Turbo, small T4 and the stock cam,

MattKab · Post by **MattKab** » Tue Apr 15, 2008 10:45 am

Hi Jonas,

T1 EDIS (too many 1000's of miles) nearly 12 months on MS now:

zorst, will be lagged in black:

secondary collector/mount to cylinder head:

Can't wait to show you how the intake turned out!

Matt

type3 · Post by **type3** » Tue Apr 15, 2008 11:25 am

Good stuff!

bj · Post by bj » Tue Apr 15, 2008 4:33 pm

wow...impressive work. i've followed your posts on the FI forums too.

how do you suspect your header will work out for you? what are the specs on the header (if you can/want to give them out)?

i like your intake manifolds too. i was wondering if the injectors/fuel rail would hit the aprons?

bj

Wally · Post by **Wally** » Wed Apr 16, 2008 10:55 am

MattKab wrote:
That 411 will be at the second Euro Bug-In!

Matt

Cool! Would be nice to finally meet

MattKab · Post by **MattKab** » Wed Apr 16, 2008 10:58 am

Hi Dan, bj,

Thanks!

The 1.5" primary pipes are ~40" from the valve to the collector. The stub-pipes are 4" long with 8mm flanges. The longest primary is less than 0.5" longer than the shortest. The 1.75" secondaries are 15" long. The secondary collector is about 9" long and forms the start of the 2" tertiary pipe which is the same length as the primary from the start of the secondary collector to the turbo.

The exhaust from the turbo is also 2" and will have an all-stainless straight-through muffler with the tailpipe in the stock location (far right of the rear valance).

I don't know how or if it will work is the truth, it's a compromise between the theory and what is physically possible.

The injectors may foul on the shelves (which are T1 Injection), if they do I'll simply remove them, they can stay with the T1 injection tinware. Easy enough to make new ones when the T4 finally arrives in the the back of my Beetle

Very excited about that!!

Did I mention this T4 project is in year 12?

More to follow soon.

Matt

MattKab · Post by **MattKab** » Wed Apr 16, 2008 11:19 am

Wally wrote:
MattKab wrote:
That 411 will be at the second Euro Bug-In!

Matt
Cool! Would be nice to finally meet

Hi Wally,

That was I, who tried to push you out of the mud last year!

You have a pm about 9" Cup2's on my 411

Wally · Post by **Wally** » Wed Apr 16, 2008 11:59 am

MattKab wrote: Hi Wally,

That was I, who tried to push you out of the mud last year!

So it was after all?!! Never could figure that out, but your friendlyness did make me wonder if...
Thanks after all

The mud gave me a hard time with the tech inspectors each time I appoached the drag race starting line haha! They allowed me to race anyways luckily.

You have a pm about 9" Cup2's on my 411

Must have missed that I suppose

bj · Post by bj » Wed Apr 16, 2008 2:42 pm

Mattkab wrote:Did I mention this T4 project is in year 12?

no worries, i've been working on my vdub since 02' as well. my wife thinks that i'll never drive it!!

bj

MattKab · Post by **MattKab** » Wed Apr 16, 2008 4:30 pm

Cool, post a pic or two in here if you like! Remember there is no off-topic in this thread!

Matt

jonas_linder · Post by **jonas_linder** » Sun Apr 20, 2008 3:55 am

MattKab wrote:The exhaust from the turbo is also 2" and will have an all-stainless straight-through muffler with the tailpipe in the stock location (far right of the rear valance).

That header looks great

Turbos really like NO backpressure. Why a 2" after the turbo? I would go larger if possible!

MattKab · Post by **MattKab** » Sun Apr 20, 2008 12:00 pm

Hi Jonas,

Thanks, and yes, I was thinking the same, originally. Only the flange I got from ebayUS has a hole only 53mm ID and I have more than enough 2" elbows and straights. You may not like where the turbo is mounted due to the shape the exhaust has to be to pass the tertiary pipe through the lower tinware.. ('not even drilled a hole in this car yet!)

I think a 3" pipe would be sweet, maybe too big when bent 180deg compared to a 2"...

2.5"...? I'll go have another stare at it.

I need to drill out my header flange (which is now on some 2" pipe) can be finally welded in place. Only then, can I start on the exhaust..

More pics later tonight, just finalising the fuel rail route. Plenty nice stock parts!

Matt

jonas_linder · Post by **jonas_linder** » Sun Apr 20, 2008 1:14 pm

a cone twice as long as the diameter in the turbo going up to as big as you could fit would be nice!

Or if you have space issues, just make the pipe fit, I don't know if you have seen this?? This is from my bug.. no space for a longer cone though

This is the same size outlet as your gt17!

MattKab · Post by **MattKab** » Sun Apr 20, 2008 4:09 pm

Cool, I think I too will have to go with something short, like that.

I can't wait much longer for your break from study and production back upto speed Jonas.

I went with a great deal on a GT2860RS.. Recall this is a test motor...

2liter with all the better stuff to follow.

I took some pics tonight, flange with 2" pipe:

19mm with wastegate pocket:

10mm header flange with exhaust pressure port to LogWorks:

Turbo oil drain:

RHS injectors and stuff:

MattKab · Post by **MattKab** » Sun Apr 20, 2008 4:17 pm

Another older pic of the header. Lots of cutting and internal cleaning (when poss.) to get the primaries equal. I said earlier the primaries were 40". They are not, they are 30", and secondary collector to turbo is 30" aswell

And a stub pipe, these will each get an EGT thermocouple:

Header hanger bracket:

jonas_linder · Post by **jonas_linder** » Mon Apr 21, 2008 6:42 am

looks great, I thought you would be going with a gt17.. my bad

I can't wait for my break either.

Building that header looked like great fun

Keep the pictures coming, it sucks being 130km from my hobby