95 TSI AWD Project VGT Holset no 56k - HomemadeTurbo

aero · 09-10-2008, 04:47 AM

I know DSM's are pretty much outcasts on here, but there are some things that some of you may find interesting. A few HMT style mods too.

It was a pretty big project this summer, correcting a lot of DSM style little breakdowns and previous owner fuck ups as well as some of my own.
Really trying to clean the car up and make it nice again. Unfortunately I ran out of time to do the paint and body work. Got the typical severe hrysler clearcoat fade.
The basics of the setup:
95 AWD
Stock trans
ACT 2600
94 Galant 2.4l
Eagle/wiseco 8.3:1
1000CC delphi's.
Whinebro 255HP
Stock 2g head/cams/intake
Megasquirt 2E 2.01
Stock exhaust manifold, with HMT style adapter to fit the turbo with included CDM 38mm gate
E85
For the moment, no intercooler and 8" of 3" pipe for the exhaust
Now the interesting part, VGT turbo, Holset HE351VE from a 6.7 Cummins.
Housing variable from something very small, 4-6cm^-25cm^2
The stock actuator on the turbo is an electrically controlled actuator normally controlled by the ECM. Unfortunately I haven't figured out what kind of signal the ECM sends to the unit to position it. My experimental solution is a 14b wastegate actuator on the VGT rack arm. I didn't think it would work worth a shit, but so far its working pretty damn well.

aero · 09-10-2008, 04:50 AM

Pictures of the turbo.

Exhaust housing

VGT vanes/rack
Closed

Open

Compressor cover

The actuator

Compared to a 14b

Turbine housing compared to a BEP for an HX 40

aero · 09-10-2008, 05:01 AM

The HMT style manifold adapter. Added the CDM gate to act as a safety if the VGT control didn't work properly, and because I suspected the VGT couldn't open enough to keep the boost down.

Fitment with the stock radiator is very tight slightly better than it looks the rad isn't bolted on the top and is sitting back. Fabricated solid front motor mount out of something similar to nylon or delrin to help wheelhop and prevent contact with the radiator.

My assitant for the project, she spent most of the time lounging around watching.

The actuator connected to the arm and mounted on the front motor mount.

LilWayne · 09-10-2008, 05:11 AM

cool cat

aero · 09-10-2008, 05:51 AM

The actuator holds the VGT closed until 6-7 psi, then spool slows down. Its weird, driving normally you can't really hear much exhaust note wise the only thing you hear is the turbine wheel whistling, keep in mind this is through 8" of exhaust. Once it hits 6-7 lbs, the note changes totally, the rack is open fully by ~10-11 lbs I beleive. It sounds sort of like an electric cutout opening, but not as loud. I think even though it has a huge hotside the vanes still help quiet it down, but make it whistle more. Go under and overpass and it sounds like a jet flying by.
Here is a log from ~70mph cruise in 5th gear showing the transient response. 70kpa, to 9psi in about .95 seconds at ~3000-3100rpm.
It spools a good 1000-1200 rpm faster than the small 8 blade HX40 in the .55A/R bullseye housing I had on the car before. Even with the VGT open fully which is somewhere far above 1A/R. Over 3500rpm or so the boost keeps climbing, by 4400 rpm it reaches 24lbs and climbing rapidly. I'm really glad I included the external gate. I'm waiting on a 14.7 lb spring I ordered to hook it up to a boost source, so it will be a little while till I can do a full pull.
Anyone able to calculate the A/R given the nozzle area and wheel diameter?
Open is the wheel given below and opens to 25cm area. I'm going to clay another turbo I picked up to see how tight it squeezes. I know it has to be pretty small given the fact the 6.7 cummins uses the turbo closed up as an exhaust brake and the stock 5.9 turbo is a 9cm housing and doesn't act as a brake.

Wheel measurements
Turbine
EX 2.357
IND 2.755

Compressor
EX 3.38
IND 2.37
Compressor is as close as I can measure since its a 7 bladed wheel. Measurements similar to the large 6bladed HX40.

rprznt · 09-10-2008, 08:38 AM

that turbo is fucking pimp...... good work,

+1 for making it work

turbo4life · 09-10-2008, 09:24 AM

sweet what truck is this turbo off? the new 6.7L Cummings

aero · 09-10-2008, 12:28 PM

From the 2007.5+ the Dodge Ram went to the 6.7 and this turbo.

Tom-Guy · 09-10-2008, 12:38 PM

DSM owners aren't well liked because the are traditionally limp wristed whiners. Basically, everything you aren't.

I hereby remove your n00b status and give you permission to do what the fuck you want here. Thanks for posting.

CspecRun · 09-10-2008, 08:59 PM

Looks awesome man. I saw a similiar Holset on ebay one time that had that electronically controlled bullshit. I passed it up simply because I wasn't sure how that would work, or if it would work. Mad props to you for gettin' er done...