Tubular Manifold and Garrett GT 35R Installation...LONG
05-11-2005, 07:10 AM
#1
AudiWorld Super User
Thread Starter
Tubular Manifold and Garrett GT 35R Installation...LONG
I thought you all would enjoy a sequece of events type write-up on this installation that took place last weekend. As I researched and started putting parts together, Audi2ptzero, provided some helpful advise on his GT 35R's performance. I have assembled a running commentary from several posts to the urS4/6 list. Here we go:
1) The install started Last Friday morning here in Evahboost CO.The Menehune Men of Evahboost have been busily conjuring up a change in the Force. Even though I thought I had everything we needed, I must have made 20 trips to Flaps, TEC, and Home Depot this weekend. A little early but I have to give thanks to fellow lister Dave Dawson and Ian for doing 98% of the install work. Not home yet but almost there.
<img src="http://pictureposter.audiworld.com/15038/img_1318.jpg">
4" Intake
<img src="http://pictureposter.audiworld.com/15038/img_1319.jpg">
<img src="http://pictureposter.audiworld.com/15038/img_1322.jpg">
Adapter
<img src="http://pictureposter.audiworld.com/15038/img_1325.jpg">
3" Turbine Outlet and 3 1/2" Downpipe
<img src="http://pictureposter.audiworld.com/15038/img_1327.jpg">
2) Well, we finally got my car fired up about 4:30 Sunday afternoon. It had a leak at the wastegate downpipe but with the v-band collars we were able to solve it without too much trouble. Lots of false starts and do-overs because of fitment and hardware issues so it always takes longer than you think ;-)
As far as driving impressions the big GT 35R hits about 500-600 rpm later than my TA34/T04e 57 trim. The new trubo is full on at about 4000 rpm in the lower gears. I'll see what I can do to get that better but all in all its right where I thought it would be. Oh my, does evrything flow! The new Turbosmart wastegate had my boost right at 25 psi from the get go. The boost is impressive to say the least. With only 25 lbs the butt dyno has this new combo at 20% beyond the old setup of RS2 manifold, 57 trim turbo, and stock wastegate. The acceleration is mind numbing. After about 40 miles of hard driving my driving style was broken-in to the higher threshold.
Any regrets Hap? None whatsoever! Dave Dawson really wants to see what my car will do with a GT 30R so that might be coming our way in the not too distant future. I'll post more impressions tomorrow. I'm tired so good night. Here's a few pics of the complete installation.
Cool Blanket is a temporary fix that keeps the fuel filter cool.
<img src="http://pictureposter.audiworld.com/15038/img_1344.jpg">
Custom 4" Intake and 928 S4 MAF with SVT Cobra Snorkel Airbox
<img src="http://pictureposter.audiworld.com/15038/img_1346.jpg">
Bling Bling
<img src="http://pictureposter.audiworld.com/15038/img_1347.jpg">
3) Well, early this fine Evahboost Monday morning found me driving the Beast to DIA for a day
trip to San Diego. I am in fact at altitude as a write this missive. I have had
several inquiries about the tubular manifold, the Garrett GT 35R dual ball
bearing turbo, the Turbosmart Wastegate, the adapter I came up with, the install
in general, and my driving impressions so here we go.
The Tubular Manifold:
This manifold was built in Sweden by RS Tuning. We chose mild steel vs
Stainless because of the brittle nature of Stainless in these applications. When
Dave Dawson and I made the first installation attempt, we met with defeat because
the original orientation of the turbo would not allow the the turbo intake to
fit behind the headlight assembly. It seems that Ronnie of RS Tuning had
designed these manifolds for S2/RS2 applications with a parallel to the head mount
and we were very disappointed. I tried to sell the manifold and source
another with no success. Stuck with what I had, I began to engineer. TEC came to the
rescue with a set of machined T3 flange plates that would accept a 2 1/2"
stainless pipe. Next was a 45 degree mandrel bent pipe that could place the turbo
at an angle and further outboard. The pictures I have posted show the
placement. EGTs are significantly lower to the tune of 200-250 degrees. More
observations to follow. Dave has 3 of these manifolds available if you're interested.
His e-mail is:
Djdawson2@aol.com
The Garrett GT 35R Turbo:
Dave Dawson has a GT 30R turbo with mostly stock paraphenalia with the
exception of forged rods and pistons and LWFW. He even has the stock I/C. His turbo
spools at about 3600 rpm but he did see an improvenment when he went from a
.82 ar hotside to his current .63. The GT 35R does not come with a .63 hotside
so I had TEC machine a GT 30R .63 hotside to accept my GT 35R. Since the GT
30/35 turbos come without the turbine housing, this was a simple paperwork fix
but a much more complicated machining challenge. TEC had to model the profile of
my turbine wheel and then machine out the inside of the housing. The results
are outstanding. The boost threshold is about 3-400 rpm higher but the flow is
amazing. I have seen redline pulls of 22 psi in first, and 25 psi in second
and third with no drop off. Simply amazing. Charge air temps are a little lower
but with the Happersized FMIC, its hard to tell a difference. My Davtron I/C
temp gauge's inlet temp probe has been kaput for a while so I don't have any
quantative data on the input side, just the output side. Lower EGTs are
attributable, for the most part, to the new tubular manifold.
Turbosmart Wastegate.
I have had a lot of questions concerning the WG. Like WHY??? Well, our stock
WGs are pretty ugly even if you polish the cap like I had done. Second, the WG
orientation and fabrication of the WG downpipe and its orientation to the
exhaust DP are the hardest part of this type of mod. As I was exploring options
with Jim Latour of TEC, we came up with the Turbosmart WG and its dual V-band
clamp mounting assembly that gives a you 360 degree option to the WGitself and
the WG DP. The BLING factor had nothing to do with this decision. You guys
trust me on this don't you????????????
The Adaptor.
The TEC provided T3 flange plates are stainless. They machined out a 2 1/2"
female receptacle that allows the mounting of the 2 1/2" SS pipe. The pipe had
a 45 degree mandrel bend and about 10" of straight on either end. We ended up
using the entire 45 degrees and made the cut right at the junction going to
straight pipe. Dave also rotated the bend upwards to raise the turbo and give us
the maximum room for placing my current SVT Cobra Snorkel airbox and
PBMAF(Pederhousen Big MAF tm) below the compressor inlet. The bottom of the box is now
2" lower than before and I'm gonna have to do some surgery to cut the bottom
of the box.
General Stuff.
I thought I had everything we needed for Dave to get the install done
starting Friday morning. I had backups and backups to backups. I still ended up
running about 10 trips to Flaps, TEC, and Home Depot. Dave's partner Ian helped all
day Saturday and Ben Howell made several bailout runs with extra odds and
ends. We needed all the extras we had and then some. Check and recheck all your
parts and always have extras. You can always return what you didn't need.
Having a major turbo distributor almost next door is a real plus. If you've got
turbo needs call TEC at 303-271-3997. They can help anyone with your turbo needs.
This type of mod is not for the weak hearted. It really helps to have friends
with lots of expertise and lots of tools. You have to be bale to think and
replan when things can't go the way you originally planned. It really helped
that I already had the FMIC and snorkel intake with the original airbox removed.
I have already posted that it might have been easier had we not had to deal
with my airbox/MAF placement. This type of mod also gets real expensive real
quick.
Driving Impressions.
I was able to flog the car around the hills of Evahboost last night and this
morning, I drove to DIA so my impressions are limited. I can't wait to get
this thing on the dyno and the track. The powah delivery although at a slightly
higher threshold is very linear and the but dyno is severely tested. Its kinda
scary to stay on the throttle. The push is mind numbing. I am guessing a
15-20% increase in my hp/tq numbers. Dave and Mike Pederson have reported a
tendency for tubular manifold cars to die when coming to a stop as they drive along.
I have the same problem. Something familiar yet weird going on here. My custom
dyno tuned Sportec software seems to have held up very well with the new
hardware. I did have to increase the fuel pressure to compensate for the increased
flow with the current A/F at 12.5 with 25 psi of boost. It was really hard
early, 5:00 AM, this morning on the drive to DIA to keep from flogging the car
hard. Big Brakes are very important for survival. My old turbo and RS2 manifold
were impressive but the new stuff is just over the top. The sound is
different. Things are quieter around town and on the highway but the intake howls when
the GT 35 comes on. I need to find somebody locally that can do some sound
bites or better yet video. Yahooooooooo. That's all for now but more will
follow.
4) I was able to get a few projects done on the Beast Tuesday. Here's my new turbo heat shield. Gotta love dah Bling!
<img src="http://pictureposter.audiworld.com/15038/img_1348.jpg">
<img src="http://pictureposter.audiworld.com/15038/img_1350.jpg">
<img src="http://pictureposter.audiworld.com/15038/img_1351.jpg">
Well, that's all I've got for now. The guys on the urS list have been hounding me to get the car on the dyno and that may happen this week. I have pulled 430tq and 420hp ATW with my old setup so I should see a significant improvement. It sure feels significant.
Hap, wit dakine Mondo TURBO in Evahboost
1) The install started Last Friday morning here in Evahboost CO.The Menehune Men of Evahboost have been busily conjuring up a change in the Force. Even though I thought I had everything we needed, I must have made 20 trips to Flaps, TEC, and Home Depot this weekend. A little early but I have to give thanks to fellow lister Dave Dawson and Ian for doing 98% of the install work. Not home yet but almost there.
<img src="http://pictureposter.audiworld.com/15038/img_1318.jpg">
4" Intake
<img src="http://pictureposter.audiworld.com/15038/img_1319.jpg">
<img src="http://pictureposter.audiworld.com/15038/img_1322.jpg">
Adapter
<img src="http://pictureposter.audiworld.com/15038/img_1325.jpg">
3" Turbine Outlet and 3 1/2" Downpipe
<img src="http://pictureposter.audiworld.com/15038/img_1327.jpg">
2) Well, we finally got my car fired up about 4:30 Sunday afternoon. It had a leak at the wastegate downpipe but with the v-band collars we were able to solve it without too much trouble. Lots of false starts and do-overs because of fitment and hardware issues so it always takes longer than you think ;-)
As far as driving impressions the big GT 35R hits about 500-600 rpm later than my TA34/T04e 57 trim. The new trubo is full on at about 4000 rpm in the lower gears. I'll see what I can do to get that better but all in all its right where I thought it would be. Oh my, does evrything flow! The new Turbosmart wastegate had my boost right at 25 psi from the get go. The boost is impressive to say the least. With only 25 lbs the butt dyno has this new combo at 20% beyond the old setup of RS2 manifold, 57 trim turbo, and stock wastegate. The acceleration is mind numbing. After about 40 miles of hard driving my driving style was broken-in to the higher threshold.
Any regrets Hap? None whatsoever! Dave Dawson really wants to see what my car will do with a GT 30R so that might be coming our way in the not too distant future. I'll post more impressions tomorrow. I'm tired so good night. Here's a few pics of the complete installation.
Cool Blanket is a temporary fix that keeps the fuel filter cool.
<img src="http://pictureposter.audiworld.com/15038/img_1344.jpg">
Custom 4" Intake and 928 S4 MAF with SVT Cobra Snorkel Airbox
<img src="http://pictureposter.audiworld.com/15038/img_1346.jpg">
Bling Bling
<img src="http://pictureposter.audiworld.com/15038/img_1347.jpg">
3) Well, early this fine Evahboost Monday morning found me driving the Beast to DIA for a day
trip to San Diego. I am in fact at altitude as a write this missive. I have had
several inquiries about the tubular manifold, the Garrett GT 35R dual ball
bearing turbo, the Turbosmart Wastegate, the adapter I came up with, the install
in general, and my driving impressions so here we go.
The Tubular Manifold:
This manifold was built in Sweden by RS Tuning. We chose mild steel vs
Stainless because of the brittle nature of Stainless in these applications. When
Dave Dawson and I made the first installation attempt, we met with defeat because
the original orientation of the turbo would not allow the the turbo intake to
fit behind the headlight assembly. It seems that Ronnie of RS Tuning had
designed these manifolds for S2/RS2 applications with a parallel to the head mount
and we were very disappointed. I tried to sell the manifold and source
another with no success. Stuck with what I had, I began to engineer. TEC came to the
rescue with a set of machined T3 flange plates that would accept a 2 1/2"
stainless pipe. Next was a 45 degree mandrel bent pipe that could place the turbo
at an angle and further outboard. The pictures I have posted show the
placement. EGTs are significantly lower to the tune of 200-250 degrees. More
observations to follow. Dave has 3 of these manifolds available if you're interested.
His e-mail is:
Djdawson2@aol.com
The Garrett GT 35R Turbo:
Dave Dawson has a GT 30R turbo with mostly stock paraphenalia with the
exception of forged rods and pistons and LWFW. He even has the stock I/C. His turbo
spools at about 3600 rpm but he did see an improvenment when he went from a
.82 ar hotside to his current .63. The GT 35R does not come with a .63 hotside
so I had TEC machine a GT 30R .63 hotside to accept my GT 35R. Since the GT
30/35 turbos come without the turbine housing, this was a simple paperwork fix
but a much more complicated machining challenge. TEC had to model the profile of
my turbine wheel and then machine out the inside of the housing. The results
are outstanding. The boost threshold is about 3-400 rpm higher but the flow is
amazing. I have seen redline pulls of 22 psi in first, and 25 psi in second
and third with no drop off. Simply amazing. Charge air temps are a little lower
but with the Happersized FMIC, its hard to tell a difference. My Davtron I/C
temp gauge's inlet temp probe has been kaput for a while so I don't have any
quantative data on the input side, just the output side. Lower EGTs are
attributable, for the most part, to the new tubular manifold.
Turbosmart Wastegate.
I have had a lot of questions concerning the WG. Like WHY??? Well, our stock
WGs are pretty ugly even if you polish the cap like I had done. Second, the WG
orientation and fabrication of the WG downpipe and its orientation to the
exhaust DP are the hardest part of this type of mod. As I was exploring options
with Jim Latour of TEC, we came up with the Turbosmart WG and its dual V-band
clamp mounting assembly that gives a you 360 degree option to the WGitself and
the WG DP. The BLING factor had nothing to do with this decision. You guys
trust me on this don't you????????????
The Adaptor.
The TEC provided T3 flange plates are stainless. They machined out a 2 1/2"
female receptacle that allows the mounting of the 2 1/2" SS pipe. The pipe had
a 45 degree mandrel bend and about 10" of straight on either end. We ended up
using the entire 45 degrees and made the cut right at the junction going to
straight pipe. Dave also rotated the bend upwards to raise the turbo and give us
the maximum room for placing my current SVT Cobra Snorkel airbox and
PBMAF(Pederhousen Big MAF tm) below the compressor inlet. The bottom of the box is now
2" lower than before and I'm gonna have to do some surgery to cut the bottom
of the box.
General Stuff.
I thought I had everything we needed for Dave to get the install done
starting Friday morning. I had backups and backups to backups. I still ended up
running about 10 trips to Flaps, TEC, and Home Depot. Dave's partner Ian helped all
day Saturday and Ben Howell made several bailout runs with extra odds and
ends. We needed all the extras we had and then some. Check and recheck all your
parts and always have extras. You can always return what you didn't need.
Having a major turbo distributor almost next door is a real plus. If you've got
turbo needs call TEC at 303-271-3997. They can help anyone with your turbo needs.
This type of mod is not for the weak hearted. It really helps to have friends
with lots of expertise and lots of tools. You have to be bale to think and
replan when things can't go the way you originally planned. It really helped
that I already had the FMIC and snorkel intake with the original airbox removed.
I have already posted that it might have been easier had we not had to deal
with my airbox/MAF placement. This type of mod also gets real expensive real
quick.
Driving Impressions.
I was able to flog the car around the hills of Evahboost last night and this
morning, I drove to DIA so my impressions are limited. I can't wait to get
this thing on the dyno and the track. The powah delivery although at a slightly
higher threshold is very linear and the but dyno is severely tested. Its kinda
scary to stay on the throttle. The push is mind numbing. I am guessing a
15-20% increase in my hp/tq numbers. Dave and Mike Pederson have reported a
tendency for tubular manifold cars to die when coming to a stop as they drive along.
I have the same problem. Something familiar yet weird going on here. My custom
dyno tuned Sportec software seems to have held up very well with the new
hardware. I did have to increase the fuel pressure to compensate for the increased
flow with the current A/F at 12.5 with 25 psi of boost. It was really hard
early, 5:00 AM, this morning on the drive to DIA to keep from flogging the car
hard. Big Brakes are very important for survival. My old turbo and RS2 manifold
were impressive but the new stuff is just over the top. The sound is
different. Things are quieter around town and on the highway but the intake howls when
the GT 35 comes on. I need to find somebody locally that can do some sound
bites or better yet video. Yahooooooooo. That's all for now but more will
follow.
4) I was able to get a few projects done on the Beast Tuesday. Here's my new turbo heat shield. Gotta love dah Bling!
<img src="http://pictureposter.audiworld.com/15038/img_1348.jpg">
<img src="http://pictureposter.audiworld.com/15038/img_1350.jpg">
<img src="http://pictureposter.audiworld.com/15038/img_1351.jpg">
Well, that's all I've got for now. The guys on the urS list have been hounding me to get the car on the dyno and that may happen this week. I have pulled 430tq and 420hp ATW with my old setup so I should see a significant improvement. It sure feels significant.
Hap, wit dakine Mondo TURBO in Evahboost
05-12-2005, 03:07 PM
#5
AudiWorld Super User
Thread Starter
Dyno Day will be soon.
I've got a couple of minor projects to complete and then its off to the dyno. That might happen next weekend. The car pulled 430tq/420hp ATW on the cast RS2 manifold and Garrtet T04E 57 trim. The butt dyno says +15% or more so we shall see.
Hap, wit dakine dyno prediction from Evahboost
Hap, wit dakine dyno prediction from Evahboost
