LOL, I can't understand how some high torque at low RPM is causing drivetrain failures.

 

Probably guys doing what rotary guys do ...being an idiot.

 

the idiot part is being too cheap; a chain is only as strong as it’s weakest link

 

oh ....................so it's no problem doing burnouts on bumpy roads then ? ..... good to know !

 

it’d probably be more truthful to say that none of us are as smart as we think we are (we includes me).

the idiot part isn’t doing that, it’s not having beefed up a drivetrain than can be broken with the original torqueless wonder NA engine

i.e. is the idiot half full or half empty?

 

More accurate to say it's a combination of the two things ...plenty of people manage to make their boosted engine drivetrains last many years with no issues.

 

sure, but not upgrading it limits how aggressive you can be.

Just picked up another used PAR S1 6-speed racing dog gearset.

 

I was told by a former VAG tech, when developing the TDI's many years ago, they discovered that high torque at low RPM triggered oscillations in transmission, thereby transmission self destructed. Solution was to have a dual mass flywheel. I have no clue at what frequency the oscillation problem occurred.

 

Update:
Have the old manifold out and test fitted new design.Fits really well,but looks like I'll need to modify every single connection to the turbo now. So it had better work cuz there will be no going back once it's done.

 

Any update...or awaiting material for the modifications?

 

Bought myself a welder so had to spend a bit of time relearning how to weld! Now have the new manifold tacked together and ready to fully weld. Once that's done I'll have to modify the downpipe , wastegate pipe , compressor inlet,outlet and oil drain. Lot bigger job than I imagined ...but that is just normal for me ....

Really excited to see how it goes though!

 

....

Yeah, ...hoping I don't have to become an artisan to maintain my boosted 8.

 

Tell the truth...you're slowing working your way to full on kit design. M/b a market for a Brettus Kit. I can see it now... "Kiwi your 8 with the Brettus Kit".

 

I don't see why this wouldn't sell, offer the full package, kit + tuning. Build it and they will come!

 

Well I was looking for a design that not only bettered what I already have, but was easily replicated. Right now I don't know if either of those goals will be met .... but If they are, I might think about getting a few made

 

Soo if I understand this correctly: Improvements are being made to the most heavily researched Renesis turbo project in the world and when complete the "Brettus Turbo Package" complete with tuning will be available to all. Where do I sign up??? Additionally how do I get RotoryMachine to assist with the install...………because he has worked through a couple of these projects and is close by (compared to brettus)……..LOL

 

Haha .... I'll tell you one thing. If that ever happened , I wont be making the parts! I'm no fabricator, and this is taking sooooooo long. If I were charging it out at shop rates it would be costing a fortune!

So far:
*Manifold is super compact
*The turbo (with 1.06 turbine housing) and associated pipework all fits in beautifully
*I have way more room than with previous setup
*Heat management should be a breeze
*Good flow paths for all associated pipework
*Have retained the 38mm wastegate ....this is quite small comparatively, but it worked great in previous setup and my flow path to it is almost as good so ...fingers xd
*It had better work because I've modified too many parts to turn back now

 

practice makes perfect

 

All back together and tested .

*No issues
*Boost control is perfect ... am able to hold 6psi spring pressure all the way to redline (no creep at all). Makes 280whp at only 6psi
*Small gain in low range which I think is more to do with improved siamese flow pre opening of WG (old setup used siamese solely for WG duties , new one doesn't)
*Stock ground clearance . was able to reuse stock crossmember
*spoolup is the same (still good but no improvement)
*Power is the same up top (still good but no improvement)
*Exhaust tone has changed markedly once WG opens ...nice aggressive tone but a little quieter.

Overall ....pretty happy with result even though the major goal was not achieved.
Still have something up my sleeve that I can try now that I know boost control isn't an issue.

 

280 @ 6# ...very nice! That portends good things when you start opening her up.

Good boost control..., stock ground clearance, and ability to use the large crossmember for protection on a lowmount ....well done.

 

Thanks Curtis .
Never been able to run as low as 6psi so didn't know what I'd se there but at 12psi power is much the same as before .

Pic showing WG arrangement

 

Tidy.

 

So , been driving it around a fair bit giving it plenty of jandal.
*Only running 12psi ATM (due to lack of ethanol) but car still feels very quick and responsive.
*Am missing the extra sound that I used to get from the dual exhaust when the WG opened - think I might have to remove one resonator from the WG pipe to get that manic scream back !
*Been thinking about pulling the manifold again to make a tweak . Will drive it around some more just to make sure there are no issues first. I cut out a notch to allow crossflow on the twinscoll but I'm now thinking that I really didn't need to do that . Replacing it should improve spoolup ...x-fingers!

But even as it is right now ...am pretty excited about the way it has worked out!

New manifold @ 12psi (no boost cut)

 

Good looking curves...at 12 psi, and w/out the safety of ethanol.

W/b interesting to see the comparative performance at 14 psi to your previous VD @ post # 2070...

 

Yeah ...lucky it's winter and my iats don't go over 80F under boost.
Don't tempt me to go higher , you know I can't resist!