The Green Monster Project - Stroker GT30

[Faheemo]

Hold on to your hard on for the Head Job porn show i have ..

[Jamo]

Got my mate to pull the engine out, and take over the engine repairs.
Searched the breakers yards until i found a good crank, from a 2.5Ltr VW microbus (transporter). 92.6mm stroke.

@ Jamo - I recall reading from Marcos stroker post that 92.6mm crank on 220mm block is capable of revving to 8500rpm safely. have you done the math on this ? - I havent. Other wise i have just wasted alot of money on a good head job for my car.

* Faheemo goes to pull out calculator and sharpen pencil *

Not a chance in hell

a) Hydro lifters cant survive above 7.5k rpm

b) Where has this 92.6 crank come from?

Never heard of it? I know of a 92.8 that 034 sell from the industrial machines.

[Faheemo]

Not a chance in hell

a) Hydro lifters cant survive above 7.5k rpm

b) Where has this 92.6 crank come from?

Never heard of it? I know of a 92.8 that 034 sell from the industrial machines.

Correct - Hydro Limited to 7500 - max 7800rpm.
Meant that In theory what would the safe piston speed be.

I always understood the crank to be 92.8mm but Javad @ 034 claims that its 92.6mm.
The crank comes from a 2.5ltr 10valve engine found in the 2.5Ltr VW microbus produced in south africa and mexico until about 2002.
http://www.motoring.co.za/index.php?...ticleId=230383
part number is 034 105 101 J verified by local VW agents in SA.

[caterpillar]

it shuld be 92,8 i think: they are in 2,5 liters 10v microbusses lie the pics( rare car , then they are from 95-2001 for south africa) but the crank are inn front engine cars too; like the PETROL 10v engine 2,5liters( in norway , in ambulances)..... and use the 92,8 crank and dieselblocks and really long conrods( 158-165mm ) you may turn it too a stroker, AND high rpm tooo..... RACE IT!

[caterpillar]

a gt 30 are tooo little for the stroker, anyway and 7a camms arent the best way to go.... MORE camms(dur and lift) and really bigger turbo will do the job +55-60mm inntake and A/R at +- 1,0

[Jamo]

GT30R works just fine i've seen 3 dyno plots now with GT30R and stroker engines and it's the perfect everyday turbo with serious power.

1 plot of Aronmatics and one of 034 then other on motorgeeks all superb.

[Faheemo]

a gt 30 are tooo little for the stroker, anyway and 7a camms arent the best way to go.... MORE camms(dur and lift) and really bigger turbo will do the job +55-60mm inntake and A/R at +- 1,0

My turbo has 0.86 AR - it was purchased without the intention to run on a stroker. (b4 the meltdown)
I've been looking at the dyno plots from various audiouns around the world and confer that maybe a GT35R would have been the all out - big balls turbo to run on strokers.

But then again as Jamo put it the GT30 runs fine for everyday with serious power !!

I do have some other serious headwork and bigger valves for increased performance in the higher rev range. may kill the bottom end - but i not interested in bottom end.

Head Job Pictures to follow soon. heres b4 the work.

[Jamo]

a gt 30 are tooo little for the stroker, anyway and 7a camms arent the best way to go.... MORE camms(dur and lift) and really bigger turbo will do the job +55-60mm inntake and A/R at +- 1,0

http://www.motorgeek.com/phpBB2/viewtopic.php?t=15035&postdays=0&postorder=asc&highlight=stroker&start=25&sid=c2f53f768ae1420ce700d57b2144788d

Notice the quote

Thoughts on the build...
If you like torque and can afford a 2.6...DO IT! Don't over turbo the engine. A GT35R might "seem" better for the displacement and will put up bigger bragging #'s but The powerband will be narrower and you're already limited to around 6500 redline. (Unless of course you don't mind replacing engines on a regular basis.) The GT30 was a perfect choice for this car. The torque band is amazing, unlike anything turbo car I've ever driven except possibly a few Buick GN's with a lot more displacement.

Here are the stroker dyno plots with a GT30R

Red Barons 220mm block 95.5 crank



Christian 034 220mm block 92.8 crank



Aronmatic2 220mm block 95.5 crank





I don't see a thing wrong with this turbo for this application

[caterpillar]

ok, i'm a rpm head, so i like more rpm before the torque goes down..... the gt 30 for the every day use; its powerful
i like the every day use,AND raceready at the end of the week.....

[Faheemo]

I'm happy with what the turbo is capable off. - just rite for monster street performance.
with the 3071 i killed an E55 AMG - not many street cars will be faster than me with my new setup.

Got the head back .. looks good.

20 x new billet cut 1 piece stainless steel valves.
Valves are oversize by 1mm dia.
Valve stems are narrowed down and valve faces machined to have good heat dissipation and light weight.
Valves and valve seats cut and radii-ed .

[A80Avant]

i used for a little while a manual boost controller.the effective way to use one is having it completely shut at first and then begin runs slowly opening it for more boost,while keeping an eye at the EGT sensors for the temps.i used it only for the time until i did my remap so that i wouldnt overboost more than 1bar.
i still have it for possible future use.

nice work done on the head.Im afraid to do something like this in the future.I read the thread on the south african audi club forum and i must admit that my car has eaten lots of $$$ and it is still eating on fuel.So possibly i will have a 430ish the most everyday car and if it manages to kill an E55AMG then it is good enough for me!
Im also glad i didnt go the tubular EM route and kept the RS2 manifold.Perhaps the only modification for the future will be a SQmanifold and that only if the rs2 one begins to break.Furthermore i have heard that in the UK there is a shop somewhere which uses special material to grind the inner tubing of the cast manifolds,making them with less pores.Now that along with cryogenic treatment i believe can do wonders!

What EM are you going to use now?

Also i noticed that you are also using water injection.My IM temps were getting much lower with it's use,and im not spraying any large quantity.snowperfomance also told me that the injector i use it topping it's perfomance for around 400hp,but since im not mapping with the WI on it is ok.good for the summer!Mt IM temps got down by 10C+ with the use of it,although EGT didnt the last few times i tried it because i was getting more steady boost when i used it!

anyway good luck and keep us posted!

[Faheemo]

I'm using a dual injector setup with a variable controller.
Water injection lowered my intake temperatures by 10deg as well, but i don't tune for water injection. The biggest advantage of the water injection is that the intake temps fall quickly after the car is stuck in traffic on hot day or you have a lot of heat soak in the engine bay.

I decided to weld my own Exhaust manifold ....
Read a post on Vortex and it looked like a DIY Job...
not too handy with the argon welding so after a while i had to call a friend to help me out. He's not so good either

Looks a little better after i ground the excess welding and sent it to the engineers to skim the surfaces.

[A80Avant]

what's with the big collector?i know it should help,but a question comes to mind....gasses still have to go through the hole exit of the EM,...so?do you think it will make a difference?

[Faheemo]

Heres Some good shots of the porting that was done on the head.
Pictures show :
1. Inlet
2. Exhaust
3. Valve stems

[Faheemo]

what's with the big collector?i know it should help,but a question comes to mind....gasses still have to go through the hole exit of the EM,...so?do you think it will make a difference?

The angle of the shot makes the collector look huge ..
I used of the shelf shed 40 stainless steel bends and tube for the runners and a cone for the collector.
Made it very easy, easier than fabricating the collector myself.
I'll post more shots of the manifold later.
I'm kinda embarrassed to post shots of my manifold - its like DIRTY PORN ...