W202 OM606 GT2359v+Pro52 - Printable Version

W202 OM606 GT2359v+Pro52 - Printable Version

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+--- Thread: W202 OM606 GT2359v+Pro52 (/showthread.php?tid=6189)

Pages: 1 2 3 4

RE: c220d om606 taxiSTD - erx - 06-12-2016

(06-12-2016, 01:16 PM)Mr_Robs WOW awesome man 505hp! I'm aiming for close to that with valve springs, NA cam, redone cylinder head and 16cm hx40 super 200cc 8mm pump too.

I'm surprised the 3inch is still causing restriction. Do you think you will do 4inch downpipe next and 3 inch for the rest of the system?

There was 4" downpipe and 3" muffler with 0,7bar backpressure. Now it is straight 4" to the end, few more improvements and then dyno again. I went to One Mile Challenge race, top speed competition on 1 mile distance. Got 259kmh on 1 km then cooler hose popped off and 1 mile speed was 276 without power. Next time we'll do better. Little overfuel, need more boost.

RE: c220d om606 taxiSTD - Mr_Robs - 06-12-2016

Interesting! Seems a bit overkill on the size of the exhaust but of course the results will tell all. Did you do a new WG spring at the same time as well? I love everyones reaction when it starts spinning tire in past the stands haha.

RE: c220d om606 taxiSTD - erx - 06-13-2016

(06-12-2016, 09:08 PM)Mr_Robs Interesting! Seems a bit overkill on the size of the exhaust but of course the results will tell all. Did you do a new WG spring at the same time as well? I love everyones reaction when it starts spinning tire in past the stands haha.

Seems a bit overkill really but if I asked my tuning specialist friend what could be the reason of not getting over 3,2 bar boost then the first thing he asked was exhaust size. He laughed and said that you have up to 1bar backpressure with single 3" and 600hp. WG is turned to max now and boost is 3.5bar, soon I test backpressure again and then I can say if it's overkill or not.
No grip on 3rd gear with 235 tires and 2.65 diff.

Great book says that 600hp is good with 2x3" or 1x4".

[Image: 12443134_10208509541198584_1203460122_n_zpsjicar0kh.jpg]

RE: c220d om606 taxiSTD - Petar - 06-13-2016

Note that chart is likely made for a gas engine and a diesel will certainly move more air per hp. How much i don't know but i would estimate 20-30% more

RE: c220d om606 taxiSTD - -Mackan- - 06-27-2016

Would have been interesting to see the hp/nm figures with the hx40 and 4" exhaust. I have seen people with 500whp + using that setup Smile

Have you dyno your car with the new exhaust and hx52? Smile

RE: c220d om606 taxiSTD - erx - 06-28-2016

(06-27-2016, 03:59 PM)-Mackan- Would have been interesting to see the hp/nm figures with the hx40 and 4" exhaust. I have seen people with 500whp + using that setup

Have you dyno your car with the new exhaust and hx52?

Yes I've seen videos of 500whp+ with hx40 but there's always little possibility that dyno shows a little less or more hp than another, so I never took other's results 100% accurate. Ofcourse bigger exhaust and some more adjustments would have made more than 433whp but now we are looking for 500whp++.
No I haven't dyno again, waiting for some parts at the moment.

RE: c220d om606 taxiSTD - -Mackan- - 06-28-2016

(06-28-2016, 01:57 AM)erx
(06-27-2016, 03:59 PM)-Mackan- Would have been interesting to see the hp/nm figures with the hx40 and 4" exhaust. I have seen people with 500whp + using that setup

Have you dyno your car with the new exhaust and hx52?

Yes I've seen videos of 500whp+ with hx40 but there's always little possibility that dyno shows a little less or more hp than another, so I never took other's results 100% accurate. Ofcourse bigger exhaust and some more adjustments would have made more than 433whp but now we are looking 500whp++.
No I haven't dyno again, waiting for some parts at the moment.

Yeah thats probably correct! Smile

Im considering if I should buy hx40 super or gå straight for the hx52. I do have an 8mm 190cc meken pump and straight 4" exhaust. What i dont want is mega late spool so it wont be abel to do a burnout. Im looking in to installing line lock as my next uppgrade. (To be able to disconect the rear brakes.

Im also using 722.6 and Ole Controler.

RE: c220d om606 taxiSTD - erx - 06-28-2016

(06-28-2016, 02:58 AM)-Mackan-
(06-28-2016, 01:57 AM)erx
(06-27-2016, 03:59 PM)-Mackan- Would have been interesting to see the hp/nm figures with the hx40 and 4" exhaust. I have seen people with 500whp + using that setup

Have you dyno your car with the new exhaust and hx52?

Yes I've seen videos of 500whp+ with hx40 but there's always little possibility that dyno shows a little less or more hp than another, so I never took other's results 100% accurate. Ofcourse bigger exhaust and some more adjustments would have made more than 433whp but now we are looking 500whp++.
No I haven't dyno again, waiting for some parts at the moment.

Yeah thats probably correct!

Im considering if I should buy hx40 super or gå straight for the hx52. I do have an 8mm 190cc meken pump and straight 4" exhaust. What i dont want is mega late spool so it wont be abel to do a burnout. Im looking in to installing line lock as my next uppgrade. (To be able to disconect the rear brakes.

Im also using 722.6 and Ole Controler.

I would definitely choose hx40 super, mine was with 8 blade small compressor, super would be better. Hx52 would be great with hx30-35, single turbo hx52 is very uncomfortable to drive. On 1/4 mile I was quicker with hx40 because spoolup with stock 722.6 is really slow, it needs high stall converter for drag race.

RE: c220d om606 taxiSTD - erx - 07-27-2016

Made some improvements, stiffer valve springs from KM Cams from Norway and 100kw na cam.

[Image: 20160707_233311_zpsutigxhxm.jpg]

[Image: 20160707_233344_zpsvuk8g6az.jpg]

New dyno results are 408kw/544hp/858nm from wheels, so about 480kw/640hp/1000nm from unopened stock engine.

[Image: 20160726_183614_zpsnppjtwgb.jpg]

RE: c220d om606 taxiSTD - TurboTim - 07-28-2016

I think me and you should look into a higher stall converter. I think it would really make our cars wake up!

RE: c220d om606 taxiSTD - -Mackan- - 07-28-2016

Awesome!

Did the valve springs and N/A cam make a big difference?

Do you run complete 4" exhaust now?

We need incar videos Big Grin

RE: c220d om606 taxiSTD - erx - 07-28-2016

Last time was 505whp/799wnm, this time 544whp/858wnm, so about 40hp and 60nm more. Only mods were valve springs, na cam and 4" exhaust. Hard to say which of them gave the most but I think exhaust was main problem. It was 3", now straight 4" from turbo to the back and Y-pipe to 2x3" before back resonator for less noise. On dyno sheet 502whp/826wnm was with one end pipe blocked, so only one 3" end resonator from previous 3" muffler was opened and it took 3hp/32nm off. Whole 3" muffler would have restricted a lot more than only end resonator, so I can say that 3" is small for 500+whp.

RE: c220d om606 taxiSTD - bigblue - 07-29-2016

Do you have photos of the 4" to 2x3" exhaust? I'm curious how you ran/fabricated it. I'm sure it's impressive looking

RE: c220d om606 taxiSTD - TurboTim - 07-29-2016

So it may have helped even more because you still have 4 inch down pipe during your testing.

RE: c220d om606 taxiSTD - bruno_pinho - 07-30-2016

Incredible numbers...

Make a video....my W202 with 420 hp (321 whp) goes already well,I imagine with 544whp.

RE: c220d om606 taxiSTD - erx - 07-30-2016

(07-29-2016, 06:04 PM)bigblue Do you have photos of the 4" to 2x3" exhaust? I'm curious how you ran/fabricated it. I'm sure it's impressive looking

It's nothing special actually. First I made 4" to the end for testing but it was a little too noisy. Big Grin

Now I have 3" resonator and one extra 3" pipe which is blocked when daily driving and can be opened on racetrack.

RE: c220d om606 taxiSTD - erx - 08-24-2016

Fastest diesel on One Mile Challenge, 296kph on 1 mile distance. Start is poor because I use 2.47 diff with stock 320cdi box and it takes time to spoolup with hx52. https://www.youtube.com/watch?v=zBd-uaGFLqY

[Image: 14040086_10154483752672704_1647899830533...64jf5y.jpg]

RE: c220d om606 taxiSTD - maxypriest - 08-24-2016

183mph!!!!!!!!!

RE: c220d om606 taxiSTD - -Mackan- - 08-24-2016

Very impressive!!!

RE: c220d om606 taxiSTD - NZScott - 08-24-2016

Wowsers that's quick!

Compound time? Tongue

RE: c220d om606 taxiSTD - Spoolin - 09-01-2016

This is bad ass! Awesome build, fabrication, and fantastic results. Thanks for sharing.

RE: c220d om606 taxiSTD - erx - 09-01-2016

Because from 300kph there are many safety requirements like roll bar, certified seat and seat belts, fireproof clothing, brake parachute and also fuel system needs to be completely rebuilt then I believe I will not go again to top speed race. Therefore I don't need max hp from engine anymore and next I try to make it more fun to drive. I want to use two turbos but I'm not sure yet which ones to choose, I think HX52 stays but not sure what smaller turbo to take. I want it to spool instantly so hx35 is big, I was wondering something like stock turbo from OM613/648. It should spool instantly and hold nicely to 4000 when hx52 takes over.
I've driven 7.5mm pump with stock OM606 turbo with boost raised to 2bar, it was very fun on street, spools instantly and great torque on low rpm.

RE: c220d om606 taxiSTD - erx - 10-30-2016

Now running with Baldur's DSL1 and EDC pump.

[Image: 20161030_232804_zpstvcpx3nd.jpg]

RE: c220d om606 taxiSTD - Hario' - 10-31-2016

How about a small blower mounted where the AC compressor normally goes?

How is the user interface for changing fuel points in the map on the DSL1?

Excellent choice of laptop sir!

RE: c220d om606 taxiSTD - maxypriest - 10-31-2016

(10-30-2016, 05:35 PM)erx Now running with Baldur's DSL1 and EDC pump.

How many CC's can the EDC pump supply and what size elements?
very interesting development.

RE: c220d om606 taxiSTD - erx - 11-02-2016

I went back to 7.5mm because 8mm was making horrible knocking noise and I couldn't burn 220cc. I modified EDC pump magnet, so rack travel is now from stock 18.5mm to 21mm, it should make max 180cc. These EDC and DSL1 are all new for me so I need to learn and test it but we have snow here, not the best testing conditions at the moment.
I'm doing compound this time, adding little turbo to HX52.

[Image: 20161005_220948_zpsdqiyxbuh.jpg]

[Image: 20161006_231334_zps6rf6s3d6.jpg]

[Image: 20161010_214230_zpsfhz2qjt4.jpg]

[Image: 20160923_104615_zpsrqxk8j5j.jpg]

RE: c220d om606 taxiSTD - kashi123 - 11-03-2016

(09-01-2016, 03:36 PM)erx I've driven 7.5mm pump with stock OM606 turbo with boost raised to 2bar, it was very fun on street, spools instantly and great torque on low rpm.

I have exactly this set up in my G-wagen, only boost set to 1.2 bar. Is there any problem with the turbo if boost is raised to 2 bar?
I can easly go higher than the 1.2 if I adjust my boost controller. Also I have a large water cooled intercooler fitted.

And yes, it does spool very fast which is great in a 4x4

thank you

RE: c220d om606 taxiSTD - erx - 11-03-2016

(11-03-2016, 04:34 AM)kashi123
(09-01-2016, 03:36 PM)erx I've driven 7.5mm pump with stock OM606 turbo with boost raised to 2bar, it was very fun on street, spools instantly and great torque on low rpm.

I have exactly this set up in my G-wagen, only boost set to 1.2 bar. Is there any problem with the turbo if boost is raised to 2 bar?
I can easly go higher than the 1.2 if I adjust my boost controller. Also I have a large water cooled intercooler fitted.

And yes, it does spool very fast which is great in a 4x4

thank you

2 bar is ok if it's on short period but I think 1,5-1,6 bar is safe and no problems with overload.

RE: c220d om606 taxiSTD - kashi123 - 11-03-2016

(11-03-2016, 05:14 AM)erx
(11-03-2016, 04:34 AM)kashi123
(09-01-2016, 03:36 PM)erx I've driven 7.5mm pump with stock OM606 turbo with boost raised to 2bar, it was very fun on street, spools instantly and great torque on low rpm.

I have exactly this set up in my G-wagen, only boost set to 1.2 bar. Is there any problem with the turbo if boost is raised to 2 bar?
I can easly go higher than the 1.2 if I adjust my boost controller. Also I have a large water cooled intercooler fitted.

And yes, it does spool very fast which is great in a 4x4

thank you
2 bar is ok if it's on short period but I think 1,5-1,6 bar is safe and no problems with overload.

Great,,thanks a lot. As I have zero smoke at the moment I can turn the pump up a bit Big Grin

RE: c220d om606 taxiSTD - street_666 - 11-03-2016

How did You modified the magnet to 21mm?

RE: c220d om606 taxiSTD - erx - 11-04-2016

(11-03-2016, 07:15 PM)street_666 How did You modified the magnet to 21mm?

Little drilling here, little grinding there. Smile

RE: c220d om606 taxiSTD - Turbo - 11-05-2016

(11-04-2016, 05:13 PM)erx
(11-03-2016, 07:15 PM)street_666 How did You modified the magnet to 21mm?

Little drilling here, little grinding there.

RE: c220d om606 taxiSTD - maxypriest - 11-07-2016

(11-02-2016, 05:31 PM)erx I went back to 7.5mm because 8mm was making horrible knocking noise and I couldn't burn 220cc. I modified EDC pump magnet, so rack travel is now from stock 18.5mm to 21mm, it should make max 180cc. These EDC and DSL1 are all new for me so I need to learn and test it but we have snow here, not the best testing conditions at the moment.
I'm doing compound this time, adding little turbo to HX52.

Super - glad you are experimenting with this setup :-) 180cc is alot :-)

RE: c220d om606 taxiSTD - erx - 11-13-2016

I drove out from garage today, first time with DSL1. Idle is hunting a little but almost normal, throttle response is very sharp, it revs very fast and goes back to idle also very fast. I can't drive properly because there's something wrong with CAN-bus between DSL1 and Ole controller. Box controller is not getting information from DSL1 sensors, I hope Baldur will figure out what's wrong.

RE: c220d om606 taxiSTD - Spoolin - 11-18-2016

That engine sounds awesome! Can't wait to see what power you get out of the 7.5 edc pump. How did the compound setup turn out?

RE: c220d om606 taxiSTD - starynovy - 11-18-2016

How did you balanced elements?

RE: c220d om606 taxiSTD - erx - 11-19-2016

(11-18-2016, 10:49 AM)Spoolin That engine sounds awesome! Can't wait to see what power you get out of the 7.5 edc pump. How did the compound setup turn out?

Engine sounds ok but not perfect, still knocking too hard and idle is going up and down a little, needs fine tuning. Compound setup is waiting at the moment, I want to dyno this pump with single HX52 to compare different pumps with the same turbo. Then I take it to peaces and make whole new exhaust side.

I balanced elements just on engine idling, it needs skill to do this by just hearing and looking. I wanted to see and hear that whole setup running first and now I know what to look when I put it on test bench. It is running smooth even now but I need to test it on bench anyway.

RE: c220d om606 taxiSTD - Petar - 11-19-2016

Try playing around with the fueling map to fix the idle hunting, i can see that in you map fueling is set to 6.0cc at both 500 and 700 rpm. Try setting the fuel at 700 rpm to 4-5 cc or maybe set at 500 rpm to 7-8cc

I like this project, hope it turns out well. No doubt that the EDC pump can mapped for smoke free operation, and with compound turbos it will still spool well. Which turbos do you plan on using?

RE: c220d om606 taxiSTD - erx - 11-19-2016

(11-19-2016, 04:11 AM)Petar Try playing around with the fueling map to fix the idle hunting, i can see that in you map fueling is set to 6.0cc at both 500 and 700 rpm. Try setting the fuel at 700 rpm to 4-5 cc or maybe set at 500 rpm increase to 7-8cc

I need to set the whole table because I have different rack position on idle and this table is for 6mm elements. This video is made just after some small adjustments to make it idle and it is smoking like crazy at the moment. All other parameters from idle are still on default. With default settings it was holding idle on 2000rpm, tables are so overfuelling at the moment.

I'm not rushing with it, can't test it over 2 bar anyway because roads are wet and snowy.

[Image: 15101809_10208075086451745_636466760_o_zpsjl44pxpe.jpg]

RE: c220d om606 taxiSTD - erx - 04-10-2017

I have DSL1 and OFgear controllers working together quite well for now, some speed fail errors sometimes but it's working. Exhaust manifold is in progress, small turbo is also from 3.2cdi and big is now pro52, little bigger than hx52, both with 16 housing.

I made turbo flange position-device-thing from scrap parts, so with next manifold big turbo sits on the same position and I can use the same downpipe also. HX52 is very heavy and it's very hard to place turbo flange on right position, now it's easier. Manifold looks rough at the moment, one more wg coming and then final welding, sandblasting and painting.

[Image: Icr8JqJ.jpg]

And now I have paddles also. Big Grin

RE: c220d om606 taxiSTD - Turbo - 04-11-2017

what indusor and exdusor size on the compressor side on that pro52? turbine side?

RE: c220d om606 taxiSTD - erx - 04-11-2017

(04-11-2017, 03:17 PM)Turbo what indusor and exdusor size on the compressor side on that pro52? turbine side?

Compressor 71,5/98mm, turbine 71/86mm

RE: c220d om606 taxiSTD - Turbo - 04-12-2017

so how much air do you plan to put in the engine?
I really love those paddles, any tips?

RE: c220d om606 taxiSTD - erx - 04-23-2017

Manifold almost finished.

[Image: JlhM7jA.jpg]

RE: c220d om606 taxiSTD - hooblah - 05-08-2017

How have I only just noticed this?! Loving your work.

RE: c220d om606 taxiSTD - erx - 08-27-2017

Car is running, compared to last year's setup it's much more refined and fun to drive. It is much quieter because now I have 7.5mm elements again and on normal driving exhaust gases are going through small turbo, feels like stock car. It starts spooling instantly with approximately 1bar@2000rpm and 1,7bar@3000rpm. Max boost is at 4500rpm and it goes easily to 4bar but no power gain over 3.5bar boost. Big Grin

I need to improve dual wastegate controlling to make sure they fully open on full load and at the same time can hold enough gases when small turbo is working, at the moment it's poor on both.
I tried it on 1/4 mile and best result was 12,6sec 199kph.

[Image: sZIploT.jpg]

RE: c220d om606 taxiSTD - Turbo - 08-28-2017

what a peace of work Smile

How does it work if you have full gas, leave off and full attack again, it boost quickly?

RE: c220d om606 taxiSTD - maxypriest - 08-29-2017

Superb work! Need some vid action!!

RE: c220d om606 taxiSTD - Lucian189 - 10-07-2017

Amazed by your work !

RE: c220d om606 taxiSTD - erx - 10-07-2017

(10-07-2017, 01:55 PM)Lucian189 Amazed by your work !

Thanks!

Car is running great, I did some improvements with bypass wastegates and now spoolup is even better than before. it's hard to take off because 1-2 gears have absolutely no grip and need to be gentle with gas pedal. I tried 1/4 mile and best time was 12.4 198kmh, with better grip and full throttle it would be much quicker. I have simple opened diff and car is not built for drag at the moment.

https://www.youtube.com/watch?v=lN_1wlMy0Jg&index=23&list=WL