Homemade Turbo 1600 Single Port recipe, DYNO'ED, NOW T3/T4!!

[MO Turbo Manx]

Hi folks,

Not sure why I haven't posted here before but here goes.
I posted my combo and results on other sites before.
I built this combination back in March '07.
I beat it like a rented mule when I have it out and it's been going strong ever since.
Then again, I'm VERY meticulous with oil changes, valve adjustments, fueling and timing control.
Yes, you can run 18 PSI of boost through a STOCK 1600 single port successfully.
No, I'm not a mechanical engineer.
Just another VW nut like you all who got a wild hair to "see what I could do".

Here is my combo, results and pictures.
Enjoy!


The engine:
Your basic budget rebuild 1600 single-stock crank, rods, 4 dowel stock weight flywheel, stock cam and lifters, aluminum pushrods, rebuilt stock heads with single hi-rev springs (MUST HAVE!), 1.25 rockers, swivel feet adjusters and bolt-together rocker shafts (for peace of mind).
Turbo:
T25 from a '95-99 Mitsubishi Eclipse from Ebay used. Rebuild kit from gpopshop.com including Carbon Seal.
Boost control is by the stock internal wastegate controlled by a GRAINGER valve (that allows me super fast boost rise and spot-on 18 lbs. boost on a 10-12 lb. wastegate).
Carburetion:
390 Holley used from Ebay (rare dual line model, easier to tune!).
Jetting: 52 primaries and 66 secondaries.
Lightest spring in the vac. canister
Boost reference 1.5 power valve (easy to do with JB Weld!).
50cc accelerator pump and huge squirter (drilled out by me).
Electric choke even works!!!
Fuel System:
Holley Red, no regulator.
Ignition:
009 set at 30 degrees total timing (NOT locked!).
MSD 6A box and BTM module set at 1.25 degrees of retard per lb. of boost resulting in approx. 10 degress at full boost.
Taylor wires, blue coil, stock plugs.
Engine monitoring:
Auto Meter boost and A/F gauge (used from Craigslist) using a Denso heated O2 sensor, Summit racing tach with shiftlight.
Exhaust:
2.5" bends and flanges from local auto parts store and Dynomax stainless muffler (straight through but VERY QUIET!) used from Craigslist. Muffler unbolts in about 1 minute and wide open sounds amazing.
Sounds like a BIG CC motor and boost response is better.
The header (finished 12/28/07) is homemade using a previous baja header that WAS on the buggy (ugly but it worked), a ding-and-dent special from Mid-America and tubing from my local muffler shop (about $75 total as you see it).
Let's just say the new header works MUCH better than the old one.
Incredible improvement in structural integrity and flow!

This combo has been running successfully since spring '07.
Only valve adjustments and oil changes since.
It averages 23-25 MPG with my HEAVY foot......take it from me, boosting is ADDICTIVE!
I couldn't be happier.
Just driving around town, the motor behaves just like a smooth stocker but boost is always a downshift away.

It will build boost starting about 2500 rpm AND, courtesy of the GRAINGER valve, it'll ramp up FAST to 15 lbs. BY 4500 and 18 if I stretch the motor to 5000.
Let's just say it'll bury the speedo at will!
93 octane pump gas, by the way.

It starts up perfect hot or cold (choke works GREAT!) and runs stupendous.

Reliable, ignorant power from a beloved 1600 single.

I mortally wounded a stock swingaxle tranny in July (spun third and fourth hubs).
So a monster swing was built by Archway Imports in St. Louis.
Comparable to a "Super Pro Street", it has every conceivable mod including 3.88's.....I HIGHLY recommend 3.88's, they load the motor nicely for building boost, make first gear usable (!) and really make driving the car MUCH more of a pleasure.
Remember, you don't need deep gears for a turbo....no need to spin the bejeezus out of a turbo motor.

That's it in a nutshell.

Enjoy the pics!
First is of the new header, tacked and mocked-up.
Second is of the finished product after it's shakedown cruise.

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[Bashr52]

Nicely done, though I think the stock internals would be the weak point, especially with 18lbs.

[Rowroy]

Any plans to dyno this engine?

What would you estimate the HP and TQ to be?
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Suicide is man's way of telling God, "You can't fire me; I quit!" - Bill Maher

[MO Turbo Manx]

[MO Turbo Manx]

[73 KAFER]

One thing nice about a Buggy.....lots of room Nice by the way.

Mark
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1973 Beetle
#3 http://www.thesamba.com/vw/forum/album_page.php?pic_id=775620Kafer-Cup vintage road racer

[MO Turbo Manx]

[shok]

first major motor work i ever did was heads and cylinders on a baja bug, i just sat on a milkcrate behind the car and did it.
_________________
1974 Baja Bug Hackjob
1968 Baja Bug

1971 Squareback parts car

[MO Turbo Manx]

Hey folks,

The "1600 single that won't die" is still going strong, not using oil and sounds like a 2332!

Today I did something I've been wanting to try for a LONG time: RACE FUEL.
I went down to the local race fuel depot and picked up 10 gallons of 110 leaded.
5 gallons of 110 and 5 gallons of 93 later, I'm on the road.

Good God......
I twisted the timing retard back from 1.5/lb. of boost to .5!
Incredible.
I KNEW it wanted more timing but I couldn't with the straight 93 I had been running.

The resulting approx. 102 octane can withstand much more than I'm throwing at it right now.

BUT.....our weather went to hell in a bucket within about 4 hours: from 72 to 30 and heavy snow!?!?!?!
Welcome to St. Louis, MO ladies and gentlemen.

The next warm spell, I plan to bump the boost back up to 18 (It was there before but made me sweat a LOT on pump fuel) and maybe even add a little more timing.
FYI-I'm at 22.5 degrees at 15 lbs. boost on the blend. On 93, I was 10 degrees total!

Come on spring!

[bigpapakamen]

how did you run the oil lines

[MO Turbo Manx]

[joetron]

so what would be your total cost?? if you dont mind me asking.

i'm HIGHLY considering your design/parts!
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[1mechanic]

[perrib]

Nice job. My friend did a real junkyard turbo conversion on a mostly used 1600 engine (new rings and bearings). At Glamis when he hit second gear it would pull away from my rail (15.5 second 1/4 mile) like I was standing still. Have you thought about wrapping the header. It ran for about four years including road trips from Phoenix to Guadalajara Mexico Glamis and Buttercup before he traded it for a VW 16 v engine. Have fun with it.

[MO Turbo Manx]

[MO Turbo Manx]

[seabeebuggy]

[miniman82]

[seabeebuggy]

thanks
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Seabee turbo buggy build
(Quote Runslikeapenguin said)
so to everyone else whos not a retarded butt pirate marine with an tacky ugly ass car covered in auto zone bolt and stick on s**t. (end quote)

A better place to talk offroad

[MO Turbo Manx]