engine parts

[vwrallycar]

For the guys that have turboed their 8v engines, what did you do for pistons, rods etc? are you using forged pistons, and if so where did you buy them from?
thanks
Andrew

[Oneofthegreats]

How much power are you thinking of making?

Thats the biggest factor concerning boost pressures & engine internals.


Just for interest sake. Have a read of my 8vT K-Jet build. Plenty of info & making some nice power. Not exactly sure how much, but it can run with low 13sec cars on the street.

http://www.vwwatercooled.org.au/f55/...ild-38095.html


This is also a stock un-opened low compression GX US spec engine with only a Autotech 270 cam & heavy duty valves springs.

Nothing more & I've wound it upto 22psi! But only for a couple of weeks

I wouldn't recommend it though


Now running a safe 16-18psi for street use

[twin eng, twin turbs]

The best option i found for value and strength is from Import Performance Parts - Import Performance Engine & Racing Parts they have a piston and rod combo with coated Wiseco pistons and Toga Rods. Great quality and will handle as much power as the 8v head can possibly flow.

[vwrallycar]

Hi guys, thanks for the info.
golfworx, i would like to make 200hp, and not have to run huge boost. the engine is a mk2 1800 8v digifant engine running a wolf ecu. it is setup in my beetle. i have been slowly reading your build and its very well done. does anyone in australia sell forged pistons for these engines or am i best chasing some from the states? stock piston size is 81mm i think and i see you can buy 83mm. also what exhaust manifold did you use? i have seen TDI manifolds but thought they would be too restrictive

[Oneofthegreats]

Hi guys, thanks for the info.
golfworx, i would like to make 200hp, and not have to run huge boost. the engine is a mk2 1800 8v digifant engine running a wolf ecu. it is setup in my beetle. i have been slowly reading your build and its very well done. does anyone in australia sell forged pistons for these engines or am i best chasing some from the states? stock piston size is 81mm i think and i see you can buy 83mm. also what exhaust manifold did you use? i have seen TDI manifolds but thought they would be too restrictive

200hp should be a walk in the park considering you have an standalone ECU already wired in.

I'd suggest before you go ordering parts to strip the engine & get everything measured up.
You may find the engine may only need a hone to go to 81.5mm or even upto 82mm.

If the bores don't need hogging out to go to 83mm I would suggest against it.

If you really want it reliable to take all punishment thrown at it, I'd suggest a cheaper alternative & one which I've considered myself when my setup goes bang.

Source a set of 20vt rods & pistons if your bores don't need honing. If they do, then just go for the rods & outsource the pistons & rings. The rods will cope with the power output of a mild 8VT all day, everyday

For the exhaust manifold I went with a ATP turbo cast iron piece. Extremely heavy duty & should out last the engine!

VW - 8v Turbo Manifold : atpturbo.com

Fueling etc. could be also sourced from a 20vt for the injectors. You could also use a VL turbo fuel pump which are very cheap also along with a rising rate fuel regulator.

Now for the fun part.
The turbo could be sourced 2nd hand of a Saab or another Garrett turbo'd based car. Or you could splurge on a brand new item. It will have to be T3 based as that's what the exhaust manifold is based around.

I'd suggest for a 200hp a straight T3 with a .48A/R exhaust housing should be up to the task no worry's with around 15-18psi wound into it. Full boost should be around the 3.5-4K mark.

If you feel like you'll go a step further (& trust me, you will, cause once you've got the bug, its only a matter of time!) I'd go a T3/4 hybrid which will be able to make the same power but with less boost required. So when you do wind it back up to your original boost setting you'll be making more power.
I've considering this for my setup once my turbo lets go as well.

Oiling is very straight forward. Fitting straight out of the oil filter housing & then bang in a drain for the turbo into the sump. Dash -4 for the supply, Dash -10 for the return.
Watercooled turbo's will also required the cooling system plumbed in as well as the oiling system.

My turbo is both, but I only run the oil system. To hell with the water! haha

You'll also have to help your engine breath & suggest fitting a large rocker cover breath pipe running into a well vented catch can! Not back into the inlet system!


Or you could do it the very easy way, as I did!

Just leave you engine as is, bang a turbo setup on it, tune it for around 15psi & you'll have that power I reckon.

All that's left to do it enjoy it & cross your fingers & toes hoping it doesn't pop! haha Which I still do everyday I drive it!

There are more ins & outs & I'm hoping twin eng, twin turbs will jump in with more info, as he's also turbo'd the good ol 8v & making more power than me! haha

[twin eng, twin turbs]

So what is your budget?... I am guessing that you have mid mounted the gti engine in your beetle?

You are better off buying all your performance gear from the states. Forged pistons here are over priced i was quoted $1200 for JE pistons and told that was cheap but found them for $450 online at ebay motors USA. 20vt pistons and rods are a great option as Golfworx suggested if your bores are fine, but measure them with a internal micrometer to be sure.

A cast manifold (not the TDI one though) would be a good option if you are only chasing 200hp, the majority of cast manifolds are suited to T3 exhaust flanges though you would be better to have a T25 one in my opinion. Because depending on your budget a garrett GT25 or GT28 will give the best response and drivability coming on boost very early and flowing 300+hp. I have tried many different turbos on my gti engines and roller bearing ones are the only way to go. I had my car coming on boost hard from 2000rpm with a GT25 and had no lag what so ever! This turbo made 138 kw atw on 13psi boost with an internally stock engine and 150000+kms. I made my own manifold tune length 4 into 1 with the turbo above the gearbox. If you make your own be sure to really make it solid due to heat distorting the manifold and causing leaks.

Intercooling is another thing. You may consider using a water to air intercooler for ease of placement and the obvious lack of airflow near your engine for air to air intercooling. I made my own heres the thread http://www.vwwatercooled.org.au/f46/...tup-30550.html.

It is great you allready have the stand alone ECU, thats one big expense sorted.