Mild 1600TP Turbo engine

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Re: Mild 1600TP Turbo engine

Post by Bratjie »

Wentzel wrote:Hi Bratjie,

I'm glad you sorted it out, stuck with it and by now you are hooked!! Going EFI makes a lot of difference with adjust-ability. Keep us up to date please. The other people don't expect responses like that from a Beetle and it is just so much fun to see the faces.
Will do mate, thx's for all your input throughout the build :hangloose:
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Re: Mild 1600TP Turbo engine

Post by eben »

:D They are annual stars. You get them for years of membership.
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Re: Mild 1600TP Turbo engine

Post by Bratjie »

eben wrote::D They are annual stars. You get them for years of membership.
Awwwww :( , ok. but I'm still chuffed for the amount of views hey?, awesome :D
Esté robusto, ser fuerte!!!!

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Re: Mild 1600TP Turbo engine

Post by Bratjie »

One week later, driven like a mule and still no hickup's. just need a little time before I go see 4Agedub for the Gotech system and then back to testing :flogging: :whip:
Esté robusto, ser fuerte!!!!

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Re: Mild 1600TP Turbo engine

Post by vader »

Keep going...
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Re: Mild 1600TP Turbo engine

Post by Bratjie »

So on Thursday night we go out driving around just the odd boost here and there, then on one nice boost going to fourth boost just dropped and never came up again, she runs normally below boost and no extraordinary sounds or signs of damage, Friday morning the wife takes her to work and as soon as she stopped the biggest oil leak you could ever imagine appeared under the car :shock: ,

It was the turbo leaking from the shaft seals and when I took the compressor housing off it has so much play on the shaft :shock:

Oil pressure is good, oil feed lines all clear and without any obstruction. I'll take it in tomorrow to find out why this would happen so soon? It was supposedly a brand new Turbo but now I'm thinking I bought a Fong Kong Garret.

Fitted the old exhaust system and she's running just fine.
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Re: Mild 1600TP Turbo engine

Post by vader »

That will leave a mark....
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Re: Mild 1600TP Turbo engine

Post by Bratjie »

vader wrote:That will leave a mark....
Yup, it did, had to go clean it up a.s.a.p too, Bosal has very strict environmental processes in place, health and safety officer was'nt very happy with me and neither was the wife :lol:
Now her colleauges are making fun of her saying, "all you had to do was put up a sign with your registration number on to mark your parking spot" :twisted:
I say the Bug was just marking it's territory very aggressively :hangloose: 8) , so even after Mothersday love & care I'm not very popular.

Will take the turbo in for examination later today, I also suspect contaminated oil originated from when we snapped the cam head off when my son dropped a nut inside the dizzy hole
Esté robusto, ser fuerte!!!!

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Re: Mild 1600TP Turbo engine

Post by Bratjie »

Got hold of a Garret GT2056 turbo, dropped it off at Stallion Turbo's for a quick lookover, hopefully we'll be boosting happily ever after by the weekend,
Was told that my oil drain was a huge problem and could've caused the destruction of the Turbo, I had a 90 deg bend coming out of the Turbo housing, due to space limitations, which would keep the hot oil from flowing away from the turbo after shut down. also read another interesting comment on the Garret site " never drain back into the sump below the actual oil level mark" Go figure :( , I added a thinline sump just to be able to drain without having to lift the Turbo higher, now my drainplug in the sump is lower than the oil level, just can't win, maybe a scavengerpump could help draining to somewhere else.
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Re: Mild 1600TP Turbo engine

Post by Wentzel »

I added a sump also but drain the turbo to the casing above the oil level but run the oil level lower that std [Low level on dipstick] the extra sump oil cooler filter etc make up for the lower level. My sympathies I also had a lot of issues with oil drain but I hope it is sorted out now.
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Re: Mild 1600TP Turbo engine

Post by Bratjie »

The turbo I have now is a GT 2056, just for comparison to the old turbo ( Mario )

All I have on the old turbo is that the Compressor a/r was .48 and Turbine .47

The Gt 2056 I have a few more info : Compressor a/r is .53 Inducer - 41.5 mm, exducer 56mm with a 55 trim
The Turbine a/r is .46 with 72 trim and a 47.0 wheel
Thr pressure ratio is 1.69 and for some reason I am unable to calculate CFM so I used Mario's last calc which is 9 lb/min
I plotted it on the maps and need some feedback please

Ps: I have no idea how to read the Turbine map:
This is more or less what I have on the maps;
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Re: Mild 1600TP Turbo engine

Post by AirPower »

Better late than never I guess, sorry for the slow reply, been sorting out some other stuff.

Sorry to hear about your trouble with the old turbo,I hope this one lasts!

From that map, it seems this turbo is marginally too big for your 1600 (it still is a 1600?)
It should spool soon enough, but your motor cannot flow the amount of air that the turbo wants to move. It will still work though - don't get me wrong, it's just not ideal and is very close to the surge line on the left.

I see on the garret web site that it's recommended for 140 to 240 HP motors. That's why the dot at 9lb of airflow is so far to the left on the map.
Using Garret's own airflow calculator, I got 7lb of airflow at 3500 rpm and 11lb at 5200 rpm for 99HP at the flywheel.

You do have an intercooler in place? That should take care of any additional heat in the turbo discharge.

You are using a blow-off valve (to vent the pressure during gear shifts)?

NOW MOST IMPORTANTLY - do you know what that internal waste gate is set to? 8psi, 12psi, 14psi?

You cannot work with a pressure ratio of 1.69 if you don't know what boost the wastegate is set to maintain, since the pressure ratio is an indication of actual boost pressure.

All the best getting that oil drain pipe sorted! Go big .......or you'll be pushing it home :mrgreen:

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Re: Mild 1600TP Turbo engine

Post by Bratjie »

Been off the air a while, just want to say that the new Turbo is still holding up and she's still runnung like a bomb, had to change the wastegate actuator as factory was set at 1.2 bar, fitted another and set it to .9 bar max, still a little detonation now and again but still have to fit the Gotech to retard ign under boost, still giving carrots to Tazz's, Velocit's, and most other 1600 and some 2l factories.
Anyway, I'm happy with the overall performance, still a daily driver,

Want to fit fuel inj and bigger Charge cooler radiator and pump in the summer, with Gotech fitted by that time and a good dyno I'm sure to have a nice crisp and reliable engine and looks like it will last a long time,

With this turbo (GT 2056) I'm getting boost off the line and holds up all through the rev range even nice boost in 1st gear,

Till next time :D
Esté robusto, ser fuerte!!!!

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1959 Karmann Ghia Lefty, soon to be turbo'ed and chargecooled
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Re: Mild 1600TP Turbo engine

Post by Ron&Gill »

That's not surprising as can you multiply your cc by your boost to get equivalent cc: 1600x1.9=3040cc normally aspirated. Are you making >100kW?
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Re: Mild 1600TP Turbo engine

Post by Bratjie »

Ron&Gill wrote:That's not surprising as can you multiply your cc by your boost to get equivalent cc: 1600x1.9=3040cc normally aspirated. Are you making >100kW?
Hi Ron, what does the 1.9 represent in your equasion?
Used to make 71kw with the old turbo on a scaley dyno :D , have'nt had a chance to redyno the new Turbo yet,
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74 Beetle 2.1 WBX Turbo'ed & chargecooled
1959 Karmann Ghia Lefty, soon to be turbo'ed and chargecooled
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