So, I have promised Richard that I would come on here and post up the results of our install on a custom turbo set up we did on a VW R32. We are an Aquamist dealer here in Connecticut, USA. We specialize in building custom turbo systems for European cars.
We began with an HFS-5 system and added some parts from there. We went with a direct port set up w/ a 7th jet pre-TB. This will give us the best of both worlds, direct port for ideal anti-detonation, and pre-TB for charge air cooling. Just got the car fully assembled and out on the road today. We will fully tune the car and then turn the w/m on and begin spraying at about 10psi. We will add as much timing as it will allow. Target is about 20psi for now, and with the size of the turbo we used we should be at roughly 500whp. On to the pictures.
The intake manifold I built uses thin wall runners so I had to weld on some bungs. If your manifold has thicker walls you could go ahead and tap the runners directly.
I left the bungs "blank" and welded them on
Then machined them all to the same height
Then drilled and tapped them all
Finished product with plumbing installed
The 6 jets are .3mm
We had to mount the pump and reservoir up front because the customer had some custom stereo equipment occupying the hatch area. This is not exactly advised by Aquamist, but hopefully everything will be OK.
Remote filler
High speed valve
Flow meter
Here is the 7th nozzle (.8mm) mounted on the charge pipe pre-TB. Also note the installation of a check valve. This is to prevent the lines from emptying when the plenum is in vacuum and the pipe is not.
Jet sizes were calculated using injector size.
We are running 6 x 850cc injectors.
Our duty cycle is only about 60% (estimated) for now. We will use 90% for the calculations though as we have plans to make upwards of 700WHP in the future, which is why we chose such large injectors.
Calculated as follows: 6 x 850 x .9= 4590cc total flow
Using 15% W/M flow as a base line, we need ~700cc of W/M
(1) .8mm jet gives us about 364cc at 100Psi (125psi pump pressure - estimated 25psi of boost)
(6) .3mm jets give us about 360cc at 100Psi
Total= 724cc/min.
This should be close enough.
We wanted to be able to make the system turn on at an exact pressure. So we decided to use the enable by MAP option. We did this so if the customer is just cruising around town he can have the boost controller off and not have the meth. turn on. We will make the system turn on at about .5psi higher than the waste gate spring, which should be about 10psi.
The car is MAF based and therefore has no MAP sensor from the factory. Instead of wiring in an automotive generic one, we aquired an industrial unit. You supply it 12 volts and it outputs a 0-5v signal. This one is a 0-30psi unit with a proof of 60psi.
You can see it on the right side of the manifold in this picture
Here is the custom installed HKS EVC boost controller
Here are some shots of the fully assembled turbo system we designed and installed. Most of the parts were made in house, including the full exhaust, intake manifold, piping, etc. For people who don't know the car it is a VW R32. 24V 3.2L 15? V6 (or VR6) that makes roughly 260BHP naturally aspirated. This car did not come with a turbo from the factory. It is equipped with a 4 wheel drive system. We added front and rear limited slip differentials just in case
. It has a stg. 5 custom made clutch, full Moton remote reservoir suspension as well as many other goodies.
I will post back with results as we get further into tuning it. Please feel free to ask any questions you may have.
I have to thank Richard for all his help, he and his company are truly stand up people and one of the best to deal with in the industry. He will go above and beyond to make sure you are satisfied!