revolutionary or idiot.... you decide!!!

[01b5a4qms]

haha! ok. so i'm broke... nothing to unheard of in this day in time for your average college student. but i still want to make my car fast and not wait till graduation to do it. so i improvised. alot of my friends own dsm's (mitsubishi, eagle, plymoth for those who may not know) but they just happened to have a perfectly good evo 16g sitting in there garage. then after some deliberation and brain storming we decided to attempt the frankenstien 1.8t 16g project. this project is just about the most budget damn thing i believe i have ever done in my life. more than 90% of the stuff i used was free. putting a 16g in my car was one of the most frustraiting things i have ever done. now to get on to the frankenstien kit, i hope don't get to shamed by the audi comunity for doing this. ok, so to start out i had the 16g turbo which is a mitsu 4 bolt patern and sadly i mated it to the stock audi manifold.... haha! so to accomplish this i had to build an adaptor plate which i made by punching a center hole to the size of the manifold outlet, then drilling holes to the patern of the manifold. once this was done i welded some grade 8 bolts with the heads cut off into the the three outside patern holes so they would bolt up to the manifold. once that was done i moved on to welding that plate to the exhaust housing of the turbo using a stick welder with nickle rod (hopefully the best for welding to cast iron due to the large amount of nickle in it) taking my time welding it, carefull as to not crack the cast housing it toke me an hour and a half to complete the four sides of the weld. with this done everything bolts up nicely to the manifold now but getting it into the engine bay was a different story. doing this project showed me why every upgraded turbo setup in a quattro has a top mount manifold.... but it was nothing a little grinding of some nubs on the exhaust housing of the turbo and the motor mount wouldn't fix.... now with the turbo mounting up nicely and a long battle with the waste gate actuator i moved on to exhaust, haha! which is kinda non existant... i ran 4ft of pipe that dumps right under the passanger seat along with a waist gate dump to go along with it, the thing sounds like a tractor, i like it!! but i'm guessing some people wont... then with all the hard stuff taken care of it was just putting all the plumbing to it, prime it, and start it up. now on to some results of my fluid dynamics nightmare know as frankenstien.... so with my k03 on a 17psi spike and settling around 14psi (i was trying to get the most out of that little guy) i was flowing around 136g/s on vag. now with the 16g i flowed 180g/s on only 9psi!!! with no knock!! and 22 degrees advanced on the timing!! the only down side is i'm kinda close to maxing out my injectors... idc's are about 82% right now i'm gunna try to squezz 12psi out of these injectors but not pass 95% idc's.

so yea, there is my 1.8t 16g frankenstien project. i'm gunna go out on a line and say i may be the first to do this... but i'm not sure. so you guys can make me feel stupid or smart. haha! tell me what you really think of it. i really enjoy your feedback on stuff.

[ILoveT]

Pics and paragraphs.

Sounds interesting. What does your AFR look like?

[djwimbo]

i was flowing around 136g/s on vag. now with the 16g i flowed 180g/s on only 9psi!!! with no knock!! and 22 degrees advanced on the timing!! the only down side is i'm kinda close to maxing out my injectors... idc's are about 82% right now i'm gunna try to squezz 12psi out of these injectors but not pass 95% idc's.

so yea, there is my 1.8t 16g frankenstien project. i'm gunna go out on a line and say i may be the first to do this... but i'm not sure. so you guys can make me feel stupid or smart. haha! tell me what you really think of it. i really enjoy your feedback on stuff.

... wow, paragraphs. I didn't read all that b/c my brain doesn't like it.

Anyways. Good job on doing a "Frankenstein" project. I don't know if you're the first or not, I know a CT26 has been fitted to a 1.8T, so why not a 16G.

Is it a "Big 16G" or a normal one?

I wouldn't push it any further, especially without a wideband, and definitely not if you're already at 82% IDC. You don't want to go past 85%, most say 80%.

As far as your MAF values, I don't know what to tell you. I'm hitting 175g/s on my K03s, you should be able to push more than that. BUT are you on a "chip" or diode mod + AFPR?

[t1demont1]

Thats pretty sweet, what you using for tuning? megasquirt? what you using to monitor afrs? id imagine a 16g is much more lively than the little k03

[lowandslow4now]

Sounds like an interesting project and a for getting it done. Now some pics would be good. I like to see others creativity

[01b5a4qms]

well this is where i may get shunned... my o2 censor is dead... and no wide band yet... no afr's available yet... reall fat tune right now using lemmiwinks.... and about the livelyness of it, it only wakes up top end. it's a fluid dynamics nightmare. that tinny little manifold is blowing into a 2in. inlet on the turbo... i get all 9psi at about 3600 rpm.

that is crazy that you are flowing that much on the k03!! you must be at a lower elevation than me. i live in idaho... i'm kinda up in the nose bleeds.

and sorry about the parragraphs... i'll work on it. i'm just a little excited right now.

[01b5a4qms]

and yes! big 16g

[01b5a4qms]

haha! and no chip....

[01b5a4qms]

[01b5a4qms]

next purchases will be: injectors, afpr, walbro 255, then save up for some better tuning system. really wanting 034 IIc system with the drive by cable converstion.

hopefully that gives you guys an idea of where i'm going.

[billyblooshoes]

haha wow. subscribed. i wanna see how this pans out.

[djwimbo]

well this is where i may get shunned... my o2 censor is dead... and no wide band yet... no afr's available yet... reall fat tune right now using lemmiwinks.... and about the livelyness of it, it only wakes up top end. it's a fluid dynamics nightmare. that tinny little manifold is blowing into a 2in. inlet on the turbo... i get all 9psi at about 3600 rpm.

that is crazy that you are flowing that much on the k03!! you must be at a lower elevation than me. i live in idaho... i'm kinda up in the nose bleeds.

and sorry about the parragraphs... i'll work on it. i'm just a little excited right now.

Wow dude, I'm kinda impressed. I don't know if I'm more impressed b/c it works or that it hasn't gone into self destruct mode yet.

Definitely need to monitor your A/F.

As far as MAF readings based on elevation, I don't know what to tell you. IIRC my area is ~800ft or so above sea level.

[Poopie]

sick budget project. I'm all about the git-r-done mods. I love it.

My name is poopie and i approve this message.

[Stampy]

Sweet project. How does it fit in the bay? Any pics of everything installed

[Militant-Grunt]

Wow, awesome home made piece of kit. A 16g is about the size of a 2871r, so if you actually had a person to tune the motor you could potentially get some nice #'s, though I don know how well would that adapter plate hold up under real boost.

[01b5a4qms]

afr's are a huge deal. wide band is a first on my list. i actually plan on doing all my own tuning. i've been reading alot on lemmiwinks lately, it's a pretty stable program for just keeping timing and fuel in check so i don't blow stuff up before i stand alone or possibly some piggy back system.

as far as it working i am as impressed as you all are. i had so many doubts starting into it. clearance was a huge issue. the motor mount proved to be a problem. all i did was grind a nub off both the exhaust housing of the turbo and a nub on the mount. slid in beautifully. the waste gate was a large problem to. espcially since the waste gate had been removed cause the previous owner went external. i got a new flapper in there and modified a stock k03 actuator to fit it. clearance was a huge deal not going top mount.

with the welding.... i'm very frightened of failure as well. but i did take all the precautions to make it a strong one. using nickle rod, then welding only about 2in. then pinging it with a welding hammer untill it was cool to touch (the pinging releaves the stress in hopes to prevent cracking). the whole thing toke about 1 1/2 to 2 hours to complete the 4 sides.

as for the the elevation i'm way up there, which explains the flow difference.

by the way. thank you for the input. i live in a town full of dsm's, diesl trucks, and gay honda's with exhaust tips.... i don't get much audi luv.... i'm kinda an outcast around here. haha!

[sean1.8t]

nice work man! can't say i agree with using an adapter plate with the stock mani. just doesn't promote good flow at all. but i can totally agree with a ubber budget build. props to you man.

if you're ever in the northern utah area, give me a holler, i'd love to see this thing and ride in it. we could compare it to my gt28rs too

[pipe7284]

lovely project bro. I would go with a high flow mani such as ATP. They have the stock location, but with alot more air flow. you should try it.

[01b5a4qms]

nice work man! can't say i agree with using an adapter plate with the stock mani. just doesn't promote good flow at all. but i can totally agree with a ubber budget build. props to you man.

if you're ever in the northern utah area, give me a holler, i'd love to see this thing and ride in it. we could compare it to my gt28rs too

haha! it does not promot good flow at all. and i'm actually down that way quite a bit. will do.

[maxspeed]

lovely project bro. I would go with a high flow mani such as ATP. They have the stock location, but with alot more air flow. you should try it.

hed still need some kind of adapter to bolt the 4 bolt DSM to an atp mani

[sean1.8t]

hed still need some kind of adapter to bolt the 4 bolt DSM to an atp mani

no he wouldn't. direct swap

[boostedup]

couldnt he just use tuning from a 2860 or 2871, and tweek it from there. get an adapter plate fabbed up for an spa manifold and hes on his way??

i dont know just throwing ideas out there......

[boostedup]

no he wouldn't. direct swap

really i thought the atp mani was the stock pattern.

[01b5a4qms]

http://www.atpturbo.com/Merchant2/gr...VW-157_450.jpg

heres the atp mani. i could only find it for the transverse. looks mirrored to my stock one. but should work if i build a new down pipe.

[01b5a4qms]

http://www.atpturbo.com/Merchant2/gr...VW-156_450.jpg

nevermind. i found it for the longitudinal.

[le91688]

!!!! DSM and audi worlds collide!!!!!!!

[t1demont1]

Id imagine a t25 flanged manifold would work great, you can find them on ebay for dirt fuckin cheap, probably like 100-150. Im not sure what flange the 16g uses but a t25 for the manifold would open it up a good deal.

[01b5a4qms]

!!!! DSM and audi worlds collide!!!!!!!

haha! all my friends own dsm's. it was bound to happen.

[djwimbo]

haha! all my friends own dsm's. it was bound to happen.

I should have looked when I worked for a DSM shop, but how far off is a DSM 4bolt from a T25 or T3 flange?

I'm not really looking for myself, but it's worth asking.

[01b5a4qms]

I should have looked when I worked for a DSM shop, but how far off is a DSM 4bolt from a T25 or T3 flange?

I'm not really looking for myself, but it's worth asking.

i'm not sure exactly... i'll ask one of my friends tonight. i don't think they match up though. i believe the mitsu flange is a touch smaller.

[djwimbo]

i'm not sure exactly... i'll ask one of my friends tonight. i don't think they match up though. i believe the mitsu flange is a touch smaller.

That would be the adapter I'd be shooting for. T25/T3 -> DSM4 bolt. That would allow you to pick up a relatively inexpensive manifold, make an adapter and hopefully pick up some faster spool.

[slopoke]

im subscribed

[maxspeed]

no he wouldn't. direct swap

16g isnt T25 or T3. how would it bolt up?

[01b5a4qms]

That would be the adapter I'd be shooting for. T25/T3 -> DSM4 bolt. That would allow you to pick up a relatively inexpensive manifold, make an adapter and hopefully pick up some faster spool.

yea. that would be a pretty good idea. i could make another adapter plate easily.

but untill i get some money saved up, how much you think i could port out of the stock mani? i didn't look like alot to me... but i thought i would ask

[djwimbo]

16g isnt T25 or T3. how would it bolt up?

to the best of my knowledge it wouldn't. I know somewhere along the way the DSM's used a T25 turbo, but it wasn't the 16G.

Somebody somewhere makes an adapter like this one... to go from the T25 or T3 to the DSM 4bolt. I just can't find it anymore.

http://www.dnamotoring.com/dnamotori...ADAP-T3T25.jpg

[KajunAudillac]

Some Good stuff there.

[djwimbo]

... forget what I said. I overreacted.

[KajunAudillac]

What HP/TQ numbers you pushing (or hope to push)? Rpms it pulls? Max PSI you want etc..
And from your original post, it seems you have a friendly rivalry with your buddies. Hope you can show them the superiority of the Audi.

[sean1.8t]

16g isnt T25 or T3. how would it bolt up?

imma gonna let you figure this one out. but i'll give you a clue....

lovely project bro. I would go with a high flow mani such as ATP. They have the stock location, but with alot more air flow. you should try it.

[Poopie]

those atp manifolds are junk. stay with the stock manifold if you aren't gonna go with a t25 flange.