Breaking the 200hp barrier in a Golf PD150
 
After two years on a remap the standard clutch started slipping (105k). This was my chance to fit an upgraded item and finally decided to go for a Sachs Cover and Organic plate.
 
March 2008 - Clutch
 

 

 

 
In addition a new Sachs Dual Mass Flywheel and release bearing were fitted.
 
April 2008 - EGR Replacement
 

 
Before
 

 

 
After
 

 
As I have blocked the exhaust manifold end I decided to remove all this (not had any problems with cabin heating):
 

 
April 2008 - ProVent 200
 

 
May 2008 - 312mm Audi TT set up - these might look like scrap metal but they are actually in very good condition
 

 
 
May 2008 - The important part - hybrid turbo Custom Spec- all mods done internally - 360 bearing, biggest compressor and exhaust wheel that can be housed
 

 

 

 

 
May 2008 - Turbo back Milltek exhaust system
 

 

 

 
May 2008 - New top suspension mounts (plus bearings), ARB bushes and 312mm set up fitted
 

 

 

 

 
May 2008 - Exhaust system fitted - just a comment to say this was one of the best after market systems I've fitted went straight on.
 

 

 

 
May 2008 - Picked up a rear Audi S3 brake set up 256mm vented with calipers & carriers
 

 
June 2008 - Alloy boost pipes finally landed
 

 

 
June 2008 - Alloy boost pipes and turbo fitted
 
Ok lets start of with the turbo first:
 
We decided to fit the turbo from the top so removed the inlet etc
 

 
Standard Vs Hybrid unit
 

 

 

 
Fitted
 

 
Next the Allard pipe kit:
 
First problem no documentation - so we were left to make calculated guess's.
 
Started from the turbo side - this runs as long the front driver side wing, as you can see had to trim the cover to get clearance
 

 
Fitted to the standard intercooler pipe
 

 
Problem number two tyre rubbing on alloy pipe - design error - So had to play with the bracket to gain any clearance (managed about 2cm)
 

 
After adjusting the bracket
 

 
Third and forth problem top boost pipe to inlet not correct - the gap is just shocking, so ended up making rubber mounts and then bolted it down.
 

 
Bigger rubber mounts fitted to hold top boost pipe and to over come pipe making contact with power steering fluid bottle
 

 
Problem number 5 the lower boost pipe bracket gap is just too much to bolt together.
 

 
Different angle
 

 
Ended up making an alloy spacer and drilled another hole for alignment and trimed the extra off
 

 

 
Also note the swarf inside the Allard pipework - this MUST be cleaned before fitting
 

 

 

 
June 2008 - Upgraded dog mount bushes
 

 

 

 
 
August 2008 Audi S3 Rear brakes 256mm

Calipers cleaned up and painted

6mm spacers required

October 2008 After a few development map the Final map is loaded and RR booked

No smoke and running 1.9bar boost

December 2008 - OEM Xenons

Order all the parts needed for the loom:

Loom made up:

Made the connectors waterproof:

Used oem tape for the loom:

Quick test:

25-3-09

Now with increased boost and fueling - boost mapped to 32psi. However, map is not as clean as the 220hp map in terms of smoke.

4-4-09

Went for a RR and it made (check the boost LOL):

Flywheel figure

Wheel figure

Boost LOL

The operator reckons it will make 240hp on a cool day - I was logging during the RR and discovered my air charge was 39.8 degree. On the road I was seeing 28ish degree. So def more power there on the road :)

August & September 2009 - Water/meth injection

Decided to fit water/meth injection - I ended up buying the Devils own kit stage 1. The kit comes with everything you need. I also went for the dual nozzle set up (pre turbo):

Made a panel to fit all the switches, LED's etc out of hard plastic:

Started work on fitting the nozzles - first started with the inlet manifold:

Drilled the correct size hole:

Tapped the 1/8 NPT threads:

Mounted the nozzle:

Repeated the same process on turbo intake pipe (pre turbo)

Fitted the self sealing bulk head (22mm hole required):

Fitted

Relay and pressure switch:

Got hold of some meth:

WMI tests:

Inlet

Pre turbo

Custom bracket for the water pump

Fitted

Panel with manual on/off for WMI - LED to confirm when the pump is running and 3.5mm female jack for the headunit

Been to set up the WMI on a rolling road and below are the outcomes (Red line WMI off and Blue is with WMI on) as you can the peak power is pretty much the same but the power over the same rev range better (holding power). I found having the WMI coming in at 18psi worked best for me. I also ran without the pre turbo nozzle and confirmed it made no difference to power so I'll be disconnecting that. In the future I'll try mounting the nozzle before the map sensor. Looks like if you want more power you'll have to put in more fuel and live with the smoke or get a bigger turbo.

Water injection update MAP sensor moved

Decided to relocate the MAP sensor AFTER the nozzle position and fitted a proper air charge monitor (samples 3 times a second) in the old nozzle location:

MAP sensor flange welded in place:

4mm plate for nozzle:

Plate made up to block old MAP sensor location:

MAP relocated and nozzle repositioned:

Cheers
Bobby

Exhaust system fitted

 looking good mate how much power are you expecting to be pushing by the time its finished?

and whats the provent mod thing?

Joe

Hi Joe,

I'm hoping for 200hp @ the wheels. Flywheel figures are guessing games but some where around 230 - 240hp with about 350 torque. If i get it to do 14sec 1/4's I'd be happy.

The Provent is a upgraded breather system - do a search for it on this site.

Hope that helps

Bobby

 Hi mate great job your doing with the look of things,just a couple of questions : i have seen the thread about cutting the pipe what meets up with the ehr delete is it easy to do cos thats one thing i am scared of doing on mine,how much was the clutch complete with the flywheel ? and what type of price did you get the turbo done for? every time i asked the question with turbo retailers they said there wasnt much worth doing with them.

have you kept with standard IC pipe work or gone for the allard set up also?

sorry to be a pest but its something i am good at

leach76:

have you kept with standard IC pipe work or gone for the allard set up also?

 

Jon.

Hi,

Im not fully sure if i understand which pipe on the egr you wish to cut? can you highlight it on this pic:

All my items were trade prices so dont apply to the public but generally speaking

Cover - £237.54 +vat

Organic plate - £223.06 + vat  (Sachs performance range has just had a 7% price increase)

DMF - £200 - 250 (Euro car parts)

Release bearing £45ish

Turbo - My plan is to experiment with this turbo as its very custom spec - so no price at the moment - £800 roughly using a brand new turbo as a base

As for the intercooler i will use the standard item and purchase the Allard set up.

Can get very costly.

HTH

Bobby

harveysduvet:

leach76:

have you kept with standard IC pipe work or gone for the allard set up also?

 

Was going to ask the very same thing!  Are you keeping the standard 150FMIC or are you uprating this as well?

Jon.

Hi Jon

See above mate

Cheers

ON your egr valve top right of the picture the hose still needs to have the standard fitting ie pipe push in to each other ie on egr and intercooler etc but the delete pipe needs a standard push over fitting with a normal hose clip so on most threads i have read people have to remove the metal colar from pipe so it slides over delete mod pipe,can you let us know what the baby goes like when done also? 

leach76:

ON your egr valve top right of the picture the hose still needs to have the standard fitting ie pipe push in to each other ie on egr and intercooler etc but the delete pipe needs a standard push over fitting with a normal hose clip so on most threads i have read people have to remove the metal colar from pipe so it slides over delete mod pipe,can you let us know what the baby goes like when done also? 

The penny just dropped lol

If you want mate i'll do it FOC as long as  you can cover the postage or bring it down I'm based in Southall Middx.

I'll put up some logs and a power graph once its all done and mapped :)

Cheers

B

 19-5-08 - picked up rear brake set up from a Audi S3.

 what front 312mm discs are you using mate?

I just ordered some carriers to allow the 312mm discs to fit on my 288mm carriers, but I'm unsure which discs/pads to buy! 

Hi I use OEM on the front with ATE pads - for track I would recommend DS2500.

HTH

Bobby

Thanks mate, lol unfortunately I wont be using it on a track. On another thread a guy said the Ferodo's are good for normal road use, but there pretty expensive

11-6-08 - alloy boost pipe kit finally here...

 16-6-08 - Alloy pipes and turbo fitted

 Ive got brembo drilled front discs and ebc green stuff pads they have a very good bit and feel to them cost me £150 but im trade,i got them from gsf. 

Good work mate, looks like Allard have changed the design of their kit to allow the engine cover to be refitted, doesn't look like they have done a very good job though!  Your kit looks to be a worse fit than mine was.

I can't believe Allard sell these as a 'direct replacement' for the OEM pipework, shocking IMO.

Glad it's all coming together though

Sem:

Good work mate, looks like Allard have changed the design of their kit to allow the engine cover to be refitted, doesn't look like they have done a very good job though!  Your kit looks to be a worse fit than mine was.

I can't believe Allard sell these as a 'direct replacement' for the OEM pipework, shocking IMO.

Glad it's all coming together though

Thanks mate :) your car is a real credit to you.

I totally agree with your comments about Allards pipe work kit its just shocking you pay that much money and you get a poor quality item - according to them its a DIY job....ye right. In fact I've written a email stating the problems I had and requested some money back for the extra work that was involved. Im not holding my breath for a reply.

Another note they provided a 'L' bracket for the Vac bottle as it requires relocation and I fitted to where I thought it could go (another calculated guess) considering the length of the Vac pipe etc. But as you can see from the above pic its current location prevents the engine cover to go back on.

Cheers

looking at that the engine cover will still require cutting from wher the pipe goes in under it. as to the diy it dont fit, lol, it would not suprise me you had to do things to get yours on and i doubt you will get any money back from them. its very shocking, a well established company selling goods like this is unbelievable. are you using a 312mm brake setup? my mate on his anni has the allard turbo conversion and the brakes cannot handle it, i have R32 brakes on mine like sem and they are more than up for the job but you would have to see how yours hold up.

Bobby_Singh:

Another note they provided a 'L' bracket for the Vac bottle as it requires relocation and I fitted to where I thought it could go (another calculated guess) considering the length of the Vac pipe etc. But as you can see from the above pic its current location prevents the engine cover to go back on.

heres where i have re-located mine to. i only did this as i ran out of vac pipe when i accidentally cut one in half when i did my head change. it keeps all the vac stuff in one place and looks quite tidy i think. i know yours has a relay box up there but still plenty of room. if not just bung it down the back on the bulkhead somehwere lol

T8UPS

You are correct the engine cover still requires work to fit - at this rate i might just leave it off lol.

Currently using 312mm set up with ATE pads - at the moment they ok if not I'll go for ds2500 pads.

how did you find the dogbone mount mate? which version did you go for?

fenwick458:

Bobby_Singh:

Another note they provided a 'L' bracket for the Vac bottle as it requires relocation and I fitted to where I thought it could go (another calculated guess) considering the length of the Vac pipe etc. But as you can see from the above pic its current location prevents the engine cover to go back on.

heres where i have re-located mine to. i only did this as i ran out of vac pipe when i accidentally cut one in half when i did my head change. it keeps all the vac stuff in one place and looks quite tidy i think. i know yours has a relay box up there but still plenty of room. if not just bung it down the back on the bulkhead somehwere lol

I've now relocated the vac to the correct location - but as above the engine cover still needs more work to go back on :(

fenwick458:

Bobby_Singh:

Another note they provided a 'L' bracket for the Vac bottle as it requires relocation and I fitted to where I thought it could go (another calculated guess) considering the length of the Vac pipe etc. But as you can see from the above pic its current location prevents the engine cover to go back on.

heres where i have re-located mine to. i only did this as i ran out of vac pipe when i accidentally cut one in half when i did my head change. it keeps all the vac stuff in one place and looks quite tidy i think. i know yours has a relay box up there but still plenty of room. if not just bung it down the back on the bulkhead somehwere lol

See latest engine pic - vac bottle relocated to the correct location - engine cover still not going on though.

R44MS_K:

how did you find the dogbone mount mate? which version did you go for?

Hi mate - i went for powerflex bushes. They are harsh but i find them settling down with time.

Btw were you in Southall over the weekend? Im pretty sure I spotted your car.

Cheers

yep, i was dude, either myself or the missus was driving!! was you in your beast?? should have flashed me!

i had the powerflexed "r32 mount" but after 1000 miles it was still too noisy for me!!

I was in my wifey's Passat (chipped of course lol) and caught your car in the corner of my eye down South Rd - looks nice :)

As for the mount i think it will always be noisey, but then again I come from a RS Turbo and Cosworth background I've had good training in cancelling unwanted sounds.

Cheers

Btw the mapping has started on my car :)

 What kind of power are you hoping to achieve bobby, I know it's 200+ but do you have a rough figure in mind?

Just letting you know I'm well and truelly put off fitting the allard FMIC, your the second person who's found it a mare to fit and i'm not mechanically minded so I don't even want to attempt it. Do you know of any alternative's to the allard IC for a TDI?

afro gti:

 What kind of power are you hoping to achieve bobby, I know it's 200+ but do you have a rough figure in mind?

Just letting you know I'm well and truelly put off fitting the allard FMIC, your the second person who's found it a mare to fit and i'm not mechanically minded so I don't even want to attempt it. Do you know of any alternative's to the allard IC for a TDI?

Hi mate - My comments are only based on the Allard pipe work kit not the FMIC. I would just fit a PD150 fmic, I have no ACT issues (at the moment).

As stated above the turbo I'm using is very custom and is abit of a gamble to be honest, and as such no base map is available but early indication are good. Running at 1.5 bar once the fueling is right further boost will be requested.

I will be more than happy with 200hp @ wheels.

i see! cheers, car looks more OEM now that the coilovers are off!!

do you go down Ace cafe?

 any more updates?? waitin in anticipation

When is ACE cafe?

Tasberley no updates - the provent will be next hopefully

last tuesday of the month - i have not been there in around a year or so  - someone may want to correct me!!

 Cant wait...

Is the turbo a hybrid version of the standard ARL engine turbo?