After cutting my teeth on a type 1 EFI turbo engine for the last 10 years, I've decided to stop fighting the laws of physics (mainly heat and head temps) and accept that watercooled is the way forward when running a boosted engine.
With a lot of work and development I managed to get my little 1776cc type 1 motor to produce 194BHP / 222lbs @ 21psi boost. It works great on the road and provides a massive smile per mile, but struggles with heat whenever I take it onto a circuit track and give it some sustained use of the "go pedal".

I've seen the success of Buildabiggerboxer, Ambrosia, Fastback and Marcomansi, amongst others, with their WBX conversions and can't go on ignoring it!
Having just picked up a 1990 2.1i DJ engine, I'm now starting to plan how I'm going to go about the conversion into my '72 super beetle.
I've researched loads on here and other forums and I'm starting to get a plan together, which I will create a build thread for when it actually starts to happen (probably Autumn 2016).
First problem with my build plan:
What I'm really struggling with at the moment is exhaust header choice for the turbo. I've not found anything straight off the shelf. I currently use the CB hideaway header but don't think this will be suitable for the new engine due to it not placing the turbo high enough (see requirements below) and clearance of a dry sump pump. Can anyone give me some pointers?
Things to consider:
[*]I plan to use a dry sump pump, so need to consider clearance of the pump body. (Favourably looking at Thorsten Pieper's pump at the moment).
[*]I would like to mount the turbo higher than the sump and rely on gravity to drain the oil from the turbo back into the case.
[*]I want to run a water/air chargecooler. I'm not afraid to use the package tray area behind the rear seat but need to retain the rear seat for when I take the kids out on a Sunday drive.

I wonder if the over-tranny mounted turbos would enable me to keep the rear seat?
Torque is king!
The car will be predominantly street driven with the occasional blast around a circuit.
Because of this, I don't plan to run a huge Holset or T4 turbo. I will be looking for low down power and torque delivery and keeping the torque curve as long and flat across that dynograph as I possibly can.... I think that will give me a great street car..... and if I can boast a BHP number of around 300 that would also help!


A friend ran a Borg Warner EFR 6258 (T25 flanged) on his 1.8 20V turbo golf (360BHP) and I was very impressed with the way that performed, so I'm leaning towards using one for this build.
So, enough waffling. Can anyone recommend an exhaust header?
Pictures and examples are always welcome!

Many thanks!.