dunno if anyones interested

i had a spare couple of turbos from the Zed, so i knocked up a manifold and stuck them on the GTti, turns out from the compressor maps, its pretty much ideal. it should haul now :hyper:

 

 

 

 

 

 

 

 

 

 

ive made the oil supply lines and got the oil drain sussed. i just need one more flange to go out the turbo and down to the exhaust :(

 

oil line all made up and flared

oil drain flange made and pipe cut and ready to weld on

flange welded and bolted up to turbo

trial fit

this isnt the final downpipe, just one thrown together so could hear it go. il use this as a jig to make a better one later.

Very nicely done :bow:

:bow: :bow: :bow:

Damn thats cool fella! Looking forward to seeing the results!

next step is using the zed EGR valve to make an anti-lag. ive got a 2wd cossie intercooler to mount on the front, then its just a case of piping it up.

 

the only thing that made me shove this turbo on was the turbine ring seal was worn on the std IHI turbo and a replacement was going to be £370+vat.

ive bought a rebuild kit for this Garrett so il over haul it now i know it fits.

:bow: awesome project there bud! I'm very excited to see the finished article!

cheers guys, youl maybe appreciate the last mod i did then:

 

The standard throttle body is very narrow (34mm), and im pretty sure there are gains to be had in fitting a larger one. The thing is theres not much else will fit it, after obtaining this RS turbo item i thought id fit it. problem is, obviously the flange holes PCD is different (larger and wont line up with the bolt holes) so i spent today modifying the std GTti plenum and machining an adapter flange to mount the RS turbo throttle body Steve gave me.

 

started with a bit of 6mm aluminium, marked and drilled the holes and roughly drilled out the center

 

 

 

 

then used the rotary file in the drill to smoothen out the middle (god i wish i had a plasma cutter and a milling machine!:lol: ), and counter bored the inner (original standard flange) holes and turned bolts on the lathe so the heads would sit flush with the top of the plate.

then hacksawed a flat so i could tighten them up. then i cut the bolts to length.

 

 

 

 

 

then i tapped the outer flange (for the RS throttle body) 8mm. After drilling the clearence holes in the throttle body (which were originaly 6mm)

 

 

then this assembly was bolted to the plenum and checked for flushness. i used the cut down bolts as studs for the throttle body.

 

 

 

 

the neck of the std plenum is about 2mm slightly smaller than the throttle body bore. so i tapered the plate to help flow, id like to have enlarged the hole more, but didnt want to risk reducing the wall thickness of the neck too much and cause i fracture in the future....

 

 

 

 

here is it fitted and bolted up (no gaskets yet) just to see how it looks and how smooth the bore is....looking nae bad so far..............

 

 

 

 

 

 

here is a look down the bore with wide open throttle

 

 

 

it looks more restrictive than it is, i think its jst because the metal is shinier there but as you will see in the next pic, its MUCH better than the original (shown in the middle)!!!

 

 

 

 

standard GTti throttle body top:

 

 

:bow: :bow: :bow: :bow: :bow:

Excellent! Good to see, look forward to knowing the results.

wow top work fella

Good project there mate!! You going to rebuild the tub yourself? Or send it out?

That's frigging awesome mr bigglesworth! :D

 

Can't wait to hear it :) Can you take some vids of it when it's running???

Nice!-all home-grown too ;) !

thats awsome fella nice work :bow: :bow: :bow:

Hehe, bet thats gonna go like stink!!

really impressed, well done :bow: :bow: :bow:

where are you mounting the rad ? the tubbie seems to be close to where the rad should go , do you forsee any problems with overheating ? excellent project mate

 

cant wait to see the results

 

Steve

cheers folks, never posted my other projects on here before as they were non-zed related.

 

the turbo its self isnt close to the radiator (or certainly no closer than the std turbo was) the down pipe looks crap cos i run out of bends, but it does swoop close to the rad. not close enough to cause any problems with it tho.

il be moving the rad back about 4 inches and angleing it slightly to allow the cossie Intercooler to sit bahind the grill between the 2 headlights. there will be more room now as the std intercooler which was down the bottom in front of the gearbox will be removed.

That's Wild, I like it.

what a cool project :bow: :bow: :bow:

Sorry for asking a silly question but what car is it?!

Daihatsu charade GTti

 

& that one is going to be a corker :bow:

 

Very nice work there

 

J

lol i hope its got a thick head gasket on!

 

I had a metro turbo, the vaccum line to the actuator split

 

Got about 20psi when it should have been running 7psi max = melted block.

 

Whoosh - bang - pop - doh

 

lol

Very impresive :bow: :bow:

 

Fingers cross and look forward to seeing the results.