[LatDSM]

My buddy is planning on a turbo upgrade for his 2g TSi AWD and I just want to make sure that we have everything sorted out right, so the parts can be ordered in a timely manner.

First of the main part - the Turbo. The plan is to use a 20G with the TD06H turbine wheel. There are pro's and con's but that is the choice. Especially since we plan to stay on the stock internals for now and not push it above 300whp.

Next - tubular manifold. The plan is to use the DNP-38 manifold. (click to see what I mean) Now will this work since it says it will fit a 20g turbo and turbos with td05 turbine housing? Will it still fit the tdo6h housing?

Since it comes with an external wastegate kit we'll have to add a 40mm Tial external wastegate to the list and get the turbo without an internal gate. Right?

To support the air we plan on using 650cc injectors. Can smaller injectors (like 550cc) be used? The Walbro 255lph pump is already installed.

In addition we'll need a turbocontroller and AFPR for general tuning. The SAFC, EGT gauge is present + the car will be tuned on a dyno. It has a FMIC, Shep tranny and ACT clutch kit.

What O2 housing should be used? The car already has a 3" turboback on the other side of the O2 housing.

What have I forgotten? Missed out on? Like?

Cliff notes/questions asked:
1) Will the DNP-38 tubular manifold fit with a TD06H 20g?
2) Smallest injector size for the setup - 650cc?
3) What O2 housing to get?
4) Has anything been forgotten for this setup?

 

[greenstreak]

If the goal is only 300whp then that turbo is larger than what is needed for that goal. I'd assume that is only a short term goal though.

The TD06 will bolt up to the DNP manifold just fine.

Yes, if you are running an external on the O2 housing you will want the turbo with out the internal wg. You want the turbo to have the flapper welded shut and sealed completely with an external on the manifold.

With a turbo of that size you won't want to go smaller than 650/660cc injectors.

Use any O2 housing you like. Shop around as most vendors have offerings. They won't be specific to your setup.

My buddy is planning on a turbo upgrade for his 2g TSi AWD and I just want to make sure that we have everything sorted out right, so the parts can be ordered in a timely manner.

First of the main part - the Turbo. The plan is to use a 20G with the TD06H turbine wheel. There are pro's and con's but that is the choice. Especially since we plan to stay on the stock internals for now and not push it above 300whp.

Next - tubular manifold. The plan is to use the DNP-38 manifold. (click to see what I mean) Now will this work since it says it will fit a 20g turbo and turbos with td05 turbine housing? Will it still fit the tdo6h housing?

Since it comes with an external wastegate kit we'll have to add a 40mm Tial external wastegate to the list and get the turbo without an internal gate. Right?

To support the air we plan on using 650cc injectors. Can smaller injectors (like 550cc) be used? The Walbro 255lph pump is already installed.

In addition we'll need a turbocontroller and AFPR for general tuning. The SAFC, EGT gauge is present + the car will be tuned on a dyno. It has a FMIC, Shep tranny and ACT clutch kit.

What O2 housing should be used? The car already has a 3" turboback on the other side of the O2 housing.

What have I forgotten? Missed out on? Like?

Cliff notes/questions asked:
1) Will the DNP-38 tubular manifold fit with a TD06H 20g?
2) Smallest injector size for the setup - 650cc?
3) What O2 housing to get?
4) Has anything been forgotten for this setup?

 

[Boosted3000GT]

This is a question as much as it is an answer, but Isn't 40mm kinda large for a wastegate on a 20g?

Good call on the DNP manifold, they make great stuff.

Mike

 

[LatDSM]

Yes, if you are running an external on the O2 housing you will want the turbo with out the internal wg. You want the turbo to have the flapper welded shut and sealed completely with an external on the manifold.

The external comes on the tubular manifold, thats the way it is sold. And since its on the manifold, the turbo would have to be without the internal wg and flapper on the turbo welded shut and sealed completely. Correct?

As to the 40mm external wastegate for the 20G - thats what is offered in conjuction with the manifold that fits the 20g turbo.

We're also getting a pocketlogger....so...will we be set or am I missing something? wouldn't want to postpone kicking major ass for a month just because we have to ship a part across the atlantic.

 

[LatDSM]

The 2g install kit will be required for the turbo - correct?

 

[LatDSM]

And most housings come with the external dump option...but since the wg is going on the manifold we need the o2 AS IF the turbo was internally gated?

For example the SBR 2,5" Recirculated 02 Housing ?

Is there a 3" 02 housing that will allow for the wg to be before the turbo rather than at the 02 housing?

 

[gthompson97]

instead of the safc..just go with dsmlink. although it maybe be a little more pricey, it's much easier to tune with and it's more precise, and the help you get on the forums is top notch. and if you plan on upgrading even more in the future, you'll want dsmlink for that so you might as well get it now instead of buying the safc and then having to buy dsmlink in the future.

and putting the stock internals above 300hp is not pushing it by any means..there are a ton of daily drivers that are pushing above 300hp. the stock 6-bolt 4g63 block has handled upwards of 500hp on stock internals, on more than one occasion.

 

[LatDSM]

I did not say it would be pushing it. I just stated the goal. And note - whp not hp. Did I mention the emphasis on torque rather than hp? ever heard of trade-off between those two?

1) tuning will be done on a dyno
2) SAFC is already present + datalogger is on the way
3) AEM or other standalone EMS will be incorporated with the upgrade to a 4g64 bottomend (in about a year)

P.S. I'd prefer more precise answers rather than going in a discussion on turbo choice or the privilages of DSMLink, because I've read those discussions already and there is no need to repeat them

 

[Boosted3000GT]

Just to possibly save a couple bucks... If the WG is on the manifold and you're welding the internal gate shut anyway, you can look into getting an O2 housing that doesn't have a tube or a dump, or a recirc back into the exhaust or anything, just a flat plate over the WG side and a 2.5 or 3" pipe where the exhaust exits... I haven't looked into these cause they don't suit my application but I have seen them out there and I would imagine they might be cheaper due to less material and fabrication being involved... Sorry for more speculation, but I wanted to make sure you realized that the option was open to you. Good luck with the project and if theres anything I can difinitivley answer for you, I'll make sure I post.

Mike

 

[LatDSM]

look into getting an O2 housing that doesn't have a tube or a dump, or a recirc back into the exhaust or anything, just a flat plate over the WG side and a 2.5 or 3" pipe where the exhaust exits... I haven't looked into these cause they don't suit my application but I have seen them out there

Thanks for watching out! Could you indicate where you've seen them, because I would imagine that this would suit just perfectly for the setup, but I haven't seen them anywhere I looked. Thanks!

 

[glenneclipsegsx]

this is almost exactly the same setup i had on my stock 7bolt awhile back. good choice, sounds like u did some homework. let me help u out a little bit. if u are going to run an external gate on the o2 housing (which i highly recommend. u dont weld the flapper shut. u completely take out the wastegate flapper and weld a pin in where the flapper arm was. u can have the shop u buy the turbo from do or if u have a plasma cutter and welder u can do it. just tell the shop u are running an external off the o2 housing. The Victory performance o2 housings are very nice high quality pieces for a little less than 300$. u can get them flanged for 40mm Tial externals or whatever u like but the 40mm worked excellent for me. I currently own the victory o2 housing but im not going to sell it just yet because im going to be fabricating all types of 02 housings soon and need to use it to construct a jig. Also i recommend using 650 injectors as the 550s will run out of fuel at higher boost levels. the exhaust manifold u can either run the DNP standard manifold for 500+$ or u can get the sbr cast manifold that uses a thick flange to allow clearance for the 20g without bendign the water pipe and goes for 289$ i believe all depends on preference. THe sbr manifolds come pretapped for the egt thermocouple also so keep that in mind. I wouldnt go try and tap and bung the DNP if u are planning on going that route. You are definitely on the right track for that setup. that afc will work fine. i suggest a set of cams maybe 264intake 272exhaust from HKS. u will be around 350whp on pump gas at 20psi like that and solid 400whp on race gas and 25+psi. the 20g loves around 26psi. u will see huge torque gains running around that kind of boost. GOOD LUCK!!

 

[glenneclipsegsx]

Heres the o2 housing u want

http://www.victoryperformance.com/product/Detail.cfm?ProductID=505

Ill be making these soon myself for a little less.

 

[glenneclipsegsx]

i see that u say ur getting a logger. i actually recommend a wideband instead. u can tune low and high throttle positions the same way u do on a dyno. very nice tool. i really think loggers are kinda garbage. the only good feature and u cant even see this on a 2g car anyway is the knock. but if u tune to a safe air fuel with the wideband ur not goign to be knocking so. u wont have to pay to go to the dyno all the time either. u can just go to see the numbers ur putting down

 

[LatDSM]

The EGT is tapped after the turbo for average condition readings, rather than in a runner, so we'll stick with that and are not planning to relocate it (another infinite debate on where better to tap the EGT probe).

Thanks for the pointer to victory performance. They look good.

 

[glenneclipsegsx]

as for standalones read up on Autronic. lot more user friendly than AEM. The base maps u get with AEM are junk and u find out that u have to buy a ton of other shit just to utilize the system the way u want. You really have to know the system to use it. IT takes a long time to really know how to use it and sometimes people have to go to professionals because they cant get the car to run smooth

 

[glenneclipsegsx]

ya well the thing with egt gauges is ull probably melt something before u actually realized u were getting too hot. the sensitivity on some of those thermocouplers are kinda shitty. this is an item that u get what u pay for. a really good probe will cost a fortune. not really worth it. wideband is the better way to monitor whats going on

 

[glenneclipsegsx]

i mean i had one too but dont rely on it is all im saying

 

[LatDSM]

the only good feature and u cant even see this on a 2g car anyway is the knock.

but it gives timing so if its being pulled you'll know you're probably knocking.

Also...wideband O2 vs EGT

The apex'i electronic series is being utilized...and after the turbo - it'll hardly melt, and there are references on what temps after the turbo indicate a lean/rich condition and they are hardly high enough to melt the proble there...

if it were the runners - i'd agree.

 

[glenneclipsegsx]

heres an alternative on the exhaust manifold since u seem like ur not a cheap ass and want to do shit right. they are pricey but they are top notch quality and are guaranteed to the original owner not to crack or will be replaced free. the guy has made shit for all the big dogs including john shepard and i believe he made his long tube header for him


http://shearermotorsport.com/

just a suggestion since say if ur dnp cracked on u ull have to pay another 500$ to get a new one. plus i like the fabricated unpolished look myself but u can get it polished if u want too. and he can do anything u want as far as wastegate setup

 

[glenneclipsegsx]

the thing with the shearer fab manifolds is since u buying this as a one time deal and ur getting it flanged for a mitsuturbo. you will most like be staying with a mitsu housing on any turbo upgrade in the future. when u get up to where all the big dogs are at ull want a higher flowing housing. so as of right now the FP30 housings are the only ones that u will want for flowing the kinda air u need to make big big power. but that isnt to say that u could send the manifold back to have it switched over to a garrett setup so u can support larger ARs and go with a true GT35R setup like im doing