Superb attention to detail - a really enjoyable read. I notice you had a Mk2 grille though - did you decide against fitting it?

Number crunching
 

Thanks again for all the comments, really does mean a lot :)

Had the car on the rollers on Monday,
Ill let the figures do the talking.
Standard: 101 PS / 177ft/lbs
Monday: 132 BHP / 230 ft/lbs
Now: 166 BHP / 300 ft lbs

That was 28psi boost but the exhaust manifold pressure was 26 psi so a ratio of less than 1:1 which is brilliant. As Im sure p_b82 will testify.

Exhaust manifold pressure on the standard turbo was 30 psi at just 19psi boost and that was before extra fuel was added.

The clutch held the torque no problems so a worth while upgrade.

Was very little smoke with the fuel pump maxed out on the SDI injectors so fuel is the limiting factor here.

Got some different injector nozzles on their way to experiment with so more to come :D

http://i276.photobucket.com/albums/k...psd249bfce.jpg

Good results, bet it goes.

:smile1::smile1::smile1:

nice results - same as my car currently runs up top - but without an exploding HG. well done to you and getting the ardino setup correctly.

you trying the 300TDi nozzles then, or darkside got something magic up his sleeve for you?

Im going to try a few things because Im really in the unknown now. On the list to try is:
Wingy injectors
200tdi nozzles on standard zs bodies
300tdi nozzles on standard zs bodies

Beyond that Im a bit stuck for ideas really. To be fair if non of the above work its not the end of the world, she pulls like a train now but doesnt smoke like one so I suppose I should be happy with what Ive achieved and stop there. As we all know, its never the way with cars...

Ive been meaning to ask by the way, what are your experiences with injectors over the years?
Ive only ever run my SDIs so far.

Yeah, it is never easy and a lot are unknown.

I would be wary about long term issues unless the spray patterns are verified to be correct - just because they are unknown really. the angle might be right but they may not squirt it into the correct location on the bowl.

I have used wingy's that I felt were not running right as they smoked and smoked and smoked. Matt could not get the torque up on them.
I sold them to byronstigly on .org and in his SDI they were slower - I got my hands on a second set and sold them to him and they worked for him.

I then swapped out to the hybrid injector - been using that ever since and have little smoke on them as it stands.

I have never used standard SDI's, so i dont know, but I was told by Matt that he did not think the hybrid flowed quite as much as SDI's... .org didn't think that should be the case.

I know for a fact they are a lot less smokey based on a number of people popping them in after using SDI's.

So did you never run with the second set which you sold to Byronstingly?

Ive won a complete set of 300tdi injectors on ebay which are on their way and Im bidding on a set of 200tdi injectors so plenty of experiments to come.

Ive no idea how to test or get the spray angles tested for similarity, you dont have any ideas do you?

No never put a set i was comfortable with in, and didn't need them on the hybrid injectors (sdi nozzle on zs body) got me up to 170 and 270 and no smoke....

well as we know that is more than the turbo can take and the rest is history.

I would think you need to get them sent off to a specialist - though you *might* be able to set up your own test bed on a bench with a spare fuel pump - but no idea on how you go about working out what the patterns are and if they would be suitable I am afraid.

Kris may be able to help give you pointers on that one though.

Time for an update,

So, since the rebuild she has been such a joy to drive and own, no other car has put a grin on my face in the same way this one does, especially since the remap.

The turbo is still working a treat with no seized vanes and the controller is still reliable and working well with the external wastegate.

Other than the routine maintenance, the only other mods have been carried out today and are possibly of interest to a few...

The picture below shows a few of my sets of injectors, in addition (not shown in the pic) are another set of standard 210 bar ZS injectors and the SDI injectors which were in the car when that picture was taken.

Top left, another set of standard ZS injectors
Top right 200tdi injectors
Bottom left, Dans clamps (before I finished them off)
Bottom middle, 300tdi injectors
Bottom right, 300tdi clamps (no use but they were sent with the injectors)
http://i276.photobucket.com/albums/k...psa776f2d6.jpg

So I first made a set of hybrids using the standard 210 bar bodies and the nozzles taken from the 300tdi injectors.
Looking at the holes on the end, I double checked the angle which the injector needed to be rotated, it correlated perfectly with the angle Dan's clams were set at:
http://i276.photobucket.com/albums/k...ps8849978b.jpg

The difference in angulation required to place the spray holes correctly
http://i276.photobucket.com/albums/k...pscea3646b.jpg

http://i276.photobucket.com/albums/k...ps1e730bb9.jpg

The finished 210 bar/ 300tdi hybrids:
http://i276.photobucket.com/albums/k...psfae0e043.jpg

And the clamps:
http://i276.photobucket.com/albums/k...ps24562a5d.jpg
http://i276.photobucket.com/albums/k...ps92f1b23e.jpg

I fitted them this morning:
First impressions were not good, lots of white smoke on start up and it was slow to start too, even once warm but it did get quicker as they day went on. Idle wasnt great either, fairly lumpy.
That is where the bad news ended though, I did a 70 mile drive with them and they were so much fun, in-gear acceleration can only be described as savage, much quicker than the SDIs.
Despite my car being quicker than ever, they need more work before Im happy with them so as soon as I got home I was straight in the garage making the second set of hybrids:




So for these, I dug out a second set of standard 210 bar ZS injectors and mated them with the nozzles from the 200 tdi injectors:

Left, 200tdi injectors
Right, second set of standard ZS injectors
http://i276.photobucket.com/albums/k...psba37252b.jpg

Unlike with the 300tdis, you can see here the angle is the same between standard ZS nozzle and 200tdi nozzle:
http://i276.photobucket.com/albums/k...pse3c690bf.jpg

So there we have it, the completed 210 bar/ 200tdi hybrids on the right:
http://i276.photobucket.com/albums/k...psf02eeafa.jpg


First impressions of these are much better. It still pulls really hard (not quite as hard as the 300tdi hybrids lower down though) but it idles like standard and should hopefully fire up like standard too, Ill report back once Ive done a proper cold start. Being dark, I cant see exactly how much smoke they make but Im willing to bet there is a fair old cloud on hard acceleration.

So far though, the 200tdi hybrids are looking pretty good and the 300tdi hybrids have potential but I think require better atomization to improve the idle and starting, maybe increasing the break pressure above 210 bar would help? They are definitely amazing fun though just not for a daily driver in winter!

Good read, good luck with it.

What does it sound like at tickover???