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Autocross Build 1996 TSi AWD - Restore/Autocross

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UPDATE #36 - 1/17/2019 - FIC 1650s/Walbro 450/Flex Sensor

I have begun the process of converting the car to flex fuel, something it has sorely needed with the higher compression.

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The car is running and idling on the 1650s but I will be stuck in the garage for a few more months due to the Ohio winter. There are some other plans in the works to try to wake the car up, especially on the slower/tighter courses where the turbo just isn't as responsive as I would like it. More to come.
 
Does this not restrict fuel flow? I just noticed it



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Does this not restrict fuel flow? I just noticed it

I would imagine it does to a an extent. Any transition or fitting has the potential to restrict flow, cause turbulence etc. But I wouldn't think it restricts flow any more than the factory hard line from the tank already does. It certainly wasn't an issue on the re-wired 255 and flowing 45 lb/min at redline but it could be on E85.

I think the picture is at a bad angle/lighting and makes it appear to have a smaller orifice than it actually does.

Here is a different angle:

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UPDATE #37 - 2/1/2019 - Turbo Setup Changes/New Clutch Prep

I have decided to make a change to the turbo setup on the car. The TD06SL2 20G worked well but the boost threshold was just a bit too high (4500 rpm) for many of the autocross courses. I have decided to try a 12cm Twin Scroll HX35 mated to a Morrison Fab manifold. The results from both Morrison Fab themselves and other uses on this forum are promising. I have begun taking the car apart to install this new manifold. In addition I will be moving from the SS/TZ south bend clutch and pressure plate to an SS-X/B setup which should hold the torque increase from E85 and the turbo swap as well as tolerate heat better for back to back autocross runs. This manifold will also require the secondary puller fan to be swapped to a pusher on the driver side due to the thicker than factory radiator.

12cm TS 7-blade HX35
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A few shots from late last summer:

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UPDATE #38 - 3/9/2019 - Suspension upgrades/New Clutch Install/Manifold Test Fit

Continued replacing factory suspension bits with the stuff from Bobby (ec17pse).

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Got the new SS-X/B clutch setup in and the trans reinstalled.

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Also got to test fit the new manifold for the twin scroll HX35 setup.

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It does clear the Mishimoto X-Line, a 1G radiator would have been preferable due to the offset upper hose connection but this will do for now. The manifold will be coated and the upper hose can be wrapped in heat reflective tape.

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Car is a few steps closer to being back together and ready for the season. Still have quite a list to finish up before spring but all of the parts are here and ready to go back on.
 
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Love that manifold! Couldn't possibly look better-Hopes to go the same route this year

The results posted by Morrison Fab and users on this forum are very promising. I am really looking forward to running it. And I agree, it really is a quality piece.
 
Nice work, hope you like to new feel of the front upper arms!! Just make sure to check the bolts after 1st use and use loctite to keep them in place,
Let me know how you get on
 
Did you get their DP too or just the manifold for now

As you can see above, I went with the hot parts kit. I also asked for the wastegate dump to be recirculated for noise reasons (SCCA decibel level limits).
 
Hope to see you at an MBR event or two this year! I’m finally back but with something new

That's the plan! I made it to one late last year. It's pretty close really and their course was very fun with the banked turns. Plus the surface is solid.
 
UPDATE #40 - 4/22/2019 - Secondary Fan Install / Heat Reflective Tape / Rear Sway Bar

Because of the larger footprint of the HX35 and the Morrison Fab manifold, the secondary puller fan needed to be replaced with a pusher tucked into the front radiator support. It will continue to be manually controlled from the factory AC button. I use the secondary fan exclusively to keep the car as close to thermostat temperature as possible before an autox run or drag pass. The 12" mishimoto puller is being replaced with a 12" SPAL pusher. I assume any reduced cooling by going to a pusher should be negated with the increased airflow/pressure from the SPAL.

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I also added some heat reflective tape to the 4" intake tube and the upper radiator hose. The new manifold gets very close to the hose. We will see if it can hold up.

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I also got the RM rear sway bar installed along with Bobby's sway bar mount spacers.

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Here is a quick comparison of the TD06SL2 20G next to the Holset HX35. The compressors look very similar, 52.6mm to 54mm inducer. But the Holset housings are much larger to accommodate the larger compressor exducer and the larger turbine wheel.

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Car should be back up and running soon and ready for tuning. Waiting on the turbine housing to get back from ceramic coating, then the final assembly can begin.

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I was thinking the same thing. I imagine that turbo is still going to have some lag. Either way, build looks awesome. Keep up the good work.
 
What kind of spool are you expecting from the HX35? I would figure it would get a little worse than the 20g. I guess the twin scroll helps.

I was thinking the same thing. I imagine that turbo is still going to have some lag. Either way, build looks awesome. Keep up the good work.

I am actually expecting considerable improvement. See this thread here. Also, a user on this forum posted their results here. This applies to both boost threshold and boost reaponse. The small diameter of the runners and the large wall thickness decrease runner interior cross sectional area. That combined with the twin scroll nature of the manifold and turbine housing should keep exhaust pulse velocities high. The 20G setup suffered from a poor choice in manifold on my part. I chose a forced performance manifold with the porting option. Lots of volume to fill and lots of expansion to take place before the turbine. And the 20G was using the relatively large Td06sl2 turbine wheel. Those were both chosen due to my desire to use pump gas and 10:1 static compression. They ran fine but I know I lost time due to the 4500 rpm boost threshold on the old setup.
 
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I’m very interested to see the results in person. If it works well on a 2.0 for autox, I might go with that instead of my twin scroll 20g setup for my 2.3. Will you be coming to our test and tune (5/4) or first event (5/5)?
 
I’m very interested to see the results in person. If it works well on a 2.0 for autox, I might go with that instead of my twin scroll 20g setup for my 2.3. Will you be coming to our test and tune (5/4) or first event (5/5)?

I am interested as well. I have no idea what to expect. The Holset wheels are heavier and bigger and physics is physics. If the turbo works as others have stated, it should be 16G like response with the ability to make 500 wheel. The 2.3 should make this setup even more lively. I actually have a split thrust 7 bolt block and bare 6 bolt head waiting to be built into a 2.3. But if this setup works as intended I am not sure I'd need it.

I would not expect to be there that early in the season. I still have a decent amount to finish and I need the gas to change over to summer blend which hould happen May 1st. Then I have to get the car retuned. I am hoping mid to late may to be ready to run it.
 
UPDATE #41 - 4/30/2019 - HX35 Final Install

The twin scroll HX35 setup has been finalized and installed.

-7 Blade HX35 with 12CM TS Non-Wastegated turbine housing (ceramic coated)
-Morrison Fab Small Runner TS T3 Hot Parts Kit
-Tial MVR wastegate
-Push to connect fittings for boost control

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The perfect setup. IDK how you had the patience to send that turbine housing out for coating.............

I wouldve bolted that thing on all rusty and ripped it that day! it all looks so nice
 
The perfect setup. IDK how you had the patience to send that turbine housing out for coating.............

I wouldve bolted that thing on all rusty and ripped it that day! it all looks so nice

Ha, the Cleveland weather and the fact I had half the car apart made it easier.
 
UPDATE #42 - 9/17/2019 - Dyno Tune and First Autox on the HX35

Finally the car has been tuned and I was able to run an autocross event with the new setup dialed in.

I went back to Ricky in WV to have him do a flex fuel tune for the car. I am more than happy with the results. Solid line is E67, dashed line is Shell 93.

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The first autocross on the setup went well also. I ended up second out of 48 drivers. Still have plenty of learning to do with the car but I am super happy with where it is at currently.

Video linked below. Logs attached for the curious. The Morrison Fab TS T3 manifold and TS HX35 performed amazingly well considering the size of the turbo. For the guys looking to run all disciplines of racing I can't recommend this setup enough.

 

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