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  1. #621
    Activ8's Avatar Privileged
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    I've been looking at my Intercooler setup today, doing a little maths and calculating the efficiency of my upgraded 3" TMIC.
    Been out on a logrun (v81) to capture the IC temps, (VCDS 01 Engine Measuring Block 07 Column 3)
    MAP Temp (once the van was up to fuel and coolant temps) was Low 41.4ºC to a full boost High of 58.5ºC.

    Using the Adiabatic Processes
    Heres the calcs;
    Input Temperature: 8ºC (intake or under-bonnet temperature, used 8ºC for my K&N 80mm Cold Air Intake System )
    Input pressure: 14.7psi (use absolute pressure: adjusted -0.5 psi/1000 ft elevation)
    Output pressure: 27psi (gauge pressure: usually 1-2 psi more than the reported MAP to account for IC losses)
    Compressor efficiency: 75% (typically 60-75%, but Ive mapped this so I know where it sits, a fitting VNT could increase this efficiency by c.7%)

    Post Turbo pre-IC Output Temperature: 136.667ºC (max @ 27psi) , PR 2.84 , Density ratio 1.95

    IC input temperature: 136.667ºC (My calculated K24 discharge temperature)
    IC pressure loss: 2psi ((Reduced because of the TMIC)Boost limit is 2.72bar)
    Ambient temperature: 8ºC (outside air temperature)
    Post IC MAP Temperature: 41.4ºC to 58.5ºC from VCDS
    Overall pressure ratio: 2.70
    Overall density ratio: 2.42 to 2.30

    3" TMIC Efficiency between 61%-74%. (efficiency drops dramatically when static or idling in traffic) , 80% would be very good.

    I don't have a direct comparison without dropping the old OEM TMIC & Air Intake Parts back in ! (that aint gonna happen!)
    I had a quick look at some old logs and they're NOT like-for-like , but the temp gauge reading I found for 3rd June 2018 reached 113.4ºC!
    (oops, thats the worse temp logged and prompted the intake changes I believe!.... )
    Last edited by Activ8; 20th February 2019 at 11:01 PM.

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    Fruitbat (20th February 2019)

  3. #622
    Activ8's Avatar Privileged
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    My subconcious was working overtime & overnight and I awoke motivated to revisit the datalogs for the old set-up on 3rd June 2018.
    The van has ran fine and reliably with the OEM ACV TMIC 51mm pipework etc., OEM MAF, Volvo V70 intake pipework (with breather feed and N75 feed) plus a large K&N cone filter for 8 years. The K&N drawing and sucking at cool and clean air (I hoped) from the wing vent louvres. So the maths exercise this morning was important.

    I have enough data from the days mapping to revisit the maths for calculating the efficiency on that day.... shocker!

    IC input temperature: 168.33ºC (My calculated K24 discharge temperature)
    IC pressure loss: 2psi ((Reduced because of the TMIC)Boost limit is 2.72bar)
    Ambient temperature: 29.7ºC (outside air temperature)
    Post IC MAP Temperature: Highest 113.4ºC from VCDS
    Overall pressure ratio: 2.70
    Overall density ratio: 2.12

    OEM ACV TMIC Efficiency on 3rd June 2018 was 39.5% at its lowest and 46% at its best!

  4. #623
    Activ8's Avatar Privileged
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    Quote Originally Posted by Activ8 View Post
    Received today from Cali Campers ; VW T4 Front Torsion Bar Support and Ball Nut
    Thread length 173mm with the ball nut on 148mm, thread is M18x1.5, ball nut head 27mm , up to 160Nm torque dependant on condition and how lubricated the threads are. 1 newton meter N m = 10.20 KGf.cm . Approximately 10mm of torsion bar adjustment relates to 25mm ride height.

    Attachment 11210

    I can start having a think about making it electrically or hydraulically adjustable.
    Just to post an update on this idea, I've been engaged with my Chinese contacts on developing a 12VDC actuator for adjusting the torsion bar suspension.
    They sent me a few samples to play with and I've sent them the torsion bar support to build into the design. Its a long way off but tickling along nicely....

    Click image for larger version. 

Name:	Alisa_Actuator_Suspension_Bolt_ComparisonIdea.jpg 
Views:	23 
Size:	103.0 KB 
ID:	11437

    These are serious bits of kit, moving & locking up to 15000+KG @ 6mm per minute. The picture shows the 50mm stroke extended. Anyway its taking shape ,
    Last edited by Activ8; 21st February 2019 at 06:31 PM.

  5. #624
    spedwing's Avatar Unemployed (Platinum)
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    I’ve fitted something very similar to in-laws caravan


    Sent from my iPhone using Just T4s

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    Activ8 (21st February 2019)

  7. #625
    rjhoy02's Avatar Unemployed (Platinum)
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    Quote Originally Posted by spedwing View Post
    I’ve fitted something very similar to in-laws caravan


    Sent from my iPhone using Just T4s
    On the doors to lock them in?

    Sent from the Midlands by pigeon

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    Activ8 (21st February 2019)

  9. #626
    spedwing's Avatar Unemployed (Platinum)
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    Quote Originally Posted by rjhoy02 View Post
    On the doors to lock them in?

    Sent from the Midlands by pigeon
    Lol na , to be fair there really nice good people ,

    It looks like the actuators that are used on the caravan mover , it pushes the drive roller onto the tyre


    Sent from my iPhone using Just T4s

  10. #627
    rjhoy02's Avatar Unemployed (Platinum)
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    I get you now. Great invention those motor mover systems

    Sent from the Midlands by pigeon

  11. #628
    regcheeseman's Avatar Privileged
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    Quote Originally Posted by Activ8 View Post
    Just to post an update on this idea, I've been engaged with my Chinese contacts on developing a 12VDC actuator for adjusting the torsion bar suspension.
    They sent me a few samples to play with and I've sent them the torsion bar support to build into the design. Its a long way off but tickling along nicely....

    Click image for larger version. 

Name:	Alisa_Actuator_Suspension_Bolt_ComparisonIdea.jpg 
Views:	23 
Size:	103.0 KB 
ID:	11437

    These are serious bits of kit, moving & locking up to 15000+KG @ 6mm per minute. The picture shows the 50mm stroke extended. Anyway its taking shape ,
    I very much doubt its ability to take the repeated forces exerted on the standard bolt, but happy to be proved wrong

  12. #629
    Activ8's Avatar Privileged
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    Quote Originally Posted by regcheeseman View Post
    I very much doubt its ability to take the repeated forces exerted on the standard bolt, but happy to be proved wrong
    The example image just shows an 80KG acuator with an aluminium rod, the higher torque units are made of stainless with all metal gearing & IP67 bodies. I had a mate help calc the forces through the torsion bar support and we reckon it's 8t fully loaded and cornering. So working on a 12t & 15t version for safety. Both units lock at these loads too. Keeps the black dog at bay too.
    Last edited by Activ8; Yesterday at 02:47 PM.

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