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Madmans' OEM+ Diesel Build 17 Years on!


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#61 yamaha88

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Posted 23 October 2010 - 11:56 AM

 Cheers for pics, looks really good, the standard pipes wont connect straight into the intercooler ? i think you can do logs on basic, be interesting to see how well it does it job lol


thanks craig




#62 Dan FR

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Posted 23 October 2010 - 12:11 PM

Good job mate, looks very nice!


 


That would be pretty much a straight swap for me bar the 60mm coupler.......


 


hmmmmmmmm....


gallery_39141_35970_27324.jpg

TFSI... Revo Stage 2+ ...  :D PSN: PuntoGT031087. VCDS HEX V2, MPPS, VAG Commander & VAG tacho - South Wales

Logging, Coding, SKC & Immo, Cluster mods, Auto windows etc.. The usual....  I also dabble in EDC15P mapping & tweaking, LC, Popcorn etc.


#63 madman

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Posted 23 October 2010 - 12:11 PM

no Im afraid the PD engines which use the weird VW bayonet fittings will need adapting. 1.8t's will fit straight on. It can be adapted with the SFS bayonet connectors and some 60mm silicone couplers. I think the bayonet fitting on the Ic end of the pancake could be chopped off with a hacksaw. You would then be able to use a silicone adaptor. It would be a simlilar story with the pipe up to the EGR/ Delete. Im not too up on Vag-Com only use it for faults really.



#64 madman

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Posted 23 October 2010 - 12:13 PM

Good job mate, looks very nice!

 

That would be pretty much a straight swap for me bar the 60mm coupler.......

 

hmmmmmmmm....

 

it would indeed...the pancake pipe does end up sitting back about 30mm and gets close to the driveshaft. Im gonna have a look tomorrow to see if any contact has arisen.



#65 amachleb

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Posted 23 October 2010 - 02:01 PM

 im very interested in doing similar on my 02 plate 130bhp tdi bora, could you do a little detailed list of what items u have acquired and what you have had to fit and where you got them from so i can write down and start locating, as mine is leaking as far as im aware as doesnt boost properly


many thanks


A



#66 sleeky

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Posted 24 October 2010 - 12:41 PM

Just had a thought, how are you planning on joining the 1.8t pancake to the red pipe?



#67 madman

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Posted 24 October 2010 - 12:49 PM

there is plenty of space for the driveshaft behind the PD130 pancake pipe

Posted Image



#68 madman

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Posted 24 October 2010 - 12:53 PM

Just had a thought, how are you planning on joining the 1.8t pancake to the red pipe?

51mm silicone tube and jubilee clips should do the job. Forge use a similar thing for their FMC. The red turbo pipe is 50mm bayonet it fits inside the end of the 1.8T pancake pipe but would be hard to get a seal. Im prety sure the 51mm silicone coupler would go over the end of the pancake and the red pipe bayonet inside that.



#69 madman

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Posted 24 October 2010 - 01:02 PM

 im very interested in doing similar on my 02 plate 130bhp tdi bora, could you do a little detailed list of what items You have acquired and what you have had to fit and where you got them from so i can write down and start locating, as mine is leaking as far as im aware as doesnt boost properly

many thanks

A

The list below will still use the PD130 pancake pipe.

idealy you need to replace the pipe from the EGR valve to the intercooler this is done in 57mm;

EGR delete kit

2x 57mm 90deg silicone bends                          

1x 57mm 45 deg alloy bend                               

 55mm-70mm jubilee clips                              


1X alloy adaptor 57mm to VW intercooler   SFS do them

1x 60mm straight silicone coupler in a lenghth of 75mm - 100mm

2x M6 20mm screws to screw MAP sensor into intercooler

I got all the above from ebay. the hardest part is the 57mm alloy 45 deg tube here is a link the other stuff is pretty standard

UPDATE

Just to clarify what parts  I used to fit the Turborevs uprated intercooler to a PD130 diesel:

 

idealy you need to replace the pipe from the EGR valve to the intercooler this is done in 57mm;

EGR delete kit

2x 57mm 90deg silicone bends    (intercooler - egr pipe)                      

1x 57mm 45 deg alloy bend this will need approx 35mmm-45mm trimming
off each end, best trial fit it and take off a bit at a time 
(intercooler - egr pipe)                              

 55mm-70mm jubilee clips                              


1X alloy adaptor 57mm to VW intercooler   SFS do them  (This is only used if you keep the standard PD130 pancake pipe.)

to connect the 1.8T pancake to the Alloy intercooler you will need,

1x 60mm straight silicone coupler in a lenghth of 75mm - 100mm (57mm
would fit at a squeeze but the fittings are 60mm so get that if you can)

2x M6 20mm screws to screw MAP sensor into intercooler

I got all the above from ebay. the hardest part is the 57mm alloy 45 deg tube here is a link the other stuff is pretty standard

 to add the 1.8T pancake you will need a 51mm straight silicone
coupler in a length of 75mm-100mm to go over the pancake and red turbo
hose.

You will not need the SFS adaptors when doing the full conversion.

 

Hope this helps...as I get around 4 emails a week asking. Which isnt a problem but Id just like to clear it up for othersYes

 


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#70 madman

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Posted 30 October 2010 - 10:12 AM

well the silicone hoses arrived this morning with the postman. So I jumped straight in and got the new pancake pipe fitted. First I removed the PD130 pancake

Posted Image

Pd130 to intercooler with 60mm coupler over SFS VW bayonet adaptor

Posted Image

The 57mm SFS connector in the end of the PD130 pancake to use intercooler with stock setup

Posted Image

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Posted Image

Posted Image

Pancake pipe bolts up to existing mounting point on chassis and lines up pretty well

Posted Image

Posted Image

Posted Image



#71 Dan FR

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Posted 30 October 2010 - 11:28 AM

how does that fit to the standard red turbo pipe mate? i thought it had one of those silly VW bayonet connectors aswell?


looking very nice by the way, definately giving me ideas[:P]


gallery_39141_35970_27324.jpg

TFSI... Revo Stage 2+ ...  :D PSN: PuntoGT031087. VCDS HEX V2, MPPS, VAG Commander & VAG tacho - South Wales

Logging, Coding, SKC & Immo, Cluster mods, Auto windows etc.. The usual....  I also dabble in EDC15P mapping & tweaking, LC, Popcorn etc.


#72 afro gti

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Posted 30 October 2010 - 11:31 AM

looks good mate[y]


Notice any difference in performance since swapping the pipes over?



#73 madman

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Posted 30 October 2010 - 11:48 AM

how does that fit to the standard red turbo pipe mate? i thought it had one of those silly VW bayonet connectors aswell?

looking very nice by the way, definately giving me ideasStick out tongue

 

Thanks

I used a 51mm coupler on the end of the pancake pipe and the bayonet connector on the red turbo pipe drops in and tightens up. I did squash the bayonet bits flat with a G clamp to make it more pipe shaped. I will help you empty your wallet mate[:D]



#74 madman

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Posted 30 October 2010 - 11:51 AM

looks good mateYes

Notice any difference in performance since swapping the pipes over?

cheers

I think there is a tad more lag but once it gets going it seems to rev to the redline quicker. To be honest Its pulling like a train at the moment. The 57mm piping just seems to help it loads.



#75 madman

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Posted 30 October 2010 - 04:14 PM

Todays epic clean...Well came back from working away to find the wife had been rallying
in the Golf[:o] She had been over to Bridlington looked like it was via
Dalby forest!

Posted Image

Posted Image

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So after taking the wheels off 1 by 1 I set about cleaning the
underbody with Gunk and a hosepipe. Jet wash is in bits and needs
replacing.So it was just brushes gunk warm water and elbow grease[;)]

Posted Image

Posted Image

 

after the underneath and wheels were clean it was time to carefully
clean the bodywork. I used a garden sprayer with high concentration
shampoo which I left to soak in. This was washed off with a hose.
Repeated this a few times to get rid of all the grit. I then washed the
car using the 2 bucket method. AG shampoo was used and a lambswool wash
mitt. I used plenty of rinse water along the way. Last thing I wanted
was for it to end up scouring the paintwork. Once clean I washed it
again and hosed off then dried with a waffle towel. Quick detail spray
and windows cleaned, plus a good vacuum out and its back to as it should
be[:D]

Posted Image

Posted Image

 

Winter is upon us and car cleaning becomes a harder task![cry]

 

 



#76 Simon_1.8T

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Posted 30 October 2010 - 04:34 PM

Looking good mate. Will be investing in one of those SMIC once he gets more in stock [:D]


Si



#77 sleeky

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Posted 31 October 2010 - 03:27 AM

Glad to see the 1.8t pancake pipe fitted OK, will deffo be getting one of them intercoolers when they are back in stock!


Good job you cleaned it too, how dirty was it under the arches!



#78 amachleb

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Posted 31 October 2010 - 07:55 AM

 so is it under godspeed or something else on ebay please, will look for it??


A



#79 madman

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Posted 31 October 2010 - 08:03 AM

turborevs supply them but are currently out of stock[Y] should be due in next week I think someone was told



#80 markyb

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Posted 31 October 2010 - 11:20 AM

Im i sensing that your SFS 57mm alloy adapter maybe for sale at some point soon? [:D]


Im also going the EGR delete route and looking for one [Y] Let me know if you are fella..


Really like what you have done with the engine bay and intercooler side.. fair play to you!!



#81 madman

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Posted 31 October 2010 - 12:32 PM

Im i sensing that your SFS 57mm alloy adapter maybe for sale at some point soon? Big Smile

Im also going the EGR delete route and looking for one Yes Let me know if you are fella..

Really like what you have done with the engine bay and intercooler side.. fair play to you!!

 

Cheers...I will hang on to it for a while just to make sure im happy with the setup. [O]



#82 old_n07

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Posted 02 November 2010 - 05:03 AM

Really like what you have done with the IC, just priced up the bits and it comes in at about £140 plus the IC so a cheap upgrade compared to the Forge systems.


Also Spoke to SFS and they do the coupler for £22 with the forum discount which is 25% [;)] While we were talking he did say that they have a PD130 turbo --> Pancake --> IC pipe in development at the moment.


Keep up the good work [y]


Neil


 



#83 Dan FR

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Posted 02 November 2010 - 05:17 AM

The £22 is subject to VAT and delivery which bumps it up to £29.



Think i'll be investing in one of these coolers after christmas, unless i get it as a pressie[:D]


gallery_39141_35970_27324.jpg

TFSI... Revo Stage 2+ ...  :D PSN: PuntoGT031087. VCDS HEX V2, MPPS, VAG Commander & VAG tacho - South Wales

Logging, Coding, SKC & Immo, Cluster mods, Auto windows etc.. The usual....  I also dabble in EDC15P mapping & tweaking, LC, Popcorn etc.


#84 old_n07

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Posted 02 November 2010 - 06:23 AM

 Nope, that was including VAT, with discount it was £16 something + £3 delvery + VAT so basically £20 + VAT I was charged [:)]


When you mention the forum you get 25% off [;)]



#85 Dan FR

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Posted 02 November 2010 - 08:40 AM

Sounds like i got knocked then[brick]


 


It was discussed through PM's and i was told that price included the forum discount.


 


gallery_39141_35970_27324.jpg

TFSI... Revo Stage 2+ ...  :D PSN: PuntoGT031087. VCDS HEX V2, MPPS, VAG Commander & VAG tacho - South Wales

Logging, Coding, SKC & Immo, Cluster mods, Auto windows etc.. The usual....  I also dabble in EDC15P mapping & tweaking, LC, Popcorn etc.


#86 old_n07

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Posted 02 November 2010 - 09:06 AM

 Unless the person taking my order got it wrong in my favour, I'll check my statement when it comes to make sure.



#87 madman

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Posted 02 November 2010 - 11:45 AM

cheers Neil...


Been looking at the SFS pancake there is a post in the SFS section. It doesn.t look very big and uses different fixing to the chassis. I was contemplating getting the SFS replacemnent red hose which can be ordered a tad longer and fits straight onto the 1.8T pancake. It just cost a bit more than a £7 51mm coupler and I couldnt justify it this pay month.[:o]


Phil



#88 old_n07

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Posted 02 November 2010 - 01:41 PM

 The only thing the bloke from SFS was saying is that the Red pipe from the turbo is very restrictive due to a reduced diameter hole at the end which reduces the flow.


Don't know how true this is but he was talking about 20Bhp + gains on a 150 just from pipwork upgrades



#89 markyb

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Posted 04 November 2010 - 03:05 PM

.

Spoke to SFS and they do the coupler for £22 with the forum discount which is 25% Wink

 

Neil.

Did you get get any part number or any clear description on what it was? Ive tried getting in contact with SFS *email* and have had no reply, Im in the process of talking to one of there distributors but they are having problems trying to work out what part im after, even though im describing to them im after an alloy adapter from the OEM SMIC to a 57mm dia silicone joiner?!

really interested in getting this myself seeing ive took the plunge on a EGR delete and breather kit but cant seem to get hold of the info to get one!

I guessed you spoke to SFS direct?

 

Cheers

 



#90 old_n07

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Posted 04 November 2010 - 03:27 PM

 Yes spoke to them on the phone, I think it was a chap called Lee he knew exactly what I was after [y]


But before you get one check out this thread as Pieman is having some made by the looks


Sorry for taking this OT Madman [:$]


Neil







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