Dieselboost's 524Compound Biturbodiesel

[DieselBoost]

New boost tubes, ready for painting.

[totheredline]

Awesome!!!!

[DieselBoost]

New oil lines for turbos


This will be new engine oil pressure gauge, because old one in console is replaced with another boost gauge (there is two boost gauges to LP turbo and HP turbo and exhaust pressure gauge...

[DieselBoost]

[DieselBoost]

Here is finished product.... i call this engine, biturbo evolution 1.0

[Andrew 524td]

Here is the result !!! It is fantastic! Even scary to think how IT accelerates !!

Very, very high quality work, excellent results

[DieselBoost]

And here is more stuff..... just got my new seats for my car...

[Dub-Nub]

are those e28 doorcards? they are bad ass and i want some!

[DieselBoost]

yes they are.... and stock ones...

[Dub-Nub]

yes they are.... and stock ones...

nice. looks like i need to keep an eye out for it.

[SPF2006]

What is it with you guys over there? Folks in your neck of the woods always seem to have the coolest projects!

This. Fantastic build thread.

[DieselBoost]

Aaaaaand.... here we go again.... when nothing is enough...

I started my 2.7 stroker project with inline injection pump, well i got "little bit" bigger turbos this time

[tryingtobebest]

Hello, i love your build, i am a mechanic and have 11.5 sec R32 GTR and a daily E90 335D with a straight pipe ( http://www.e90post.com/forums/showthread.php?t=1289276 ) im thinking into joining 524tD family so i have few questions for OP!):

#1 What would be absolute max boost/output of the stock fuel system? (I meant mechanical pump with upgraded lifter pump)

#2 If i throw a bigger turbo with intercooler and head gasket with studs what would be next limitation?

#3 Ever considered going something like 6.7L Holset VGT turbocharger, or something similar? Many in 4G63 community using similar on a 2.0L with manual (boost controlled) VGT fins control!?

[DieselBoost]

#1 What would be absolute max boost/output of the stock fuel system? (I meant mechanical pump with upgraded lifter pump)

#2 If i throw a bigger turbo with intercooler and head gasket with studs what would be next limitation?

#3 Ever considered going something like 6.7L Holset VGT turbocharger, or something similar? Many in 4G63 community using similar on a 2.0L with manual (boost controlled) VGT fins control!?

1: well there is no boost limit like in gas engines, well your engine goes lean, but it does not harm the engine like in gas engines... but there is no reason to go over 2bar with stock injection pump

2: bigger turbo, intercooler and mls gasket + studs.... well next limitation for power is that rotary injection pump, it just dont work in high rpm are like over 4500
ofcourse your clutch will make harakiri if stock

3: yes, but boost operated vnt:s are problematic... and vnt turbos are well known ext pressure makers... and i dont trust those,
My friend has vw caddy 1.9tdi with compound turbos LP turbo is garrett gt40 and HP is small vnt.... lot of problems with that vnt... even that is electrically controlled with ecu... but still it made 400hp

[tryingtobebest]

Thank you for a fast response man!)
So what would rough output be if lets say i put GT30R or GT35R at 2 or 2.2 bar with intercooler and MLS HG?

[DieselBoost]

Thank you for a fast response man!)
So what would rough output be if lets say i put GT30R or GT35R at 2 or 2.2 bar with intercooler and MLS HG?

with stock injection pump, max 200hp.... with 12mm cummins rotorhead up to 340hp

[DieselBoost]

m21d24 stock intake port

exhaust port

exthaust port + injector and precombustion chamber slot

precombustion chamber

[DieselBoost]

Mercedes om606 N/A injection pump's timing advance controller fitted to m21d24 pump wheel


From left to right....
My old low pressure turbo (masterpower) is new high pressure one.... changed twin scroll 0.84ar housing to 0.63ar single....
And my new low pressure turbo Holset hx55 with 65mm compressor and 71mm turbine with 13cm3 housing... (this one is only model turbo for fitting, real thing comes before summer)

[DieselBoost]

building tubes for exhaust system...

[DieselBoost]

My new invention to get my project cars in to garage while not running...

[DieselBoost]

Well this was a surprise... not even tight fit at all...

[DieselBoost]

[Cjames570]

this project is so amazing! great work!

[DieselBoost]

Well... dids some recearch with 525tds (m51d25) pistons for my m21...
This is too easy, i modified combustion area of the piston to maching m21 precombustion chambers location...
Then i tried m57 con rod with it, there is enough space to make eccentric piston pin bearing... so i will make it 2mm lower than in stock...
With that mod piston will be in same level of surface of block, so no need for thicker head gasket etc...
I did dissection after that, i found that there is enought material for this and no major weakening will occur...
this piston was cracked junk one

I soda blasted all 7 pistons before making... soon i will make this mod for these good pistons...

[DieselBoost]

Well... Thank you photobucket

I post this here, my friend just started to make scematics for my new copper flame rings, so i can make new oval grooves to my block...
Most of my time goes now with my pc25/31 Honda cbr600 project... next summer it will be turbocharged (What a surprise, a turbo in my toys)