmani/DSCF0829.JPG
http://www.dubnetworks.net/images/modmani/DSCF0830.JPG
http://www.dubnetworks.net/images/modmani/DSCF0831.JPG
The following pictures are the garbage and the 5th port he cut off... I don't know what he cut it off with, but it was a real straight clean cut.
http://www.dubnetworks.net/images/modmani/DSCF0832.JPG
http://www.dubnetworks.net/images/modmani/DSCF0833.JPG
As you can see, 3 of the 4 studs on the turbo are broken off inside the turbo... My dad has a "kit" that is used to remove bolt like this.... Sooooo... next on the list is getting all 4 of those studs replaced.
http://www.dubnetworks.net/images/modmani/DSCF0835.JPG
http://www.dubnetworks.net/images/modmani/DSCF0836.JPG
http://www.dubnetworks.net/images/modmani/DSCF0837.JPG
http://www.dubnetworks.net/images/modmani/DSCF0838.JPG
All in all I am VERY satisfied with my progress so far... One thing I am concerned about is the clearance of the firewall with the audi wastegate... I used a measure tape and figured that I am going to need close to 10 inches of room from the back of the head between the firewall... looks like there is about 11 inches behind there so I should be okay.... It should clear, but I MIGHT be buying solid motor mounts to prevent the wastegate from hitting the firewall under hard accelleration.
---------------
Also today!
I bought this diverter valve / BOV from my friend at work... He bought it to use on his turbo Chrysler LeBaron, but decided to get a nicer looking one that would better fit his application. It's made by mitsubishi (with a lowercase "m"), unfortunatly, but the price was right and it is well built. It is designed to effectively hold 30 psi without leaking!!! Awesome expandability for the future. (those dang asians can make some really nice stuff!) He was selling it for $60 shipped on a turbo dodge website, but he sold it to me for $55 since he didnt have to ship it. The pipe size is 2 1/16 inches... Or... in other words.... 2 inches, which is the exact size of the turbo outlet... a small enough pipe to prevent serious pressure drops and VERY convienient to add the BOV inline.
http://www.dubnetworks.net/images/modmani/DSCF0839.JPG
http://www.dubnetworks.net/images/modmani/DSCF0840.JPG
http://www.dubnetworks.net/images/modmani/DSCF0841.JPG
------------------
Anyway, here is the current checklist / plan of action going in order of importance.
1. Fix the turbo studs.
2. Have the machine shop make me a steel flange for the turbo downpipe.
3. Use that flange, and have a "Y Pipe" made for my wastegate and turbo. I want to do 3 inch pipe ALLL the way from the turbo back... I plan on doing a straight pipe... only restriction being the cat. I also want the exhaust to come out the side before the rear wheel for these reasons (A). Less pipe for restriction. (B) To avoid the rediculous bend in the pipe going over the rear axle. (C) To let that unchained melody of a German engine humming to the harmony of a turbocharger whistle.
4. Figure out the water line and oil lines
more to come.
As the story begins about 2 months ago...
--------------
I had a local junkyard yank the manifold and turbo from an audi 5000... It's the k26 turbo, and the 5 cyl manifold... I'll have to block off the last port, but it should be good...
Anyway, just a heads up : )
http://www.dubnetworks.net/vbulletin/images/newbits/DSCF0826.JPG
http://www.dubnetworks.net/images/newbits/DSCF0825.JPG
---------------
Allright... I finally broke down and decided to see what I could do with this manifold... It's been sitting in my basement for a month now, so yeah.. like I said, I decided to see what could be done.
First, I took it to my favorite custom exhaust shop, and asked him what he could do... He said he didnt even want to touch it. He didnt have a welder anywhere near the power that he needed to weld that thick steel cast iron! He said... "Ya gotta go to one of thems high dollar welding shops". He sent me to a place called "Barber's Welding" in Spanish Fork, Utah. I took it to them and tried to figure out what he could do... He said that he could try, but from what he has seen in the past, he hasnt had much luck... I was pretty desperate at this point, so I asked him if he would give it a shot. He decided to practice on one of the bits of scrap that was going to be cut off.
He used a high power helium / argon arc welder with a nickel welding rod, and that weld was sooo strong it was amazing... He finally decided to give the project a shot.
I came back today, and sitting on the table was my manifold. Welded to perfection! He did a freaking awesome job. I would recommend that man and welding shop to anybody!
The actual work is better described with pictures... here is the manifold in all it's glory. A few of the whole setup on a spare cross flow head I had sitting around too.
http://www.dubnetworks.net/images/modmani/DSCF0828.JPG
http://www.dubnetworks.net/images/modmani/DSCF0829.JPG
http://www.dubnetworks.net/images/modmani/DSCF0830.JPG
http://www.dubnetworks.net/images/modmani/DSCF0831.JPG
The following pictures are the garbage and the 5th port he cut off... I don't know what he cut it off with, but it was a real straight clean cut.
http://www.dubnetworks.net/images/modmani/DSCF0832.JPG
http://www.dubnetworks.net/images/modmani/DSCF0833.JPG
As you can see, 3 of the 4 studs on the turbo are broken off inside the turbo... My dad has a "kit" that is used to remove bolt like this.... Sooooo... next on the list is getting all 4 of those studs replaced.
http://www.dubnetworks.net/images/modmani/DSCF0835.JPG
http://www.dubnetworks.net/images/modmani/DSCF0836.JPG
http://www.dubnetworks.net/images/modmani/DSCF0837.JPG
http://www.dubnetworks.net/images/modmani/DSCF0838.JPG
All in all I am VERY satisfied with my progress so far... One thing I am concerned about is the clearance of the firewall with the audi wastegate... I used a measure tape and figured that I am going to need close to 10 inches of room from the back of the head between the firewall... looks like there is about 11 inches behind there so I should be okay.... It should clear, but I MIGHT be buying solid motor mounts to prevent the wastegate from hitting the firewall under hard accelleration.
---------------
Also today!
I bought this diverter valve / BOV from my friend at work... He bought it to use on his turbo Chrysler LeBaron, but decided to get a nicer looking one that would better fit his application. It's made by mitsubishi (with a lowercase "m"), unfortunatly, but the price was right and it is well built. It is designed to effectively hold 30 psi without leaking!!! Awesome expandability for the future. (those dang asians can make some really nice stuff!) He was selling it for $60 shipped on a turbo dodge website, but he sold it to me for $55 since he didnt have to ship it. The pipe size is 2 1/16 inches... Or... in other words.... 2 inches, which is the exact size of the turbo outlet... a small enough pipe to prevent serious pressure drops and VERY convienient to add the BOV inline.
http://www.dubnetworks.net/images/modmani/DSCF0839.JPG
http://www.dubnetworks.net/images/modmani/DSCF0840.JPG
http://www.dubnetworks.net/images/modmani/DSCF0841.JPG
------------------
Anyway, here is the current checklist / plan of action going in order of importance.
1. Fix the turbo studs.
2. Have the machine shop make me a steel flange for the turbo downpipe.
3. Use that flange, and have a "Y Pipe" made for my wastegate and turbo. I want to do 3 inch pipe ALLL the way from the turbo back... I plan on doing a straight pipe... only restriction being the cat. I also want the exhaust to come out the side before the rear wheel for these reasons (A). Less pipe for restriction. (B) To avoid the rediculous bend in the pipe going over the rear axle. (C) To let that unchained melody of a German engine humming to the harmony of a turbocharger whistle.
4. Figure out the water line and oil lines
more to come.