PG Turbo

Thought I'd post a pic of my expensive paper weight. Sadly no progress has been made in at least the last year although I did pick up a 16v alternator bracket off Mr Waldron the other day so that'll be going on sometime soon. Slow and steady wins the race I always say, although a car to put it in would be nice.

Turbo is a TB03 off a 2wd saph cossie and the manifold is an ATP cast jobbie

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Awesome dude, need more info

Very little to tell at the mo I'm afraid, stock internals although the flywheel has been lightened and the bottom end balanced. It's had new shells and rings. Head is pretty much un-touched. Only shooting for 200hp but should be plenty for me in a stripped out Mk2 Goof. Having some clearance issues between the turbo and the inlet manifold which is the next problem to be overcome. Thinking along the lines of a 1/2" T3 flange between the exhaust mani and the turbo to buy a fraction more clearance.

Where you not clearing dude, obviously you have cut off the old exhaust bracket on the inlet manifold?

Will get you some pics of mine, in fact hold on i think i have 1 now, be back.

That's a nice little set up! What manifold is that? Yup, the bracket's gone. The compressor housing is fouling on the back of the inlet mani. I've tired clocking the compressor housing slightly so the bulges in the casting for the bolt threads are in the best possible position but it still fouls. I've also tried flipping the exhaust manifold over (the outlet is offset to one side) but then the wastegate actuator fouls the rear engine mount.

However it may well be worth trying the turbo in the configuration you've got there. That IHI looks pretty compact mind, ideally I need to bolt the box up and see what sort of clearance I'll have.

I've only just realised the difference there. The turbo is the other way up! I was actually wondering why the turbo turbine inlet was on the right in Si's G60 turbo, and now I can see why.

Chris, have you considered using the cross-flow head? I know from discussing it with Si, that a custom inlet mani would be required, but aren't you handy with a welder, or indeed know someone who is? Fitting one of them would sort your clearance issues out

Oooh.

Long time since I saw that engine...

Get some pics of the RX up too. Must be just out of shot?

Aye I had thought about a X-flow but was under the impression they're not that easy to come by, plus you've gotta remember I'm a stingy **** and fond of the path of least resistance!

The RX has been shoved down the shed as my old man wanted his garage back. He's got the Phantom in there at the mo pulling the engine apart.

Only pic I've got of the RX really:

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I do have a soft spot for those Mazdas I've got to be fair! First time I've seen your 7, Chris!

She's a bit of a mutt to be honest, but the engine's as strong as they come which is all that really matters with an RX!

I could do with your thoughts boys, trying to decide which direction to go with this motor. I'd like to eventually slot this into a mk2 and since the supercharger brackets are long gone I'd like to rig up the alternator in a similar fashion to the stock 8v GTi. I'm planning to use a 16v alternator and bracket to get around the problem of the water-jacket blanking plate on the end of the block which fouls the standard 8v alternator bracket, however I'm beginning to think I've made a bit of a rod for my back by having the flywheel lightened and the bottom end balanced because now I'm stuck with the one crank pulley and the one flywheel, which in turn means I have to use an 02a gearbox.

Not that that's a huuuge problem but I'll have to track down the matching water pump pulley and alternator pulley to go with this crank pulley (shown in the photo) which came off some carb'd 8v that was lying on the floor in my local scrappie. I'm also not massively impressed with my flywheel as the clutch face has got a few digs in it. I'm wondering if it's possible to skim a tiny bit off the surface with a lathe without massively upsetting the balance or affecting the amount of pressure exerted on the clutch disc by the pressure plate? I need to have another look at the flywheel to see how bad these digs are, maybe they won't make much difference, I dunno. I'm tempted to track down a standard G60 crank, 02a flywheel and crank pulley (off a mk2 8v GTi or summit)....am I right in assuming that the bottom end components are pretty much interchangeable without upsetting the balance i.e. as a stop-gap could I bolt an 8v gti crank pulley and 020 clutch and flywheel assembly to a stock G60 crank?

No idea dude but i see why you like that steering wheel now the best if its in the RX

Obviously the supercharger bracket has long gone i assume you do not need another as i have 1.

Nah, no need for charger brackets ta. I think I just need to pull my finger out and find a set of pulleys that will work with the crank pulley. I'm sure the flywheel will be ok too, I'm just being a fussy barsteward.

I think you need to find a car to put it in too

So you gonna stick with the 02A and use one of those Seat hydraulic->cable adapters then? Seems like a far simpler option than retro fitting all hydraulic gear.

mrbeige wrote:I think you need to find a car to put it in too

So you gonna stick with the 02A and use one of those Seat hydraulic->cable adapters then? Seems like a far simpler option than retro fitting all hydraulic gear.

yeah,seen this used on two installs.
A nice neat solution provided by VAG

I didn't even realise they did it, until Chris told me. I now don't understand why so many people faff about with the hydro pedal box et al. Seems like a complete waste of time, money and effort.

mrbeige wrote:I think you need to find a car to put it in too

I'm watching something on ebay at the mo, the reserve is pretty much the maximum I wanna pay so I'll see how it goes. Just hoping there's no one else who wants it more than me, current bid's a fair way off the reserve with 23 hours to go. Anyways yeah, 02a with cable clutch seems the way to go.

Is that the one you showed me Chris?

Nah, another early mk2 in Mars red. Original too, not a big bumper in sight!

Oooooooooo, fingers crossed then

Also the x flow is pretty common as found on beetles and mk4 goofs.

junkie wrote:Also the x flow is pretty common as found on beetles and mk4 goofs.

What's the stock manifold like on the 2l engines? Is it one of those nasty plastic jobbies? I did a service on a 1.6 mk4 Golf which had a x flow head on it, there was no way to get access to the plugs unless of course volkswagen expect you to take the manifold off every time you wanted to clean your plugs. P*ss poor design! Anyways I can't remember if the manifold was cast aluminium or not.

MillSpeed wrote:

junkie wrote:Also the x flow is pretty common as found on beetles and mk4 goofs.

What's the stock manifold like on the 2l engines? Is it one of those nasty plastic jobbies? I did a service on a 1.6 mk4 Golf which had a x flow head on it, there was no way to get access to the plugs unless of course volkswagen expect you to take the manifold off every time you wanted to clean your plugs. P*ss poor design! Anyways I can't remember if the manifold was cast aluminium or not.

Is the crossflow head the one found on the ABA block? If so, it goes over the top of the head and I think it's cast alloy. Might be in two pieces though, like the 16v inlets