200hp 1200DP Turbo 'Challenger motor'

[CobraJet]

Hmmmm I'm just guessing, you're using a separate wastegate?

[Wally]

Yes indeed!
or go with ‘all the boost’ and “send it”

[brewsy]

Anyways, the turbo planning is underway with the 'usual' welding of the wastegate

Wally, when you do this how do you ensure that the WG is fully seated and sealed? Do you perhaps use an external bolt and pull it down super tight?
Also does it stay sealed with just those tack welds or do you eventually join them all up to make a continuous bead?

Thanks,
Marc

[Wally]

I press the valve down just as the original system would do. If you accept that the original arm keeps it shut, this will as well is my reasoning.
Surely, welding all around would be sweeter, but sealing would not change much imo and is also risky as you can't grind stuff away in that location if you make an oopsie...
The weld edge on the front side, as in the path of the exhaust flow, will hamper flow, so I never weld there anyways. All in all, I call it good as is.

If you know how quickly original internal wastegates open up, you wouldn't be concerned if, or how well or not, this seals

But anyone may proceed as he sees fit of course

[buguy]

I welded mine all the way around just because i don't want any getting past there at all. No clue if it makes any difference or not?
I also cut the arm off inside there and pull it out then weld that hole shut too. I want all of the psi to get to the heads!

[blue thunder]

Yeah, I agree, but making two dyno appointments is really time consuming and hard to do 'in between' things (and not free).

Anyways, the turbo planning is underway with the 'usual' welding of the wastegate

.....Because wastegates are for sissies

[Wally]

Hell yeah! LOL!!

[Wally]

I also cut the arm off inside there and pull it out then weld that hole shut too. I want all of the psi to get to the heads!

Thats pretty fanatic!

I like it

[my_medusa]

oh so much to see here walter, haven't been here for years. your low hp comes from low compression. otherwhise the 90hp would be possible with bigger cam or and more compression.
so here is the BERLINER , but my setup is not wild because max torque is at 3500rpm 293nm, turbo is still tiny also for the 1285cc engine. but all is on maximum for what it is, it matches. bigger turbo and little bigger ports in the manifold would make easy 300 hp with the right turbo i have all here for such a setup but will not lose the low end torque. it's streetable like a normal beetle idle like a champ at 700rpm and hopefully gets under 7l/100km. there are not much turbos that are good for torque low down and also hp in our small displacement 1200-1300cc thats why i went twin scroll. but first made the same mistake like you walter.....1600i intake....way to long!!! runners and too small ports.

can't wait to see your setup next year, you are on the right way with your manifolds and stuff. 200hp would be easy.
thumbs up!

[Wally]

oh so much to see here walter, haven't been here for years. your low hp comes from low compression. otherwhise the 90hp would be possible with bigger cam or and more compression.

Yeah, I very much agree. The whole 'used engle W110' thing was actually a big joke just to those who believe its the most boring cam in the world haha! You know who I mean
For now I'll keep the combo as is for ease of progress. Then there's always something to improve for 2022 or so
At the moment the biggest hurdle is the shape of the outlets of my big chinese air-air intercooler, which I want to keep inside the car. Bluethunder agreed to help a bit with that, so I think it will be cool

[DRED]

hello my medusa,

are you really run a 700rpm idle with a tcs20 cam? what type of valve spring do you use for that and also run 8000rpm?

i had a look on "bugfans", can you tell us more about the parts in yellow on the picture, did you put them inside you intake line?

Resized_20201022_100408_6432.jpg

Thanks, regards

[my_medusa]

@DRED

yes it does idle that low and stable, i portet the heads and chambers very equal and the injectors spray direkt to the valve, the close seat of the injectors to the valve helps too. i did not used the setup in the picture, that was each side two trumpets that had the same diameter and facing each others, i made it more simple at the end and portet the inside of the manifolds like a trumpet.
valve springs are, jpm single springs plus a set of inner scat springs.

[DRED]

Thanks for details, nice combo and result!

[Wally]

Tnx to Blue thunder for rewelding my outlet openings:

[buguy]

Is that a single inlet and double outlet?