Dane's Hybrid Conversion Thread

Morgan-VAGCHECK said:
Hi Bill,

You think the TSR one is not up to the job then ?

Or is it a cost/time scale thing that rules it out.

Regards
Morgan
Click to expand...

cost predominantly morgan.. although timescale is a factor currently

I must admit I forgot about TSR one when I posted earlier.. the confidence comment is not appropriate for that one, it looks as good as you can get a fabricated one.

TSR looks quality from the pictures

only technical question I have on it is its bore size & longer runners vs spool... From the pictures it looks like 1.5" sch pipe. Is this the size ?

PS. hope you are feeling better
 
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Morgan-VAGCHECK said:
Hi Welly,

Do you have any data or links you can share from the example(s) you have seen/heard about ?

As far as I know only two are actually in existence... mine & one that I think was sold to someone from SCN but I have not heard anything more about that one… hence my interest in what you know.

A bit more lag was indeed observed during our own first tests but we are not talking about a huge amount..

After a little fettling the impact on spool times were quiet negligible... present yes but small. To be honest with some more tweaks I think it quiet possible they could be eliminated almost completely. (Bearing in mind the turbo also has a slightly weaker actuator, & ported waste gate compared to the logs I posted ages ago made with the stock mani)


Here is one log of our mani testing where we have saturated the MAP sensor by 3120rpm, so I would hardly describe that as lag similar to what’s seen with BT's.. would you ?

TSRMani-Spoolexamplecopy.jpg


Regards
Morgan
Click to expand...

that log looks ok...
not a "fill" question, just a cost one then...

I know the work involved and its not tsr cahing in, its that labour intensive to make something like that as well as that. (whoever fabs it for tsr will be putting in many hours to make one) - its the design which makes it that labour intensive & costly.. which is why I am attempting to make a simpler version.. less parts, less welding, but hopefully functional. We will see of course. might all go tits up yet - lol
 
Welly said:
That paints a somewhat different picture to the data that I saw...

In retrospect, and taking the above into account that is not bad at all hitting full boost at 3100 is indeed not bad at all.

I will try and find the data I saw - I can't remember where it was as I was looking into it back when I was changing manifold every 2 mins late last year...

If I find it I shall PM you.

Adding to this, I have just glanced at the outputs from the hybrid on the XS power mani - that wasn't reaching full boost until 3500 using smaller runners than the TSR...
Click to expand...

Hi Welly,

If you do find it then it would be most appreciated if you can point me too it, because if this was last year then the logs in theory can only have come from my own TT... & I don't remember posting any ! (That said my memory is ****e)

I did post a log recently at Bills request here (this does show more lag, but it had a little less pre-load on the actuator than the example above) >

The Audi TT Forum :: View topic - There is no end to mods.... 297.61BHP ACHIEVED

Dane sorry for the small highjack, & I wish you all the best with your own hybrid build.

Regards
Morgan
 
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No worries mate, it's all good info!
 
badger5 said:
cost predominantly morgan.. although timescale is a factor currently

I must admit I forgot about TSR one when I posted earlier.. the confidence comment is not appropriate for that one, it looks as good as you can get a fabricated one.

TSR looks quality from the pictures

only technical question I have on it is its bore size & longer runners vs spool... From the pictures it looks like 1.5" sch pipe. Is this the size ?

PS. hope you are feeling better
Click to expand...

Hi Bill,

I am told the runners are 35mm.

Unfortunately I am still suffering a bit after the op... I just can't sit still & rest to let everything heal (Get bored very quickly!) but thanks for asking :)

Apologies again to Dane for taking his build thread slightly off topic !

Regards
Morgan
 
Morgan-VAGCHECK said:
TSRMani-Spoolexamplecopy.jpg
Click to expand...

Morgan --- the spool you are getting on that manifold is excellent. I would put that as the standard to beat for any combination of hybrid turbo / aftermarket manifold. Did you ever log up to and past redline on it? I'd be interested to see when (if?) the boost pressure drops back into the MAP sensor's range.
 
Morgan-VAGCHECK said:
Hi Welly,

If you do find it then it would be most appreciated if you can point me too it, because if this was last year then the logs in theory can only have come from my own TT... & I don't remember posting any ! (That said my memory is ****e)
Click to expand...

Will do. I'll have a look later.
 
Sorry to add to the drifting off topic Dane, here's a log of mine with the JBS manifold, i know they aren't available yet but you never know one day they might be.
sandip1-1.jpg


So is the main benefit of a higher flowing manifold so that the k04 can spool up a lot quicker??
 
high flow manifolds are there to support the flow.... and sustain it not choke it like oe one does.
whether it spools faster? hmm dont know.

Picture of TSR's mani for ref..
S7000891.jpg

fitted
S7000902.jpg


Mine is looking nothing like this - lol for good or bad
 
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slappy_dunbar said:
Morgan --- the spool you are getting on that manifold is excellent. I would put that as the standard to beat for any combination of hybrid turbo / aftermarket manifold. Did you ever log up to and past redline on it? I'd be interested to see when (if?) the boost pressure drops back into the MAP sensor's range.
Click to expand...


Hi Slappy,

Thanks for the comments.

Spool is certainly not any real issue as you note.. however I am experiencing some very light surging. It’s not so bad pressure starts to fluctuate, but certainly flow can be a little unstable at lower rpm’s when stepping on the gas unless I limit the pressure to a level I find well... unexciting

My own (hard) rev limiter is currently set at only 7100rpm although I will be raising this, so I have no logs higher than this currently.

Below is an example from the same days testing nearly touching the rev limiter with actual pressure on top measured at ~1.65 bar on my external logger. (There was less pre-load on the actuator to the log above, but a little more N75 DC allowed)

TSR-Mani-MT09copy.jpg


If anyone is wondering about the very high IAT's, these logs were more from an initial "endurance & is it going to work" mani testing session on TSR's dyno hence some long pulls at full load... IAT's do not get as hot as this in real world conditions.

Regards
Morgan
 
badger5 said:
you done much more on it since november last year?
how would you sum it up if complete?
Click to expand...

Hi Bill,

Mapping wise very little has been done.. mainly due to it taking a back seat to customers vehicles, but also plenty of little unrelated hardware issues to be resolved.. fix one thing & in a matter of days I find something else needing attention..

Leaking core in a few months old Forge FMIC... coolant leak on OE oil cooler jacket, fuel pump headaches, trip to bodyshop thanks to some idiot etc

The only real progress with the mapping is it is now calibrated for & using a 3bar MAP sensor, so I can keep boost control fully closed loop.

If I had to sum it up... its been a royal pain in the *** !

I would like to think "hopefully" & assuming no more bad luck, it will all be finalised around late June.. bearing in mind I can't currently work/drive/make any progress due to the op.

Regards
Morgan
 
I'm going to pop over tonight if thats alright Bill?

Also any word from Milltek?
 
Welly said:
That sounds useful - planning on running N75 control?
Click to expand...

Hi Welly,

My boost has always been controlled via the N75 with this hybrid... however previously in an "open loop" type manner.

Regards
Morgan
 
ps make sure your heat wrap goes around your Forge charge pipe kids

6ca311e0.jpg


melty melty
 
I think I ripped it, and now it won't stay in place :ermm:

My Sig is getting a letter every day until it says Badger 5 edition or I get my car back lol, It's a count down of sorts.
 
It came off easy enough, it had just melted around the lip on the charge pipe over the mani, I haven't been driving it that hard... honest :ninja:
 
There we go, thats the reason, Westle broke something else on my car! Thrashing it around the roundabouts - me clinging on for dear life :)
 
:lmfao:

he slapped me about and all! :slapped:

I can't remember what the first thing was(n't)
 
I appear to have de-railed my own thread lol
 
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back with new bottle, on contract with air-products now. smaller bottle, higher pressure built in regulator.. bought another flow gauge also now so I will have full control of purge.. I have to say tho this mani is a proper PIA to make
 
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