A G-Lader on a diesel? that`s really cool!

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Project Topic: VW Golf MKII 1.8T daily tracktoy

Insta: https://www.instagram.com/turboclouseau/

YT: https://www.youtube.com/user/renerene1984/videos

Ah congratulations, it turned 25 last month!

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Who? What? Where?

Oh yeah, well [filling in lame excuses:] it was kinda late last night,.


Anyway, I forgot to mention it: I also sourced a original Polo 2 GT G40 intercooler, and got some other stuff for the Volkswagen 'Classics' department in Germany to: 'Windleiter fuer ladeluftkuhler' and the part from the 'Schlosstraeger' came from those guys in Wolfburg... And 4 brand new 'vorstrahl' diesel injectors to. They are waiting to be installed, after I had the properly adjusted to 245 bar opening pressure.. Man do they 'crack' on opening! That's the con,.. the big pro on this kind of level of 'DöD' is the even the thickes lard will squeeze out in a nice straight cone of 'ready to ignite' fuel. That, and the Bosch Duratherm Chromium glow plugs will make it possible for a cold start on straight vegetable oil.

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X2!

I wonder if that would work with a G60 and a 1.6/1.9 diesel engine? Methinks the injection pump and G60 would interfere...

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If you have a 5 cylinder, you don't need a stereo.

1999 Audi A6 quattro
1990 Volkswagen Golf CL Syncro
1987 Audi Coupe quattro

any updates pookie?

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Nah,. Did do a wheel toss last night:


http://www.youtube.com/v/85SDCBw1bHU

The Diesel is now back on it's own summer wheels, the HoekHoek (formally known as ToekToek) finally got it's white rimms

(Centra Pepperpots, NOS, 14x6 et38, with P6000 175/50 r14 )

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fixed link

(Music: Morphine - Sharks )

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small update:

I just can't kill the 1300cc diesel engine I put in last year.. no matter how much I abuse the little basterd; It keeps on going.

It made me feel heroic, and I could not resist to take the car for a spin ( or 3 to be exact ) on the legendary Nurburgring Nordschleife..




Meanwhile,. the 2 or maybe even 300.000 km's only made it take about 2 liters of oil..

The abscence of any power at all forced me to take some measures on my timing skale (which doesn't exist)

Working on an inlet.

First attempt:



It turns out there might be appropriate space between the firewall and diesel-pump anyway....

From the top looking down, it sure looks like it might fit, but in real-life it's all quite crowded. Bonnet squezes everything down and does lock, but with any movements of the engine, it probably won't take long to have friction dismantle the lot...



Some space can be acquired by modifying the brake-servo's position masterbrake
still in doubt if I need a pressure-regulating system:

Standard fit on empty-body-shell:



Modded fit (top down)



But since I will fit a newer model servo, including a shorter masterbrakecilinder and small reservoir, It might be obsolete to mod the mount anyway..

I still haven't figured out if I need a pressure regulating system.. Will I need a boost-control-thingy? Will it idle under pressure? Since Google only goes 'Wisssssh" and 'Woooosh" (2fast-2furious kids) when I search for a decent, working blow-off thing, of regulation.. and there's only crap available for diesel engines (turbo charged, no mechanical compressors found yet)

We'll see.

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cool, "where no man has gone before".............

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"To boldly go..."

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WARNING: Crappy phone pics up ahead

had some welding done yesterday:



Test fit on a external engine (nevermind the dutch). With the pump on maximum pre-injection, there's room, but only just. Nothing serious, since the fitting plate has some room for adjustments build in. The (gas?)lever is freely manouvreble.

Test fitment in the car:



I hoped I wouldn't have to adjust any original Polo 2 G40 intercooler hoses, but it just won't fit.. where't that chainsaw?

Sample pic: standard Polo 2 GT G40 (petrol):



As you can see: the piping with 'Ladeluft gekült' on it won't fit,. so, to go with Dexter: "Let's Modify!"



Oh and I've been working on the engine aswell,. to make it only a little more 'Veggy-power-capable) new (brand new) injectors, slightly adjusted to 245 bar opening pressure :grin: , brand new glowplugs, Bosch Duratherm Chromium,.



Note: the glowplugs are just a few mm's longer.. but now there just off-center from where the diesel injector will spit it's veggy-juice:




With the mods it should be capable of doing a cold start on 100% vegetable oil.. in mid winter (and with the electric pre-heater, heat-exchanger, huge fuellines and isolation it'll be sweden capable )

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It's been a month now since my last posting, so time for an update..

I allready bought myself a G40 charger (Polo 2f, later model).. and have been sourcing specific Polo 2 G40 stuff since then. A Polo 2 G-charger would offcourse be the cherry on top, but I since there's a serious chance the charger will blow, and I'm not willing to destroy a 'typ 1 charger' for that purpose.

Anyways:

G-charger exit arch: Not the differences between radius and thus ' height'




Not only is the 'off-set' different from the polo 2f charger-exhaust, it's got a different angle to:




On the good-old Polo 2, the intercooler is fitted allmost directly underneath the charger, since there's no real space in the car front section. With the longer, much rounder front on the 2f, Volkswagen decided they could make things much easier for there mechanics to change stuff on the ' most powerful polo', and reduce production costs abit more. The Polo 2 G40 was quite labour intensive to build. I've read somewhere in the past that even Karmann was involded in cutting up the front section and installing the G-charger...

Anyways:I bought my charger from some guy who's doing a lysholl swap on his Polo, and the visual state of the charger was quite good. I had ' Arno ' do a checkup, and he did advice to do a complete rebuild. Picked it up last month:


It's the 51'st charger he has rebuild, and included a full 'glass-perl-blast-job', all new wearing parts (seals, bearings) a fresh lube with kluber grease, etc etc..




He did a fine job, and I really like the way he's working: clean, exact and patient.

I've been collecting polo 2 G40 hoses and piping, but the pressure-tube directly from charger to intercooler isn't easy to get a hold off: the Polo 2f version is much longer and weaker (tends to tear), the Polo 2 version is enforced, and secondhand allmost as expensive as a brandnew one from vw-classicparts (volkswagen-museum-parts-supplier).




(badging is obligatory)

With all these components, and a assortment of exhaustpipe arches,.. I think I've got the pressure side collected:




First test-fitting on the engine: no problems at all:





But,.. As you might notice, (and what I've stated before) there's about no room for the tubing to get from intercooler to inlet..




about this much:




To get ' a little extra room ' I've changed from old to newer type masterbrake cilinder:
which not only has a less spacious boosterdrum, but a shorter cilinder and reservoir:



See:



With a little help from our friend from ' bayern ' ( 90 degree angle tubing from A BMW 5-series diesel ) the top section is fixed:


..

The sub-section is mainly the intercooler part. Cut away some sheet-metal:




to get this result, completely in ' stock Polo 2 GT G40 Cup look '




bought a brand new radiator,. since the large Dieselrad will interfere with the charger




modded the front-travese section:

original:




convinced some metal to change shape:




Pliers and a blowtorch made it look like mid-evil:




fresh sheetmetal, a A smear of bondo and a large-hole-cutting-thingy-on-a-drill made this possible:




After a respray, no-one will notice the difference between this and a original Polo 2 G40




Keep you posted!

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the framerails look perfectly stock.. great job, and love the cut-outs on the lower lip.

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Nice job Sjampoo!

i contacted you before because I had similar plans. But no way I could have done this myself--> Respect!
Will you change anything on the diesel pump? Since your engine is boosted by now it could use an LDA; or isn't there any space left cause of the ic piping?

Grtz,

Ruben

Maybe it's the wrong way around, but I'm doing it the ' trail-and-error ': For starters I'll only enrich the pump (since the charger will blow from low to high revs: even on idle speed there's ' pressure ').. But if it all fails.. I'll be paying DA-brt (or what's his name) a visit to get my pump fixed/tuned/lda'ed (he doesn't know yet)

By the way: About ALL metal work has been done by Marcel86c, so mainly all credit goes to him: I'm one the guy getting his hands dirty with oil/paint/crap doing nothing really

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awesome work.. can't wait to see it done

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'68 Type 3 Squareback / Rabbit Truck 2.0 16V ITB

G40 diesel... Simply awesome. Why didnt VW think of this themselves? Any guess what hp this thing will make?

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If you have a 5 cylinder, you don't need a stereo.

1999 Audi A6 quattro
1990 Volkswagen Golf CL Syncro
1987 Audi Coupe quattro

Very nice! Looking forward to seeing this completed. Still a great idea, always wanted to build a G60 diesel, but you beat me to it!

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Caddyke......

With LESS than 3 liters consumption per 100km

But I'll be satisfied with less then the ' 5.8 ' that it's currently doing:

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