Maki

[Racing]

Could i ask you to tell me a little more about this turbo project of yours?
What the general idea is,and what the specs are.?

[Racing]

Btw.
This is how we did to make up a turbo exhaust manifold



Difference between now and then...is the routing of the pipe for the wastegate.
Streamlined that a "little" so to say to get better reaction and response out of the HKS unit.

[Maki]

Hi Racing - here are some Datas on my Project.
Bought a new 2.3-16V engine from Mercedes.
Engine was brought to Van-Kronenburg(a Tuner from Netherland).He opened the engine and said that the Original Engine Parts were already really good - so he machined the pistons and the the compression was lowered to 8,5:1 .
The KE-Jetronic was removed against an EFI with a free programmable ECU.
The Manifold is "my problem" at the moment cause i'm waiting for it for over 4 months now
Would there be a possibility to get one from you in the fact that they don't manage it to get one build??? (But i'll write you a PN about this).
As Turbo i choose a Garrett GT2871R 0.86A/R
Don't know if the 0.63A/R would have been a better option as far the spool-time concerning .
I'll run the Turbo with 1.0Bar boost at the beginning.Maybe later going up to 1.2bar but i'll see.
I'll have an external Wastegate. I'll get an Intercooler with a core from 18"x12"x3" that i'll put in front of the radioator which will be replaced against an electrical one.
Then i'll buy a bigger oil cooler.
An other thing that i am not sure is if it would be better to get ARP Headbolts. Van-kronenburg told me that that wouldn't be necessary but i'll discuss this again with him.
Then i'll exchange my cats against Racing ones with 100cpi.

My goal is to get at least 300HP which is realistic like i think. Hopefully I'll get full boost about 3500-3800RPM. Earlier would be better but we'll see.
I don't know if i forgot something.
Maybe you could give me some of your ideas -what i could do better.
Bye
Maki

[Racing]

A GT28...alright.
I think you´ll be just fine with that size exhaust AR.
The thing is...the streetrace crowd around here-the DIY boys that is-seems to find new ways to "el cheapo" turbocharging all the time,and they´re finds of lately has been that you can get away with a LOT of turbine AR if you build it right-the exhaust man that is.
Seing the NA power of the cossie..you´ll be just fine.

Mine btw..is a somewhat larger one-altho still on a T3 flange.
It´s a super T70,just cause i got it brand new for free

Compressor..is good for approx 600+

Yeah, the cossie engines really ARE full of good stuff right off the bat,and i for one settled for a little more static compression than you did.
In my case 9,2:1.
Reason..is that this is a street motor,and these days you can get away with that much comp under boost in a 16V head as they ain´t exaclty prone to detonation-as were the earlier 2 vlv designs.
Just take a look at the boosted M3 and M5 engines around and you´ll get an idea..
What one does is basically to emphasize a certain main area of use.
Ie;in my case..it´s NOT a race car,but a streeter-and i try n keep track of that.
To compensate..one simply backs off timing.

Take a look at the current crop Audis and you´ll get an idea.
Around here...they ain´t even opened up..retain the 9,2 comp IOW..and are boosted inxs of 2 bars on a 27 housing-rendering inxs of 400hp.

Exhaust.
Look.
With a turbo engine...its ALL in backpressure.
One simply measures the intake pressure vs the exhaust one to get a differential value.
The more thought out the primary piping..in lieu with the engines internals..the less exhaust backpressure there is,and the better the engine will run-EVEN ON VASTLY LARGER TURBINE ARs THAN COMMONLY BELIEVED.

Guess what....
Mercedes n cosworth..has already done the job for us
The 16V comes stock with one of the most beutiful headers i´ve ever seen-especially so in production.
What i´ve done..is simply to turn the MF upside down..
Had to reroute the No3 pipe a little,but that was about it.
This places the turbo far out in the pass side inner front fender.
Have...replaced the ASR to the intake side.
Swaped the radiator expansion box for one from a Volvo 740 series.
Exchanged the OEM windshield washer box for one of the Bosch "bag" series with built in pump and placed it right by the battery.
Works great.
Buuut....the thing is that mu turbo physicaly is about twice as big as yours.
Could say...that ample room is something i´m without broh

On the intake side..i decided to scrap the entire OEM setup.
Out the F-in door..
made up some new 50mm intake stacks and routed these to a 110mm dia plenum,which has an "entry" plenum welded atop of it to work as a diffusor-a´la the late design Audi sport intakes.
Throttle body..is at the intake end of the diffusor plenum,and is the modified stock unit.
Modified..in as much as that i elongated the throttle axle to be able to install a Ford/Haltech throttle position sensorn at the end(TPS)
IAT,CTS asf..are all Bosch/Volvo.
Same crap different day really.

The wiring n such..is all home brew.
Honestly..makes for a more "decent n clean" looking install than the average flying lead carpet most mans send with their ECUs.
IOW..it´s made to fit.
ECU is placed as pre the OEM one-Ie,behind the battery.

Btw.
As i run a somewhat larger turbo than you do,when the install is finalized it´ll sport a 3,5 inch downpipe into the full 3" sans catalyst asf already built exhaust.

[Racing]

The 60mm BOV(blow off valve).Homebrew.



The 50mm HKS wastegate.



The layout of the main pressure plenum and intake stacks.
Please observe the ad on injector bungs.
Idea is to run a set of 630cc Siemens racing in the OEM placement,and some Bosch 390ccs in the ad on bungs.



Principle layput before we started cutting and welding.Also gives you an ida of the physical dimension of the huffer.It´s fairly large



Intercooler.An old spearco element,made to fit like a glove infront of the OEM radiator.



Principle layout and angle of attack for intake trumpets and fuel rail.
As you can see,to remodel this into an independant runner setup is very much doable,altho pointless running a turbocharger.

[Maki]

[Racing]

[Racing]

[Maki]

[Racing]

[Benzinokaiser]

[Racer]

[Henger]

[Racing]

No Jonas.
We make the VEMS unit ourselves.
Mainly the VEMS has been an internet brainchild.
..and most of it has been developed here in Sweden.
It IS however open source,meaning that anyone up to it is free to contribute.