#46: Re: Project dirty deezel 1.1 to XUD9TE :D Author: ekjdm14, Location: CheshirePosted: Thu Aug 13, 2020 1:54 pm ---- Hey man thanks for coming back to me on this This swap is partially your doing & partially another guy locally who had a DT swapped 206, causing a serious bout of inspiration and "how hard can it be"-ness... (It can be quite hard as it goes, like you said in your thread i think, it's the little bits that get you!
Anyway bit of an update, found a K14 turbine shaft in the garage & decided in the interest of getting the car going quicker I'd clean up the turbine housing and repair the original snail for the moment. So last Friday it was back on the road with the boost wound down to about 20psi to stop us from overspinning the thing again lol.
And then 2 of the injectors started leaking fuel like a sieve for some reason. Half a tank in 20 miles... Thought it was the leak off pipes to begin with although it seems to be from the actual injector bodies where they screw together. This coupled with wanting to get everything ready for MoT time end of September (screen wash button, telltale lights, cooling fan and exhaust system etc) has led to us swapping the insurance over to the DT 306 for now to allow work at my leisure.
It'll be back soon though, it went too well to not want to continue & will be aiming for roughly similar power to yours. The way we make the power though shouldn't tax the head bolts too-too much as its not going to be a torque monster, aiming to make the power higher up the revs to better use the GTi gear ratios. It accelerated like a scalded cat with it's ass on fire when the boost kicked in, great fun.
As far as room for the VNT it does look like it'd fit down the back just fine, it's not much bigger than the K14 just wider, but will probably gearbox mount it to create more space for keeping the gear linkages and bulkhead cool (could feel the heat through the footwell and the gear shift bushes are starting to suffer already) not to mention the current manifold is the old squareport type and restrictive so a homebrew tubular one would be nice & it gives easy engine-in access to the VNT can because I'm sure I'll run into similar issues as you did trying to work it off boost instead of vacuum.
Incidentally what did you end up with as regards that, did you add a nipple to the other side of the can & feed it pressure through an MBC? (that's what I'm currently thinking of doing) or did you end up with a traditional WG actuator and from what?
Thanks, Dan.
#47: Re: Project dirty deezel 1.1 to XUD9TE :D Author: southwestchap, Location: DevonPosted: Fri Aug 14, 2020 5:38 am ----
ekjdm14 wrote:
As far as room for the VNT it does look like it'd fit down the back just fine, it's not much bigger than the K14 just wider, but will probably gearbox mount it to create more space for keeping the gear linkages and bulkhead cool (could feel the heat through the footwell and the gear shift bushes are starting to suffer already) not to mention the current manifold is the old squareport type and restrictive so a homebrew tubular one would be nice & it gives easy engine-in access to the VNT can because I'm sure I'll run into similar issues as you did trying to work it off boost instead of vacuum.
What size exhaust are you running? I made up a 2.5" full straight through all the way from the turbo and didn't have any issues with heat. Exhaust is nigh on half the restriction for turbos, I ran just the downpipe for testing purposes on the dyno and picked up 17hp.
Yes I planned to move the turbo but in the end I had done what I wanted with the car so I moved the engine into a 309 for a while until I decided to swap to a HDi. Would make life easier with tweaking the stop screw and ensuring the actuator rod is in the right place.
ekjdm14 wrote:
Incidentally what did you end up with as regards that, did you add a nipple to the other side of the can & feed it pressure through an MBC? (that's what I'm currently thinking of doing) or did you end up with a traditional WG actuator and from what?
Did try and force boost the other side of the vac can but didn't work as well as I hoped. So just took a stock wastegate actuator from a TD05 I had kicking around. Had to do something fancy with the mount. Didn't look pretty but it worked well. There is a photo of it mounted on the 306 forum I believe. I tried the MBC route and yes it worked it wouldn't drive happy on cruising....fine if you kept it on song but when on the dual carriageway it would spike a 60psi EMP gauge
So swapped out to a electric boost pressure switch which would open an inline valve (think it was an XUD EGR one) was a bit fierce at times but seemed to work well.
#48: Re: Project dirty deezel 1.1 to XUD9TE :D Author: ekjdm14, Location: CheshirePosted: Fri Aug 14, 2020 1:03 pm ----
southwestchap wrote:
What size exhaust are you running?
What's a downpipe? lol but honestly it's been running straight out of the elbow for the time being, and had previously noted your comments about how restrictive exhausts are so was planning a side-exit as wide as possible probably 3" or 3 1/2"
ekjdm14 wrote:
Incidentally what did you end up with as regards that, did you add a nipple to the other side of the can & feed it pressure through an MBC? (that's what I'm currently thinking of doing) or did you end up with a traditional WG actuator and from what?
Did try and force boost the other side of the vac can but didn't work as well as I hoped. So just took a stock wastegate actuator from a TD05 I had kicking around. Had to do something fancy with the mount. Didn't look pretty but it worked well. There is a photo of it mounted on the 306 forum I believe. I tried the MBC route and yes it worked it wouldn't drive happy on cruising....fine if you kept it on song but when on the dual carriageway it would spike a 60psi EMP gauge
yeah that's what I feared, having only K14s around means a bit of scrap yard shopping required there then. 60psi EMP wow, not really au-fait with exhaust pressure issues but would that be creating the hotside equivalent of compressor surge? (not to mention poor gaskets!) Think I best get a second pressure gauge and read up on that side of things
So swapped out to a electric boost pressure switch which would open an inline valve (think it was an XUD EGR one) was a bit fierce at times but seemed to work well. so basically no pressure to the actuator until a threshold reached & then it'd shuttle on/off in a semi-PWM kind of fashion to control boost in a few psi window?
Thanks again, will have to look up the 306oc post with the actuator setup but I think I can visualise what you mean hopefully.
#49: Re: Project dirty deezel 1.1 to XUD9TE :D Author: ekjdm14, Location: CheshirePosted: Thu Oct 08, 2020 1:14 pm ---- Been a bit quiet on the dirty deezel front for a while, just been running it with the rebuilt K14 and lower boost for the time being since it made an exhaust system for MoT purposes easier to knock up (pretty much all standard GTi system with the inlet lopped off and a TD one welded on, cat gutted and O2 sensor bungs welded up).
It's been pretty reliable as far as not leaving us stranded, but now the MoT is out and it's time to address how to get it tested. This is going to mean a slam panel made from steel (the chopped about original PA/GF item is cracked around the catch area now), the wiring needs tidying up and shoving in some loom tape & then the kicker, it's suddenly decided to throw an ABS code for both front sensors incoherent signal...
This coupled with the fact we now have 2 306s and recently bought a £50 SW with a cooked engine means things are progressing slowly, it will be back though
#50: Re: Project dirty deezel 1.1 to XUD9TE :D Author: ekjdm14, Location: CheshirePosted: Wed Jan 13, 2021 11:46 pm ----
Just plopping a couple of pics of the latest project here, can't work out how to upload them online other than here lol
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This swap is partially your doing & partially another guy locally who had a DT swapped 206, causing a serious bout of inspiration and "how hard can it be"-ness... (It can be quite hard as it goes, like you said in your thread i think, it's the little bits that get you!
