Turbo upgrade - "Budget" no longer applicable

[Valaas]

Hi, I am finally sufficiently motivated to convert my 2008 Classic to FA by turbo.
Tried to do my due dilligence, and have read whatever I could find on the subject. But I am relying on a friendly crowd. I certainly know the enginuity and wisdom is available here

Purchases:
-Aerocharger 8 psi
-Turbosmart GenV 40mm wastegate
-2 Bar MAP sensor
650cc@3 bar injectors
Walbro GSS342 255 fuel pump and stock/3bar regulator
-Stock header
-Viking Exhaust/Paul Pryant 2''header
-No intercooler
-Epman liquid to air intercooler + separate radiator/fan/pump circuit
-PCV AT (0-5v input from MAP sensor) + Dynojet Pod 300 (realtime AFR view+adjustment)
-Dynojet ignition module
-Barnett heavy duty clutch kit
-TTS forged low compression piston kit
-cams re-machined to street/FI
-misc OE parts incl cam chain + tensioner, piston ring kits, conrod bearings, head gasket etc.
-new driveshaft + wheel rubber cushins
-2 square meters of new tools on the wall

Way. way over initial budget. And counting.

 

[Mongler07]

Please just upload pictures as you go.
Sounds exciting
I have no clue how to help other than seeking the right guys who have done this stuff.
Why not better exhaust? I would, same for an oil cooler. Turbos have a nasty habit of heat soak.

 

[Valaas]

Please just upload pictures as you go.
Sounds exciting
I have no clue how to help other than seeking the right guys who have done this stuff.
Why not better exhaust? I would, same for an oil cooler. Turbos have a nasty habit of heat soak.

Will post pictures. Exhaust/Aircooler: reason being budget. I plan to get started and let the build grow organically

 

[Mongler07]

Will post pictures. Exhaust/Aircooler: reason being budget. I plan to get started and let the build grow organically

putting a turbo on a rocket DIY and mentioning a budget... LOL
is this going to be some janky ebay turbo and some crazy stuff?

 

[Valaas]

putting a turbo on a rocket DIY and mentioning a budget... LOL
is this going to be some janky ebay turbo and some crazy stuff?

No. If I needed an intercooler, I would have included an intercooler. If an oil cooler proves to be necessary, I will add an oil cooler.
But I'm glad you find my post entertaining

 

[Mongler07]

No. If I needed an intercooler, I would have included an intercooler. If an oil cooler proves to be necessary, I will add an oil cooler.
But I'm glad you find my post entertaining

I tried putting a 368hp 1.9l TDI engine from a Jetta into a 84 Porsche 944. I boosted her to 32psi. I am all for doing this kinda stuff. It's a good thing. You have my subscription

 

[Valaas]

I tried putting a 368hp 1.9l TDI engine from a Jetta into a 84 Porsche 944. I boosted her to 32psi. I am all for doing this kinda stuff. It's a good thing. You have my subscription

Appreciate that mate. It takes some skill and persistance, and is much more rewarding than throwing a heap of cash at a pro builder. If it ends up in flames, you just start all over.

 

[R-III-R Turbo]

Q1 Injectors: How large should I go on the injectors to reduce risk of "melted" piston? 550cc? Found a source for reasonably priced EV14 compact Bosch 731cc (@3bar), too large?
Q2 Oil feed: Can you get oilfeed from the oil pressure sensor seat (via T-fitting) or accepting unfiltered oil via a sandwich-plate an OK enough option? Other?
Q3 Oil return: Drill a hole in the oil filler cap? Hope there's a better option! E.g. anyone sent return oil directly to the oil pan via a fitting?
Q4 And this would be next to winning the lottery: Anyone got a PCV map based on a 2 bar MAP-sensor pressure readings? I guess 2 bar MAP-sensor implies FA

Re injectors you can have perfectly suitably sized ones and still go lean and melt pistons if the fuelling isn't tuned right. You'd probably be ok with 550cc ones, the stock ones are 34lb/hr or thereabouts iirc and start maxing out around 250hp region

Re the map, the engine config needs to be taken into account e.g. a 2 bar MAP with 550cc injectors will be very different to a 2 bar MAP with 731cc injectors engine and so on

 

[Kevin frazier]

Gerald shared these settup with me.

 

[Valaas]

Re injectors you can have perfectly suitably sized ones and still go lean and melt pistons if the fuelling isn't tuned right. You'd probably be ok with 550cc ones, the stock ones are 34lb/hr or thereabouts iirc and start maxing out around 250hp region

Re the map, the engine config needs to be taken into account e.g. a 2 bar MAP with 550cc injectors will be very different to a 2 bar MAP with 731cc injectors engine and so on

Thanks mate. I have been reading through your posts and downloaded your PCV map matching ECU columns and with pressure tables. If I knew what MAP pressure and injectors you run, I would know if thats a decent starting point for Autotune