95 TSI AWD Holset VGT Project Part 2

[aero_sallee]

Fitment with the stock radiator is very tight slightly better than it looks the rad isn't bolted on the top and is sitting back. Fabricated solid front motor mount out of something similar to nylon or delrin to help wheelhop and prevent contact with the radiator.

My assitant for the project, she spent most of the time lounging around watching.

The actuator connected to the arm and mounted on the front motor mount.

Here is the arm when that actuator comes off, the 2 non rusty looking areas on the flat are where the epoxy fills the coolant holes. Also you can see where the wastegate actuator arm is attatched.

Wheel measurements
Turbine
EX 2.357
IND 2.755

Compressor
EX 3.38
IND 2.37
Compressor is as close as I can measure since its a 7 bladed wheel. Measurements similar to the large 6bladed HX40"pro".

The actuator holds the VGT closed until 6-7 psi, then spool slows down. Its weird, driving normally you can't really hear much exhaust note wise the only thing you hear is the turbine wheel whistling, keep in mind this is through 8" of exhaust. Once it hits 6-7 lbs, the note changes totally, the rack is open fully by ~10-11 lbs I beleive. It sounds sort of like an electric cutout opening, but not as loud. I think even though it has a huge hotside the vanes still help quiet it down, but make it whistle more. Go under and overpass and it sounds like a jet flying by.
Here is a log from ~70mph cruise in 5th gear showing the transient response. 70kpa, to 9psi in about .95 seconds at ~3000-3100rpm.
It spools a good 1000-1200 rpm faster than the small 8 blade HX40 in the ~.55A/R bullseye housing I had on the car before. Even with the VGT open fully which is somewhere far above 1A/R. Over 3500rpm or so the boost keeps climbing, by 4400 rpm it reaches 24lbs and climbing rapidly. I'm really glad I included the external gate. I'm waiting on a 14.7 lb spring I ordered to hook it up to a boost source, so it will be a little while till I can do a full pull.

Anyone able to calculate the A/R given the nozzle area and wheel diameter? I clayed the minimum VGT opening of a turbo a friend picked up. Here is a picture of how tight it gets. You can see how thin the clay is. Its somewhere between 1.4-1.8mm gap.

Here is a pull I did after getting the external gate spring installed.

Still have some more things to try and work out. I want to build another MBC to try on the VGT actuator to see what it does to try and speed the spool back up a bit. Lost a little bit after I hooked the VGT actuator up rather than keep it closed, but it still has much more topend and still better response than anything else I've tried.

Here is a 1st through part of 4th pull and the boost control/response, with it the way I have it now.

You can see my exhaust and wastegate dump tube peaking out from under the car. She's a little short.

VGT section on my forpm, my build thread is there as well as specifics on the HE351VE VGT turbo that I used.
http://www.turbotalk.org/bb/viewforum.php?f=25

 

[costas14]

what are you using for fans? no intercooler for this? how quick does it overheat?

 

[aero_sallee]

A 14" slimline puller on the passenger side and a 12" pusher on the drivers side. I need to install a heat shield to keep turbo heat off the rad and some sealing stuff to keep more of the air through the rad.

No intercooler at this point. Running E85 so it mitigates the issue somewhat. I didn't run one because of the way the turbo outlet is and the size of it makes running the piping extremely hard. I am contemplating an Air/Water setup for packaging reasons. All this will have to come after fixing the motor after the spun bearing.

 

[costas14]

ahhhh a very unique setup, just asking but would the turbo heat after a hard run cause it to overheat if the heatshield aint there?

 

[aero_sallee]

I don't know how much difference it would make. I did have some overheating problems at first. I didn't notice much difference between a hard run or just driving.

 

[costas14]

what was the max hp this made before the bearing problem

 

[aero_sallee]

No idea. Never made it to the track and the nearest AWD dyno is over 3 hours away.

 

[KPEclipse]

Assistant Is Working Hard!
Thats What I Like To See!

 

[costas14]

maybe one of those honda radiators that are half the size might do the trick, ive been thinking of one of those too

 

[flawlessTSI]

install the fans infrount of the radiator and swap the wires around to the fans to reverse to pusher tiype not puller. thats what i did. gool luck.

 

[aero_sallee]

One is, the puller doesn't move much air when its reversed due to the way the blades are contoured and it is a bit big to fit up front, otherwise I'd have it up front too.

 

[b00stedtalon2]

pretty cool to see another holset and megasquirt powered dsm on here.

 

[flawlessTSI]

i ment to put 2 slim fans ha. i dident have a problem heating up at all.

 

[sniver]

How hard was it pulling at the 9psi @ 3000 rpm?
Does it feel gutless or does it spool quickly enough not to be a pain

I ask b/c b00stedtalon2 said his hx52 pulled like a decent 16g car at only 4psi. I have one of these holset vgt's and I am trying to determine if I want to use it on my car.

Would it flow enough for 450-500 horse? max?

 

[aero_sallee]

It felt pretty good to me, given that is low boost and all and no intercooler. It also felt like it had more power than the hx40 I had before in the BEP housing, at similar boost levels. I like the way it drives with the turbo.
Its been a while since I drove a 16g car to try and compare it to that. It spools a little faster than my old hx40, and feels like it makes more power at lower boost(even comparing no intercooler on this and a FMIC on the hx40) than it did. I attribute this mostly to the lack of exhaust restriction when the VGT opens.

The compressor is supposed to be rated around 67lb/min, and has the same dimensions as the HX40pro IIRC. Which has gone up to 650whp in the small BEP housing.

 

[aero_sallee]

Added link to the end.

 

[aero_sallee]

Fixed broken picture links

 

[joshyak]

I am developing a stand-alone controller for the HE351VE. I plan on freely sharing all the information when its done. I need another actuator to finish the work. Preferably with the circuit board intact. I'll take almost anything though. Anyone have one lying around? Please PM me if you do.

YouTube - Holset VGT Turbo HE351VE Controller Development Stage 1

 

[pj91gsx]

awesome those turbos are great i have a friend that had on his honda. it was really fast. he had to show me the power in 4th gear to avoid wheel spin on street tires.