Club G40 Forum

Technical => Turbochargers => Topic started by: VW_rae on September 18, 2009, 06:24:23 pm

Title: t40 in the making
Post by: VW_rae on September 18, 2009, 06:24:23 pm

hi peeps im currently in the middle of buliding a turbod g40 an was wondering does any one have any pics of how there project went down i mainly want to know what method you used for the coolant feed for the turbo??and the oil feed please

Title: Re: t40 in the making
Post by: Tommo on September 18, 2009, 06:57:07 pm

For the coolant feed I tapped off the pipes that go to the heater matrix. And the oil feed from the back of the cyl head where the charger one comes from.

Title: Re: t40 in the making
Post by: hayesey on September 20, 2009, 07:46:15 pm

For the oil feed I used the standard g40 t-piece in the back of the head.  For the oil drain I welded a fitting to the sump as the standard g40 oil drain is too small for a turbo.

Water supply is teed into the top water pipe to the radiator and the return goes to the small return pipe to the top of the header tank. 

some pics of some of these on mine:

(http://derby.polog40.co.uk/photos/turbo/turboworking3.jpg)

(http://derby.polog40.co.uk/photos/turbo/turboworking2.jpg)

(http://derby.polog40.co.uk/photos/turbo/watersupplyfitting.jpg)

(http://derby.polog40.co.uk/photos/oildrainsump.jpg)

Title: Re: t40 in the making
Post by: VW_rae on September 22, 2009, 02:56:42 pm

cheers mate thats realy helpful jus another qwick question.the oil fedd pipe is different to the standard g lader one isn't???or does the oe parts bolt on?

Title: Re: t40 in the making
Post by: hayesey on September 22, 2009, 10:26:01 pm

it's different, slightly thicker and has a different fiting on the turbo end to fit the turbo oil feed connection.

Title: Re: t40 in the making
Post by: VW_rae on September 28, 2009, 06:40:52 pm

sweet im just puttin everting together now thanks for the tips and info jus 1 more thing the flange :P for the downpipe can i get it from somwer or do i get it fabricated???and the gasket from vw the send me was wrong it has four studs not three does anyone have the part number for the gasket or a chasis num i can use of a passat or sumin please

Title: Re: t40 in the making
Post by: hayesey on September 28, 2009, 09:27:12 pm

no idea of the part code but it's one for a 1.8 20vt B5 passat or audi a4 you want.  You've probably got one for the golf transverse engine.

Most people just buy whole downpipes, can get them from Rothe or off german ebay (where I got mine from).

Title: Re: t40 in the making
Post by: VW_rae on September 28, 2009, 11:45:29 pm

ok kool nah im making mine cheers

Title: Re: t40 in the making
Post by: Yoof on September 30, 2009, 05:04:57 pm

Rae- Let me check at the unit tomorrow night, I think I've got a K03 flange, not sure if it's mild or stainless steel.

Title: Re: t40 in the making
Post by: VW_rae on October 01, 2009, 10:55:38 pm

nice one matey also the turbo compressor side does anyone know the size of the pipe??the one that goes to the cooler and the one that goes to the filter.cheers.

Title: Re: t40 in the making
Post by: lance on October 02, 2009, 12:00:46 am

the intake is the same size as the standard G40 pipe that goes from the rocker cover into the supercharger.
i just put that on mine the samco over the top of it.

Title: Re: t40 in the making
Post by: VW_rae on October 02, 2009, 06:57:05 pm

thanks does the same rule apply to the turbo to intercooler??

Title: Re: t40 in the making
Post by: hayesey on October 02, 2009, 07:13:11 pm

no thats slightly bigger.  If I remember rightly the compressor inlet is 45mm and the outlet is 50 or 51mm.

Title: Re: t40 in the making
Post by: VW_rae on October 03, 2009, 12:35:45 am

 ;)

Title: Re: t40 in the making
Post by: VW_rae on October 14, 2009, 09:05:29 pm

qwick question reguarding the oil feed pipe does any one know the I.D of the pipe your spose to use or were i can get one....also i need a map sensor that can read more then one bar does anyone now wer i can get it from??? cheers

Title: Re: t40 in the making
Post by: willsalter1000 on October 14, 2009, 09:08:30 pm

think you can get them from yoof and andy at PPP

Title: Re: t40 in the making
Post by: hayesey on October 14, 2009, 09:20:23 pm

yep as per the PM I just sent you in reply to the one you sent, get a map sensor from PPP.  Since they are pretty much the only people you'll be able to buy high boost turbo remaps from and the remap needs to have been made to suit the particular map sensor as not all will give the same voltage out for the amount of boost pressure they are being fed.

Title: Re: t40 in the making
Post by: VW_rae on October 15, 2009, 03:43:26 pm

lol yh i am actually called rae

Title: Re: t40 in the making
Post by: VW_rae on October 15, 2009, 08:30:36 pm

if i run abar of boost with a standard bottom end, cams and a decent air filter would i be seenin 190bhp???

Title: Re: t40 in the making
Post by: hayesey on October 15, 2009, 08:56:50 pm

not with just one bar, no.

Title: Re: t40 in the making
Post by: Doc J on October 16, 2009, 08:10:28 am

I heard Standart PY with turbo-convertion at 1bar ~ 150 bhp.  ::)

Title: Re: t40 in the making
Post by: hayesey on October 16, 2009, 09:46:09 am

yeah as above, a turbo making one bar isn't going ot make too much different power to a g-lader running one bar.

Title: Re: t40 in the making
Post by: Yoof on October 16, 2009, 10:25:54 am

They do  ;)

Andy's made 174bhp (1341cc) at 15psi.

I guess a 1272cc K03 would make circa 160bhp at 1 bar boost.

Title: Re: t40 in the making
Post by: hayesey on October 16, 2009, 10:56:22 am

yeah wihch isn't too much than you can get with a g-lader at 1 bar with similar other mods.  ;)  It aint going to make 190 anyway.

Title: Re: t40 in the making
Post by: VW_rae on October 16, 2009, 12:41:49 pm

 ;).has anyone heard from the polo performance lot i have tired pm thembut no reply i need that map sensor.does any one have on for sale?

Title: Re: t40 in the making
Post by: Andy on October 16, 2009, 01:29:42 pm

Edit...

PM replied to. :) We both have full-time jobs, so we're not always able to give an instant response!

Title: Re: t40 in the making
Post by: VW_rae on October 17, 2009, 04:00:55 pm

thats kool mate