finally

[seanfournier]

turbo arrived today. Finished making (looks like crap i know) the prototype equal lenght exhaust manifold. Tried putting it together to see the fit of things... NICE.

Next week I'm dedicating all time to do this thing right. If all fits well inside the car I'm going to make another super clean and polished exhaust manifold. Installed turbo. Two intercoolers (hidden style). All should be ready by the next NVD meet.

[R_Ethug]

Re: finally

holy crap sean your nuts lol!! are you selling your current turbo then? i'm not interested i'm just wondering

[seanfournier]

Re: finally

holy crap sean your nuts lol!! are you selling your current turbo then? i'm not interested i'm just wondering

yeah its all for sale

[Tromping_Maniac]

Re: finally

yeah its all for sale

What kind and model of turbo?

[1.8Trip]

Re: finally

Did you end up buying the Disco Potato? Whatever it is, it makes you wanna do a little dance.

[seanfournier]

Re: finally

Did you end up buying the Disco Potato? Whatever it is, it makes you wanna do a little dance.

Yeah. the disco. I was polishing the aluminum housing yesterday. This thing is going to look sweet. Monday I begin fitting it to the car. Will post major major pics in the following week on my website. www.seanfournier.com

I can't remember exactly the specs on the turbo in my car now, when its out I'll answer Tromping_Maniac's question.

[Kor]

Re: finally

Really nice. Do you still plan to turn your knowledge into a production turbo upgrade kit?

[seanfournier]

Re: finally

Really nice. Do you still plan to turn your knowledge into a production turbo upgrade kit?

Perhaps. I don't know if I really know anything of real value but I'm going to try. I'll use my car as a test unit. Its paid for and I have the money available to buy a new motor if I ruin this one.

I'm going to install 4 more injectors on my intake manifold and attempt to drive them using my own system... could work great... could be a disaster.

I bought the entire wiring harness to a mk4 1.8T last week so when I get it I'll begin messing around with the hook-up and then see where I go from there. The way I want the system to work is like this:

Fuel: At a certain duty cycle of the stock injectors (lets say (80%) the SF (my system) will begin driving the extra 4 injectors on pulse with the stock system but will only begin driving them at a very very short interval (1-2ms). This PWM will slightly increase as needed to keep a proper A/F ratio which you can actually set at each RPM point. I'm not worrying about timing YET but once I get the sequential injector driver finished I'll begin working on timing and clamping the MAP.

Its actually very simple. The higher the RPM the less time there is available to keep the injector working to provide fuel. So when the injectors begin not having enough time to provide enough fuel the SF will begin working the other 4 injectors. It will monitor a wide-band air/fuel meter to keep things on level. I hope to have a system so simple that you just plug it in and you decide how much boost you want at each RPM level and the SF will simply provide enough fuel and control the wastegate actuator accordingly. If SF sees there is a problem it will warn you.

Wastegate control: The N75 is a frequency valve. Meaning, it opens and closes a little needle valve very quickly indeed in order to allow a certain amount of air pressure from the charge tube to open the wastegate. Now, while at the Chicago auto show a couple weeks ago I saw a turbo'd mercedes engine (amazing) and looked very very carefully at things and realized that the mercedes engine don't use a pneumatic frequency system of opening the wastegate. It was using a Servo Motor. I though, damn, thats really amazing. That makes things SO much better to control. You don't have temperature variables to consider and you don't have to deal with tricky air lines and restrictors. You just need a good strong Servo motor. So, Adapting my wastegate control to a Servo system will the the next challenge after the fueling thing. I'd like to limit boost to 10 pounds in the first gear and 15 in the second and then in third gear let the pressure rise to 20-25 pounds.

Harware: The hardware I'm going to be using to do this project is not conventially used in cars. It will have a small touch screen which you can program the unit with and display different information etc.

Anyways, Monday afternoon my car begins its transformation. I think it will be a two week project 10 hours each day from start to finish.

[Smartiepants]

Re: finally

Sounds genius, but seems pretty complicated, remember fewer things, fewer things to go wrong.

[seanfournier]

Re: finally

stuff coming off. Here is a photo of my PCV that went bad. Notice oil spraying all over the area. There are lots of people with leaking PCV valves who are chipped especially. Look under your manifold and if you see oil on the suface of things your PCV is either bad or the clamps are not thight enough. I could blow through the PCV when I should be able to... thats how bad it was leaking. So then what happens is I was LOSING boost, oh no!

Update: Manifold didn't quite fit well with the turbo on the car so I'm altering it a little. Shortening it and getting the turbo closer to the block.

http://www.seanfournier.com/engineba...renaration.jpg

[R_Ethug]

Re: finally

HOLY surgery batman.. yea sean I read on 1.8T tech that people were having that issue with chipped cars and they needed to replace the clamps and/or the pcv valve..