Crazy Daves Bog Standard 16v :)

[Mr Sands 0]

Now that's fantastic news Dave. Time for me to take a trip on over to your side of town at some point this Easter break methinks!

 

Don't worry, I'll bring the lawnmower. :lol:

[CrazyDave 0]

It's a runner!

 

Finally got everything finished today and started her up, then stopped because I'd forgotten to refill the PAS fluid back up and hadn't released the belt tensioner!

 

Second attempt was much better, had to spend a while getting the air out of the power steering pump, but it all settle down after a bit of working the steering back and forth.

 

Sounds really quiet (although for some reason my video camera really picks up the tapping noises???). The cone filter sounds just right and is much quieter behind the bumper than in the bay. Exhaust is also very quiet now.

 

Nothing seems to be catching or touching which is a big relief, just a few pipes a bit close and need some minor adjustment.

 

Helix clutch is really spot on, no judder and nice and light. The rear vibramounts are also really good, I'm sure the handling feels a bit tighter? In fact I couldn't drive it to start with. Kept trying to oversteer, but maybe thats just me being used to the 'dog' (the MK2 red shed!)

 

Turbo really whistles, especially when you rev up and back off it takes ages to spool down.

 

Now I am still on the Motronic at the minute (just to get it all started and settled in, leaks etc). But I couldn't resist a gentle tickle up the road! WOW! even with really lite throttle it pulls from about 2200rpm and by 2500 the boost really comes on. Now I didn't give it any beans and kept a real close eye on the AFR cos on a standard map and injectors it'll be way short of fuel for anything like that. It drives really nice.

 

The exhaust seems OK. It doesn't seem to be catching at all, but time will tell

 

Chargecooler is nice and cold, even when sat idleing for ages. If you touch the pipes the inlet feels quite warm, but the outlet is cold. I've got test points for temperature probes but I don't have them on yet (another little job).

 

Anyway enough of me rambling, have a listen! Video is 8mb so it'll take a few seconds to download.

 

http://url.the-corrado.net/efc87b

 

 

Tomorrow I'll be fitting the 440cc injectors and getting the MegaSquirt connected up for some real fun!

[mrbeige 0]

Good work Dave. How long dot you reackon it should take you to map it with the turbo? You using EGT with MS?

[mic_VR 3]

That is amazing! So want to turbo my VR now!

[CrazyDave 0]

Yeh, EGT and wideband AFR all connected into MS.

 

The part throttle stuff will just be driving around with the autotune switched on in MegaTune. I did this before with the standard VR and it worked a treat.

 

The full throttle stuff will be the problem. Been thinking of taking it to Vince to get that done. Just going to go steady for a while and let all the new parts settle in, then book it in.

[Mave 0]

That is awesome, nice work Dave.

[Goldie 2]

Very nice indeed Dave......

 

I bet its brilliant..

[superchargedpolo 0]

Dave,

 

Have just read though the entire thread and downloaded your clip. Beautiful noise, man I miss my VR6, and absolutely superb job. It's a pretty tight fit. Hope all goes well with the remap etc.

 

I run a couple of Polo G40's at the moment but have had 2 VR6's in my time. Forced induction really is fun and the VR6 is one of my favourite engines. You have the best of both worlds.

 

I am now totally inspired to get on with my Polo G40 project.

 

Excellent effort and all the best.

Craig

[CrazyDave 0]

Thanks for all the comments!

 

I'm just reading the MegaSquirt manual to remind myself how it all works. It has been three months since I did anything with that side of things.

 

440cc injectors are in and I think I have to change the Req_Fuel settings to compensate and then it should idle on the standard map I did. Then it'll be time to richen up the boost sections of the map and maybe ease the ignition timing a little.

 

superchargedpolo, I love Polo G40's. I had my name down for a new one once. Didn't work out at the last minute, insurance problems when they found out what a G40 really was! The dealer gave me loads of hassle on the spec I wanted aswell. Gutted at the time, I'd even picked out the reg number J29 SOF if I remember correctly? Anyway, good luck with it, got any links to a gallery?

[Mr Sands 0]

Great news that this is on the road Dave!

[superchargedpolo 0]

I don't actually have a gallery of the build thus far, bat that's not a bad idea. I do have a link to the G40 website where you can see the current fleet. http://www.polog40.co.uk/owners/craigwallet.html

 

If ever you get a chance have a drive in a G40, they are excellent fun and so stealth. I think standard ones or sometimes the best. The chassis isn't anything like the Corrado's and the brakes....well they keep you focused.

 

Am trying to perswade the misses at the moment that the TT has to go and a VR6 is the way forward. That's why I have been on this site a bit recently, looking through the classifieds, and how I stumbled across your build.

 

I will keep an eye on your progress with great interest.

 

Cheers for now

Craig

[ziderapple 0]

Good work Dave, really pleased for you. We'll have to get another meet at the compass inn sorted!

[Kevin Bacon 5]

Good stuff Dave 8)

 

Your Squirt will manage 440s just fine.

 

I see you've used Schimmel's stock regulator adapter? Interesting..... tried it on mine and couldn't stop it leaking, so well done on that!

 

It does drive nice on the Stock management doesn't it? In hindsight, I wish I'd just stuck with the OBD2 2.9, 4" MAF and the BEGI as it worked perfectly. Smooth as you like and none of the cold running shennanigans standalones often bring with them.

 

Glad the chargecooler is working out. The Schimmel one is the same.... warmish intake and cold outlet.....I've yet to see higher than 10 deg C in the intake....

 

Keep up the good work!

[CorradoVR6-Turbo 0]

Nice one Dave,have you had it on the road?

[CrazyDave 0]

Thanks All.

 

It's getting sorted slowly, the more I drive it and change map settings the better it gets.

 

Did a full cold soak start this morning, started chugged a bit and then cleared after and ran with me holding the throttle for about 30 seconds, then idled spot on and revved cleanly though warmup. So it's getting better as it's tweaked.

 

I don't think I like the Schimmel standard reg adapter, it doesn't leak (mainly because I used the same sealing compound that Cosworth use on racing cars! £30 a tub) but I noticed after a run that the rail had heat soaked from the engine and it was really warm. But because the pressure regulator is on the fuel feed end of the rail the warm fuel takes a while to clear and get the rail cold again? Could do with the reg on the other end of the rail so fuel is circulating like the standard rail.

 

I had a run up the motorway to the inlaws yesterday, and you have to keep a real hold on the right foot! It just wants to go and go at motorway speeds! No need to change down anymore like a NA VR, it just pulls 5th gear really strong from 2500rpm, and thats with 8psi! And what a soundtrack to go with it.

 

Nice collection SCpolo, small and low weight, always makes for some fun! But yes I know what you mean about the brakes, I had a Polo GT Coupe for a while, lots of fun down the lanes!

 

Should be able to make the next meet at the Compass and hopefully have most of the mapping sorted by then.

[chazrad 0]

Dave. I cannot say anything that has not already been said in praise here...fantastic stuff. Looking forward to seeing it all running at our next meet.

[Kevin Bacon 5]

I don't think I like the Schimmel standard reg adapter, it doesn't leak (mainly because I used the same sealing compound that Cosworth use on racing cars! £30 a tub) but I noticed after a run that the rail had heat soaked from the engine and it was really warm. But because the pressure regulator is on the fuel feed end of the rail the warm fuel takes a while to clear and get the rail cold again? Could do with the reg on the other end of the rail so fuel is circulating like the standard rail.

 

I think he had those made for customers that specifically wanted to use the stock reg, but he prefers the SX remote reg, which I use aswell. Or you could just use a 1:1 FSE regulator....cheap as chips and work well.

The SX fittings and fuel hose guage are much bigger than stock though, so should help with fuel cooling maybe?

I would perhaps run a remote reg anyway and knock the base pressure down to 3 bar as you don't want total rail pressure exceeding 5 bar (unless using a BEGI FPR!!). You'd be getting close to that on boost with the stock 4 bar reg I suspect.

 

No need to change down anymore like a NA VR, it just pulls 5th gear really strong from 2500rpm, and thats with 8psi! And what a soundtrack to go with it.

 

I was stunned by how much faster 8psi of turbo felt compared with 8psi of Supercharger....... but it's all relative as the turbo's torque spread kicks in significantly earlier.

 

What do you make of the TIAL BOV? I love it's discretion.....can hardly hear it tbh....which is perfect.

[CazzaVR 0]

Brilliant work, Dave- really looking forward to seeing this in the metal soon!

[CrazyDave 0]

Remote fuel reg sounds like a plan. I'll run it for a bit as is, I need to get a gauge on and see just what the FP is though.

 

Tial BOV is spot on, can hardly hear it in the car, just when you rev up under the bonnet!

 

The whole thing is very quiet, even when you open it up! You do get the full on turbo sucking large amounts of air type noises. And a slight flutter when changing gear (think this is turbine stalling perhaps?). But other than that I'm really pleased with just how quiet and ordinary it all looks.

 

My only experience of a SC VR was the other week, Ziderapple kindly gave me a quick blast round the block in his (with James' old SC). Nice linear delivery and makes the most of the VR top end.

 

Cheers Chaz and CazzaVR, I might even give the old gal a clean before the next meet!

 

I spent this evening modifiying my Squirt box. It's now got the MSII processor and MSII_extra code in it. Lots of improvments over the last version, but the main thing is the processor is much quicker, so the injector control should be a lot finer. And the AD converters are 10 bit instead of 8, so finer temperature, MAP and TPS readings.

[biggerbigben 0]

I was stunned by how much faster 8psi of turbo felt compared with 8psi of Supercharger.......

 

God I've been saying that for years! Turbo every time for me! :D

[Kevin Bacon 5]

LOL, tis true tho, you were right :lol:

 

Dave, what zorst you running? 2.5" Jetex IIRC?

 

That's my next step before I can up the boost to a bar. I did hear a while back that Jetex 2.5" boxes are 2" or 2.25" internally, hence being so quiet. Dunno if that's true or not. Perhaps you could shine a torch into your box (ooer missus!) and see if the perforated pipe reduces in diameter?

 

I like quiet, so the Jetex could be for me too.... did you get a full system or just piece it together from the custom parts catalogue?

 

Yes that flutter is compressor stall.... it does go away if you use a softer spring in the BOV.....but we need a 10psi spring, which TIAL don't do!

 

 

Cheers

[CrazyDave 0]

Turbo is all I ever really wanted, just didn't want to do the extra work to make an exhaust downpipe. Was all worth it though, the result is a VR with loads of midrange torque, just what every VR owner ever wanted.

 

The zorst is a Jetex full 2.5" stainless system. I had to shorten the front pipe by a few inches and get it V banded. As far as I can tell it's 2.5" all the way through, but I'll have a look in the back box and see what I can see (it's a dirty box at the minute cos shes a bit rich!!!).

 

I have heard it catch the rear beam on a really bumpy road, but I mean really really bumpy back lanes that have giant landfill trucks drive on them all day (it's my route to the inlaws), and I haven't had the car on a ramp to set the exhaust up yet. Normal A and B roads it's fine. The turbo makes it really quiet, without it was a little bit louder than standard, well more boom at 3000ish rpm than loud.

 

Managed to get the MSII Extra running tonight, really pulled my hair out with it at first cos the Ignition triggering is different to MSI, but finally got it sorted.

 

Much smoother running and finer control of everything. I'll do a load more setting up this weekend and see how it goes.

 

Setup for a VR6 is as follows:

Trigger wheel settings

Single wheel with missing teeth

60 Teeth

2 missing

78 Degrees BTDC

Crank Wheel

 

Ignition Options

Trigger offset 30deg (This doesn't seem to have make any difference what so ever to the timing???)

Skip Pulses 7

Falling edge

Toothed Wheel

Going Low

Wasted Spark

Output D14

[KADVR6 0]

very well done Dave, i can honestly say you have had my head in a right twist mate, seeing you do all this (nearly) made me wanna go turbo route :wink: but think i'm gonna stick with the charger. just maybe attach my charger onto an R32 next year :twisted: really hope to see you/and your car soon, would love a blast in it Dave.

 

oh yehkev if you want a Jetex exhaust?? let me no mate, i can get them with a reasonable bit knocked off. :wink:

 

karl

[Kevin Bacon 5]

Cheers Dave...... one more question about the Exhaust, is it full stainless or mild? I guess it's stainless if it booms at 3000 when NA..... that's a common thin walled Stainless trait.....gets worse the hotter the metal gets too.

 

Your crank sensor parameters are OK except the sensor position, it should be 78 degrees BTDC. If you can customise the ignition dwell, I'd set it to 3000 microseconds.

 

KADVR6, cool! Cheers for that mate. I might very well be in touch ;-)

[CrazyDave 0]

Well spotted Kev, that's why when I put the timing light on today it was off the scale! All sorted now, runs great.

 

Dwell is 3.5ms

 

Jetex is full SS and nice and thick. But, I have just had a look down the tailpipe with a torch, and it would appear to be 2.25" in the rear silencer as you suggested. Not sure about the middle box?

 

Stick with the charger for now, but maybe consider a Squirt box to get it running better, I'll have all the bugs worked out of it soon. Bring the car down and I'll fit it in a day. No probs for a ride out, but I'd hang on until the mappings fully sorted, cos I'm having to take it easy at the mo :roll: