1GB Talon TSI 16G, on methanol

[turbo23]

Had a 91 tsi awd 5 speed that was my dd, had some issues launching the car, and breaking axles (3 bolt). car had started to show signs of rust, and i was constantly have issues with the clutch/pedal assembly. altough im pretty sure i had the pedal assembly issues fixed, i decided to pull the engine and build a more drag race deigned car rather than a dd. I happen to have had a 93 tsi AWD Auto (4 bolt) car sitting around that was from texas (rust free). I had bought the car a couple years back, not running, but came with 2 engines and a trans. So, I pulled the engine from my 91 and started building the 93. The 91 had gone 12.06 @ 120mph on 111 race gas with a 2.16 60ft. Also made 377 whp on 93oct fuel. never dynoed on 111 here is the engine combo with pics I manage my fathers performance engine/body shop, and i have done all the work to both the engine and the car myself.

Engine now:

stock 6 bolt short block (rebuilt w/ arp rod bolts and .040 over)

custom crank case evac setup

Cylinderhead;
Ferrea 1mm over int/ext valves
3 angle valve job with custom throat diameter and angle designed by dad and I.
hours of port work
My own spring combo (similar to kiggy's setup)
3g lifters
Comp 101200 camshafts

Also using a Hawver intake manifold, fidenza cam gears and a bit of little odds and ends.

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I'll post up pics of the car tommorow

 

[turbo23]

here is the car when i started

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painted the engine bay, I should mention that before i painted the engine bay i cahnge all the front control arm bushings, new pads and rotors on all 4 corners, put my agx/eibach suspension on as well. The suspension springs will be changed later, but for now they'll work.

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Before I installed the engine i pulled the trans apart and welded the center diff, ill have to remove the valvebody again to install a shift kit, and make some other modifications.

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start to gut the rear of the car

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also removed all the sound deadening from the floor, but i dont have any pics of that process. Used good ol dry ice and a hammer. After that was done, I started building the cage, just an 8 point for now, dont think itll go faster than 9.99 with the 16g, but u never know

chromolly cage pics

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before i put the door bars in i painted the floor (truck bedliner) and finished all the wiring for the shift light, oil psi light, dynatek arc II, innovate lc-1 and xd-16, along with all the other guages and wiring for trans, water injection bypass, and brake vacume pump bypass. Also mounted the quick diconnect wheel and the shifter, also ran the cable for it.

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now i installed the door bars

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At this point I installed the 16 gallon fuel cell

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[turbo23]

now thats finished, i painted the floor black, and the sides inside the car white.

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thought fuel door looked neat

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Then i installed the seats and harnesses

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While this was going on i purchased some of the fuel system stuff

Magna Fuel pump and Aeromtive regulator

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Magnus fuel rail

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Next is pics of the radiator/trans/oil cooler mount, and the start of the header.

 

[rowdygst]

good stuff, what did you do with the shortblock? stock rebuild or you went forged? also what are you gonna use to tune it?

 

[turbo23]

short block is rebuilt with stock stuff except for arp rod bolts, and balance work. I plan to build another short either over the summer or next winter, probably an eagle rod and custom piston of some sort, probably ross. Car has ecmlink V3, SD setup.

 

[rowdygst]

nice you gonna run 93+ methanol or straight meth?

 

[turbo23]

At this point i wanted to free up some room to build my forward facing header. I also wanted to be able to close off the frontend completely for aerodynamic improvements. Doing this in a drag only car is not an issue, but being able to street drive it with the front closed off created somewhat of an cooling issue. I had run a "bottom feeder" style radiator/ductwork setup before, first in my outlaw latemodel, then in a few of my customer's road race cars, with great success. I decided this would provide me with the room i wanted for the header/turbo setup, and would allow the car to stay cool crusing around town. Plus being run on methanol would obviously help greatly. At this point i haven't come up with a good way to close the frontend off, and i also havn't come up with the ductwork yet. here are some pics.

oil/trans coolers

Rad mount

After that was finished i built a catch can for the evac system. The catch can is baffled below and above the fittings, has a filter material under the breather tube, and the breather tube is also baffled.

nice you gonna run 93+ methanol or straight meth?

thanks, and i'll be running straight meth, no intercooler.

it took me awhile tu find a turbo location that i tought would work the best for exhaust exit, air let, and header design. After i found a location i was happy with i started building here are some pics

Muffler

Exhaust outlet

Header flange. I wasnt happy with the immediate change from oval to round that was designed into the flange. I cut the flange slightly larger than the port opening. I then made 4 transistion peices that allowed for a slower transistion from oval to round. Header is made from 1 5/8s .049 (18 gauge) 304 stainless.

Flange

Tubes 1 & 4, The collector will be a 4-2-1 style ending in 1 5/8s, then i'll make a transistion from 1 5/8s to the inlet diameter of the 16g, which in my case is around 2 1/2".

All tubes

Here is a shot from the front of the car which shows the turbo placement. You'll have to excuse the mess, spilled some oil when i removed the oil drain from the pan.. the reast of it is just a mess that i havent cleaned up.

This is the current state of the project, hopefully i'll have some more progress to show in the next few days.

 

[TofastForU_99]

Looking good Tyler. Damn good progress.
-John

 

[turbo23]

Finally got around to finishing up the new header. still lots to do...

next thing on the list is to finish up the exhaust and charge pipes..

 

[99gst_racer]

 

[1990AWD]

That must be the most extreme 16g build ever! Very nice!

 

[turbo23]

update: i've got the header,exhaust, and hard pipes finished. currently working on the shifter linkage. also got the trans, and oil coolers plumbed, still have to finish up there mounts though.

 

[GRAVEDIGGER]

It's all looking really nice! This is gonna be a badass little monster! Keep up the good work.

 

[BoosteDsm1993]

That car is gonna be suhweet!

 

[turbo23]

well, ready for the first dive and it started raining.. tommorow i hope!.. anyway here are a few pics.

and a little idle vid

hopefully tomorrow i'll take it for a ride and make sure everything is ready to rock before i start tuning.. of course its been the driest summer in a long time, and now its calling for rain for the next 3 days..

 

[Ace_gst]

My hat is off to you. Very nice looking set up, is there any support for that turbo or is it held strictly by the manifold.

 

[turbo23]

thanks man! in the pics there is no support, but since its raining still (figures). i'll make a support this morning along with a few other things i have to do..

 

[99gst_racer]

BBQtime!

 

[TalonJohn94]

Two words. BAD ASS!!

 

[GRAVEDIGGER]

Everything is looking awesome and sounds great too! The turbo placement and intake/exhaust on the turbo is a work of art. Love the muffler incorporated into the side exit.

 

[CCK90tsi]

Very cool!!! love people going all out on small frame turbos! people are doing amazing things now a days!

 

[99gst_racer]

We went to the track yesterday. She trapped 126 mph through the auto on the 16g. Pretty impressive IMO. It's making some killer power right now, and with a bit more boost and a bit more tuning, I feel the car will go 130 mph. Going back tomorrow.

 

[GRAVEDIGGER]

Outstanding results so far... That is an awesome and inspiring machine!

 

[1990AWD]

Holy crap, 126 on a 16g! Very nice!

What was your E.T.?

 

[99gst_racer]

He was having a brake issue and kept pulling through the beam, yielding 2.xx 60's. It did an 11.8 off the trailer despite the issues though. Aiming to knock a second off that with everything working properly.