Project Golf TDI ARL - PD300 304hp/530NM Now FOR SALE

[bobby singh]

Project PD150
　
Some of you may know I’ve been modifying my golf over the years and edited this thread to show a bit up to date information.

I ran the car on a stage 1 remap for approx 2 years. After this I done whole load of work and research to reach a MAX power figure of around 230hp. For anyone that reads this thinking 230hp is obtainable from a hybrid please think again as I had to run a very aggressive/unsafe map to get this figure. A true (and I mean a true power figure) for all VNT 17 based hybrids is around 220hp on stock nozzles.

I have now moved away from VNT 17 hybrids a fitted a bigger turbo unit, bigger nozzles and lots of fabrication work.

Heres the story

March 2008 - Clutch
　

In addition a new Sachs Dual Mass Flywheel and release bearing were fitted.
　
April 2008 - EGR Replacement
　

　
Before
　

　

　
After
　

　
As I have blocked the exhaust manifold end I decided to remove all this (not had any problems with cabin heating):
　

　

May 2008 - 312mm Audi TT set up - these might look like scrap metal but they are actually in very good condition

　　
May 2008 - Hybrid turbo based on a VNT17 - with bigger exhast and compressor wheels
　

　
May 2008 - Turbo back Milltek exhaust system
　

　

May 2008 - New top suspension mounts (plus bearings), ARB bushes and 312mm set up fitted

　

 

[bobby singh]

　
May 2008 - Exhaust system fitted
　

　

　

　
May 2008 - Picked up a rear Audi S3 brake set up 256mm vented with calipers & carriers
　

　
June 2008 - Alloy boost pipes finally landed
　

　
June 2008 - Alloy boost pipes and turbo fitted
　
Ok lets start of with the turbo first:
　
Fitted
　

　
Next the Allard pipe kit:
　
First problem no documentation 　
　　
Second problem tyre rubbing on alloy pancake pipe
　
Third and forth problem top boost pipe to inlet not correct - the gap is just shocking, so ended up making rubber mounts and then bolted it down.
　
Bigger rubber mounts fitted to hold top boost pipe and to over come pipe making contact with power steering fluid tank
　　
Problem number 5 the lower boost pipe bracket gap is just too far apart to bolt together.
　
Ended up making an alloy spacer and drilled another hole for alignment and trimed the extra off
　

　　
Also note the swarf inside the Allard pipework - this MUST be cleaned before fitting
　

　

　

 

[bobby singh]

June 2008 - Upgraded dog mount bushes
　

　

August 2008 Audi S3 Rear brakes 256mm


Calipers cleaned up and painted

6mm spacers required

October 2008 After a few development map the Final map is loaded and RR booked

No smoke and running 1.9bar boost

December 2008 - OEM Xenons

Order all the parts needed for the loom:

Loom made up:

Used oem tape for the loom:

April 2009 - More boost and fuel

Now with increased boost and fueling - boost mapped to 32psi. However, map is not as clean as the 220hp map in terms of smoke.

Flywheel figure

 

[bobby singh]

August & September 2009 - Water/meth injection

Decided to fit water/meth injection - I ended up buying the Devils own kit stage 1. The kit comes with everything you need. I also went for the dual nozzle set up (pre turbo):

Started work on fitting the nozzles - first started with the inlet manifold

Tapped the 1/8 NPT threads:

Repeated the same process on turbo intake pipe (pre turbo)

Fitted the self sealing bulk head (22mm hole required):

Fitted

Relay and pressure switch:

Custom bracket for the water pump

Been to set up the WMI on a rolling road and below are the outcomes (Red line is the last RR session without WMI and Blue is with WMI on) as you can the peak power is pretty much the same but the power over the same rev range better (holding power). I found having the WMI coming in at 18psi worked best for me. I also ran without the pre turbo nozzle and confirmed it made no difference to power so I'll be disconnecting that. In the future I'll try mounting the nozzle before the map sensor. Looks like if you want more power you'll have to put in more fuel and live with the smoke or get a bigger turbo.

UPDATE - 2010

I've experiemented with having the MAP sensor AFTER nozzle and can confirm it made no difference, since fitting the bigger turbo I have now removed the WMI system as the cylinder pressures are already too high.
Bigger Turbo and larger nozzles - Dec/Jan/Feb & Mar


Nozzles:

 

[bobby singh]

Turbo pics:

Note there is a lot of fabrication work that needs to be done such downpipe etc and the nozzle install is not straight forward and a lot of attention needs to be paid at different stages.

Any how the end result is excellent power delivery with a more usable power range over a hybrid. In fact the car is a total animal Running 2.5 bar boost

With the right mapping this is possible:

April 2010 - Santa Pod

Went for a 1/4 mile run and managed a 13.9 @ 102mph - Its quicker than i was expecting

Video




Further mods are still possible but i think its time to enjoy this!!! (until i get bored again)

All the work was done by myself, however I did get help from the following people:

Fenwick - gave me the push to do this

Ray and BoraChris - excellent for bouncing idea's off and for getting me some exhaust bits

Virdi and TBCupraT - for lending me a hand and helping with logging

Cheers
Bobby

 

[barney501]

Bet this is a bit of an animal bud, is it much of a looker or more of a sleeper??

 

[robjnr]

Fook me you are running 36psi of boost?

 

[bobby singh]

I will stick some pics up of the car but its totally stock from the outside

Boost wise its logging at around 35psi so not truely 2.5bar but it sounds good lol

 

[Lee Edgecombe]

I will stick some pics up of the car but its totally stock from the outside

real sleeper then

 

[gezmeister]

Very nice spec bud, done any quarter mile times yet?

 

[bobby singh]

No 1/4 miles run on the new spec but hoping to do some in a few weeks

 

[bobby singh]

Re: Project Golf TDI ARL - a True 266hp

Went for a 1/4 mile run and managed a 13.9 @ 102mph - Its quicker than i was expecting

Video

 

[bobby singh]

Re: Project Golf TDI ARL - a True 266hp

April 2010 - Car pic's

For sometime I've been asked for pics of the actual car..so here are some:

Cheers

 

[gezmeister]

Re: Project Golf TDI ARL - a True 266hp

Proper sleeper, i like it lots

 

[deanomite]

Fantastic and very interesting, love it. Does it smoke any less ?

 

[sssstew]

love it, looks standard from outside... absolutely brilliant

 

[bobby singh]

Thanks for comments guys.
As for smoke yes it does smoke especially in hot weather condition like today. I've noticed anything above 20degree air charge temp i get smoke/haze.
Note I'm still running the stock intercooler atm.

I've got a volvo inlet modified to go on pretty soon just waiting for my welder to sort out the custom TIP thats also needed. This should also help keep the smoke down.

Cheers

 

[Tony T 1985]

this is awesome - i'd love my car to have this power - maybe one day

 

[Wash It!]

Definitely time for you to enjoy the car bobby_singh, looks like you've done a lot of hard graft.

Sleepers have always been a firm favourite of mine.
This one is sweet, hats off to you.

 

[bobby singh]

October 2010 – Intercooler

Well the new found power didn’t entertain me for long, so I’ve decided to go further. In preparation for the next step I thought I’d change the intercooler. This is an OEM core (which I think are best) with modified end tanks. I didn’t have enough to time to make it perfect as I needed the car back on the road ASAP. Anyways after a lot of grinding, cutting, welding it was on – lets just say the angle grinder was my best friend 

Intercooler:

Stock Set up:

Fitted:

January 2011 – Big valve ported and custom grind cam

Over the Christmas and new years period I’ve been busy fitted a big valve ported head.

Oversized Valves:

Head: