New Turbo Idea Taking Off

NotPicky · **Posted:** Thu Apr 14, 2011 10:58 pm

Here is the 3D rendering of the flange adapter.

racertracer · **Posted:** Fri Apr 15, 2011 1:09 am

Cool.. Solidworks?

NotPicky · **Posted:** Sat Apr 16, 2011 12:12 am

not sure. I have a guy building the flange for me. He's down in Louisiana. Been working with him for two weeks on it.

Sir Sam · **Posted:** Sat Apr 16, 2011 12:44 pm

racertracer wrote:

Cool.. Solidworks?

that "render" does not look like solidworks or ProE to me.

audiboy86 · **Posted:** Sat Apr 16, 2011 2:10 pm

Looks like a possible first generation CAD 3D or possible edgecam. But hope this works out always wanted to see what these little motor were capable of. But where are you planning on sourcing bigger injectors and do you know if the block and the head will handel the increase in prssure.

METCRD · **Posted:** Sat Apr 16, 2011 2:11 pm

I think it may be done on Inventor...

audiboy86 · **Posted:** Sat Apr 16, 2011 3:08 pm

Whatever it is it is either and older or cheaper 3d modeling software. The new style inventor is super clean when it models and 3D CAD is to i use them both daily in school. I am a hugh inventor fan CAD not so much i can model things in half the time if i use inventor and with the same accuracy i can even transfer in between.

jinstall · **Posted:** Sat Apr 16, 2011 10:19 pm

When I had my CRD in Germanyit was plenty fast enough, 120mph on th eautobahn and 11min 52 sec on the Nuerburgring, not sure what more you want from it?

jinstall · **Posted:** Sat Apr 16, 2011 10:19 pm

When I had my CRD in Germanyit was plenty fast enough, 120mph on th eautobahn and 11min 52 sec on the Nuerburgring, not sure what more you want from it?

bhc04 · **Posted:** Sun Apr 17, 2011 12:15 am

Yikes. 120 m.p.h. ? Not kilometers? I'd be afraid to drive my CRD over 100 m.p.h. Not the best handling vehicle on the road at that speed.

NotPicky · **Posted:** Sun Apr 17, 2011 12:46 am

audiboy86 wrote:

Looks like a possible first generation CAD 3D or possible edgecam. But hope this works out always wanted to see .
what these little motor were capable of. But where are you planning on sourcing bigger injectors and do you know if the block and the head will handel the increase in prssure.

Found a source that can supply bigger nozzles for the injectors. Kevin at GDE said the weak point on this engine is the aluminum head. They like to crack between the valves. Would like to see 300 hp at the flywheel to start. After the turbo goes on, I'm building a complete EGR delete. The valve and everything will go away including the butterfly valve. Nice straight through design. Trying to locate a head to see what can be done to help strengthen it.

jinstall wrote:

When I had my CRD in Germanyit was plenty fast enough, 120mph on th eautobahn and 11min 52 sec on the Nuerburgring, not sure what more you want from it?

I've been over 120 mph in the Jeep. Kinda hangs its tongue out at 122. Not trying to increase the speed just the acceleration.

racertracer · **Posted:** Sun Apr 17, 2011 6:15 am

NotPicky wrote:

Trying to locate a head to see what can be done to help strengthen it.

After I replaced my faulty thermostat, I noticed a lot of air in the cooling system that was difficult to get out.

I wonder if unbeknown trapped air pockets in the head, could be the prominent cause of the heads cracking!

audiboy86 · **Posted:** Sun Apr 17, 2011 11:36 am

I think it has been discussed somewhere before about the weak points of this motor. I know that they have and aluminium not a cast iron head. All the rest of the motor is cast iron so it will handle the increase easily. You might need to have a custom head built which wouldn't be that exspensive with all new ARP bolts in the upper and lower end just for good measure. I mean 218 hp and 400lb of torque is the highest the little motors have ever been pushed.

NotPicky · **Posted:** Sat Aug 27, 2011 3:10 pm

After so many months got the Turbo adapter flange built. Its a two piece 3/4" thick. Stock CRD manifold to T3 turbo flange.

jinstall · **Posted:** Sat Aug 27, 2011 5:16 pm

bhc04 wrote:

Yikes. 120 m.p.h. ? Not kilometers? I'd be afraid to drive my CRD over 100 m.p.h. Not the best handling vehicle on the road at that speed.

If you are ever in the area I would be more than happy to show you just how well the KJ handles at high speed.

geordi · **Posted:** Sat Aug 27, 2011 5:36 pm

You must have Virginia plates on it to be able to get away with going more than 1mph over the speed limit anywhere within that state of aszhole cops. Driving my Jetta in LIMP MODE through that f-ing state, I got pulled over and accused of doing 83, when a damm Escalade with Va tags passed me like I wasn't moving. I had out-of-state tags, so I got the ticket.

I tried telling the stupid cop that my car wasn't even CAPABLE of that speed in limp mode, it was limited to 65mph (and barely got there!) but he wasn't having any of it. Even offered to let HIM drive it and if he could make it go faster than 65, I would pay the ticket on the spot. Nothing doing.

Virginia sucks.

racertracer · **Posted:** Sun Aug 28, 2011 1:59 am

NotPicky wrote:

Trying to locate a head to see what can be done to help strengthen it.

I know of a source for your cylinder head...... Contact me if your interested in a very reasonably priced cylinder head.

Racer

yrkcrd · **Posted:** Fri Oct 14, 2011 3:36 pm

Like the others said I'm not sure how the GT2560 will spool being non VNT

**Corrected ball bearing turbos do spool faster than journal bearing**
http://www.turbobygarrett.com/turbobyga ... ch101.html

Also here is a neat turbo plotter program that allows you to look at various turbo compressor maps.
Keep in mind that NONE of these are VNT as apparently VNT turbo maps used on OEM cars are closely guarded.
http://www.squirrelpf.com/turbocalc/index.php

I used target af of 22:1 and also tried 18:1, and BSFC of .36

Redline of 4k, max power of 4k, max boost at 2k, and minimum at 600 RPM these are all complete guesses so if anyone has any better data please let me know.

But just using that it seems the GT2560 is to the left of the surge line which isn't good. Again my data could all be wrong too...

yrkcrd · **Posted:** Fri Oct 14, 2011 3:39 pm

Oh and FWIW the heads on my V10 TDI are aluminum as are most of the later VAG TDI's but I agree on keeping the temps in check.

I may look at doing a different front mount intercooler in front of the radiator.

Where did you get the stock CRD turbo flange?

I am looking for one

yrkcrd · **Posted:** Fri Oct 14, 2011 9:20 pm

More info on our BSFC

From what i've found its a best of .346 at 2000 RPM and at worst .416 at 4000 RPM

The .346 is also at the highest torque point at 2000 RPM.

Do for those not familar with BSFC it is fuel consumption. So this engine is most efficient at 2000 RPM.
Not what I'm not sure if these figures are under WOT which they probably are.

New Turbo Idea Taking Off

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