Before I start this let me make a few things clear. 1. This is my project, not yours! Haters hate elsewhere. 2. I have considered many options including the top heavy multivalve engines ugh!! and this is what I have decided to do, with my time and my money. 3. This will take a while to complete. I dont even have a golf to put it into! ( I actually do, but its not going in the blue car.) 4. This isnt being built to be the most powerful thing in the world, just good fun engine and a learning journey along the way. 5. For those who like a target figure, I would like to see in the region of 250bhp with a similar torque figure, although Im not too fussed as long as it reliably goes well. So basically, what I intend is a 8v cross flow turbo. In a Mk2 Golf. Probably. The parts I have so far are: Spa turbo manifold (log type) the rear exit type with a T3 flange. A T3 from an RS Turbo with integral waste gate A TD sump with TD oil return hose ( not sure thats any use!!) ABA head removed from a US Cabby untouched from new by the looks of things, So it might need a freshen up, eh Jason G60 Cam Obviously, I still have the blue car to steal parts from including Megasquirt etc I still need / want The block Im looking for a low mile 2E, although if a set of Low CR pistons came up cheap I would use an 1800 block. Low CR pistons ( I have some modified OE ones, that I have never really looked at, although Im told they arent great, Tony??) Steel rods, not essential (until I want more power!!) but for peace of mind An intake manifold, I have my eyes on an OE one which Ill modify Intercooler and pipework A decent 2.5 or 2.75 exhaust I would quite like a tubular exhaust manifold eventually. Obviously there is things I have missed, so help me out as and when
I know a chap here in London with a counter flow 8vT. It is fitted in a MK1 and I am trying to encourage him to finish it. Should be pretty naughty. 8v Turbo is very possible to build without breaking the bank and can follow the same principal that we use on 16vTs as demonstrated on this forum by myself , tshirt2k, Gurds, and soon Nige. Start with a 2E bottom end in serviceable condition. Rods and or low CR pistons are not required for sub 300bhp with a maximum rev limit of 7000rpm Run twin MLS gaskets to reduce CR to ~ 8.5:1. Cap off with your ABA head on a stock NASP cam. You can use new head bolts to clamp the lot. You always have the option to ignore the method of reducing CR on VW EA827 motor and shell out for low CR pistons and fancy H sectioned rods. Mechanically you are not pushing the engine durability enough to warrant such expense. Porting the head will aid flow and lower boost to achieve torque/filling, but is not essential at around 250bhp and say 260lbft. Any head restrictions can be cured by squeezing the boost knob for for a little 'more' lol Use a the std NASP camshaft. There are custom turbo cams that can be used but will increase cost. Inlet you can make your own plenum. Universal turbo plenums can be found on the net and you just have to integrate to your own ABA lower section. Exhaust manifold a semi log design will be fine as it will ensure the most heat energy gets to the little Escort T3 unit Get the T3 refurbed and tested. Let the turbo specialist look at the compressor and back end and get them to tweak these to what you want to achieve. Fit a 360 deg CHRA while you are at it. D/P, Defuser exit at 2.75-30 inches, including any bends and then can step to 2.5 inch over the rear axle. Use 2 boxes. ECU - Done with std 250kPA map sensor ( 1.5bar boost max) Boost control, get an EBC or build one into the ECU. Bleeds are OK, but when your little T3 starts to run out of huff on the top end, an EBC will ensure it sticks close your desired boost , to the redline, and you concentrate of dialing torque from the cal. Injectors you need 440cc jobs on a 3bar fuel pressure regulator. Fuel pump, you need a KJet unit or a 044. Boost pipes can me made at a good exhaust fabricator. FMIC - Ebay unit, EVO 2-7 unit can be used. small fittings and sundries, Think Automotive is your friend ( speak to Matt) I would say an 8v X flow running your rebuilt Escort T3, can achieve around 260lbft@3500rpm and 250bhp@5800-6000rpm and 160lbft@7000rpm, if you are feeding the inlet plenum with 1.3bar of boost pressure. The size of the plenum will help massively with this.
Really interested to see where this goes, alot of US companies sell Turbo Chips for the ABA but im assuming these wouldnt work in our UK ECU's?
Thanks for the list eddie, lots to think about *2E was going to be my first port of call, but I wasnt sure of they had the oil squirters or not. *I have toyed with the idea of building a proper bottom end with pistons and rods, on the basis that if I get the bug winding up the boost is easy to do, I suppose conversely, build it simple and get it running properly, then develop it later on. * would you use the PB cam over the PG?? * ill buy ARP head bolts this time. * my own plenum will be built from a manifold I have just ordered and if its possible to intergrate a Cosworth YB manifold. * you mention little turbo, is it too small for a 2.0 ?? as it needs a rebuild should I just look for an alternative? * diffuser at exit? Any recommendations for an exhaust?? * ECU mods Ill send to you, or at least seek your advice, Im not sure which sensor my ECU has, can you remember. * EBC?? Is this the N75??? * Injectors I have, I own two sets of YB injectors yellow and pale green. * is the normal Digifant one not up to it? I could live with those figures 250 to 260 would do for me. Cheers
Good luck with this. I have the start point for a similarly different engine on the bench, based on a nice hydraulic Mr hillclimber 40.5/35 head and aftermarket cam. Its a hydraulic non x flow with the odd shaped inlet ports and plenum. Thinking of bolting a supercharger (mini? merc?) on the front of it at the moment. Its 1595cc, but I have other bigger bottom ends available. On a budget , of course. For no other reason that I haven't built a supercharged motor yet............. Jon
I guess my reasons Jon are a bit like yours. I have never even owned a turbo engine and I like the idea of building something different
It is a bit funny looking, but the bits I like are, 1 it's bolts straight on! 2 it has a decent length of runner to play with.
They are 444cc, low impedance. Important note, the top of JECS injectors are not the same as Bosch units and a custom fuel rail would be required.
