Ex850R;c-160194 wroteThat's a nice collector, way better than std but std was made for tight spot.
Have you seen the builds where turbo is sat where the battery and airbox was originally, it's longer runner to it but it opens up options greatly. Like sequential turbo to get rid of low down lag?
If you are referring to the collector I have fabricated, it does fit in the original space and location. Took lots of head scratching to make it work, but it is a bolt-on solution with a few little tweaks to tubing

It is clear that the Audi and BW engineers have put a lot of research and effort into this manifold/collector. Much more than a conventional turbo setup. Under 500hp I cannot see any way of improving its performance. Regarding relocation, I've built many "sidewinder" style manifolds for different engines and it has pro's and con's. Testing with thermocouples at the manifold entrance and at the turbo entrance I've seen differences of delta temperatures of up to 150`C.

On the plus-side, the engine will "see" a larger turbine housing as a significant amount of thermal energy is lost in the length of tubing. This means that the engine can make more peak power as it effectively has a larger turbine.

The cons include more radiating heat into the engine bay, a higher probability of breakage/failure and primarily a loss of transient response and spool due to the loss of thermal energy. You see this in WRX/STI's compared to a comparable engine with a comparable turbo as the manifold is so long. That is why Subaru has tried iterations of twin turbo, twin scroll and ball bearing to try and compete with Mitsubishi's simple and highly capable plain-bearing twin scroll setup...which happens to be a much larger turbo overall yet spools much faster

Well after realising the Audi manifold/turbo would not fit, I cut the turbo free of the manifold, built-up the scroll to the housing with weld and shaped it to suit the very compact proper-collect manifold I had previously begun to fabricate. It now fits perfectly including the turbos 5" outlet






5 days later
When the standard intercooler may be inefficient at the flow levels intended you can be smart and buy another intercooler, or you can be a little silly and join 2 standard intercoolers in to 1






???
definitely thinking out side the box
6 days later
Very interested to see the finished product, keep up the good work!
Raebird;c-160843 wroteVery interested to see the finished product, keep up the good work!
Thank you. The project has been delayed as i´ve had not 1, but 2 family members in hospital. Now that they are stable (though still hospitalised) I have just spent the last two days upside down cleaning the internals of the block and sump. The basic drivetrain is now installed. I´m focusing hard on weight reduction as do intend to use the car on the track both for lapping and roll racing. This means i need a manual transmission and many additional components for high-hp longevity.

I have always been fascinated by the 5-cyl character, but am currently considering if a turbo K24 (Honda) swap is more suitable, as spare/aftermarket parts are so readily available. I know that sounds sacraligeous but think about it.... there are always questions regarding the white block reliability whilst the k24 motor can support 600whp on a stock engine, the engine+gearbox is approx 90mm shorter and weighs approx 30-35kg less. this would also remove the massive array of plumbing (vacuum, water, cabling) that is associated with the white block. The K24 makes more hp and torque than the white block (both being N/A) and over a wider rpm band. Also being 4 cyl I could make best use of a twin-scroll manifold and turbo manning better response and powerband.



20 days later

So I realise that many may not appreciate the direction of this project, but it is something I have wanted to do since I first saw the Volvo Estate in the BTCC in 1994. I'm building this in a way I think Mr Wilkinshaw would've looked and had a laugh while saying "that's cool".

Currently cutting-out the sheetmetal and replacing with a mid-mounted engine setup and a triangulated internal frame/cage for a central driving position....no passengers here. A carbon flat floor and diffuser will be installed once finished.

This will keep all the weight within the wheelbase and as close as possible to the roll-centreline. Obviously practicality is not a consideration...it is just to take to the track and have some fun and run some good lap times.

Still yet to decide whether I use the K24 engine/box or the Volvo engine/box. I need to decide to continue to progress.

Also taking painstaking measures to reduce weight....great lengths.

Goals as of now are to be under 1000kg, hopefully under 950kg. Lap time goals would be under 1:45 at SMSP and under 1:05 at Wakefield Park and will probably run it down the 1/4 (though I'm not a big fan of drag racing) and see how it goes.

Builds like this are why I started this forum 🤤

timbo "Midmount rwd config? "

Yes, RWD. Basically the same transaxle setup as one would have on a normal front-drive, but sent to the rear-seat area. At the moment the rear of car is light enough that I can pick it up off the ground with no great trouble with my own hands

    You can just take the complete sub frame set up and drop it in the rear, a good friend of mine did this in the UK, he also kept the front engine as well, I'll dig you up a few links if you want, however I think you're well capable of sorting it yourself 😁

      Jamest5r_

      You can just take the complete sub frame set up and drop it in the rear, a good friend of mine did this in the UK, he also kept the front engine as well, I'll dig you up a few links if you want, however I think you're well capable of sorting it yourself 😁

      Correct. I will be using the rear subframe to line things up then create my own mounting system and suspension

        https://www.facebook.com/carthrottle/videos/1608381752506202/

        He's also supercharged both engines as well 🤣 he a bit of an mad scientist type

        Yes, I have seen his project. I really admire his ingenuity and motivation, especially when you see he is sometimes knee-deep in slushy leaves and rain. Also I think it is cool that someone so extravagant and adventurous chooses a brand of car that is so predicatable and understated. However, i think his direction and mine are somewhat aligned but mainly in a different direction, as I tend to work in a different way..

        7 days later

        Following this one! I always had the crazy idea of an 850 wagon or V70 with dual engines...single rear engine is awesome too!

          carnut222

          Following this one! I always had the crazy idea of an 850 wagon or V70 with dual engines...single rear engine is awesome too!

          I considered it as well. Having two Volvo drivetrain sitting here is tempting, but it is also a lot of addional weight and complexity

              360cf
              carnut222

              Following this one! I always had the crazy idea of an 850 wagon or V70 with dual engines...single rear engine is awesome too!

              I considered it as well. Having two Volvo drivetrain sitting here is tempting, but it is also a lot of addional weight and complexity

              Yeah, I know what you mean. It’s pretty mental doing a twin-engine car. I worked at GM in Detroit and they built a twin V6 Chevy Citation (GM X-body...yikes). It sounded insane...imagine the sound of duelling 5-cylinder Volvo engines! Mmmmm! Could have a lot of fun in the paddock but not sure the RTA would allow a dual-engine car here in Oz.

                  a year later

                  Finally a bit of progress. I have not forgotten about my project or given up. In fact, the pace of progress will begin to pick up.

                  My new turbo setup. It uses a Fabricators Warehouse turbo manifold and dump pipe setup. In this photo we have the Pulsar Gen2 GTX3071, all in v-band. The reason we went with v-band is it will allow us to change to a G30-770 if needed, as the “footprints” are interchangeable.

                  The drivetrain will be going in the back of the car, hence the long turbo manifold and unconventional exhaust layout

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