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BAE aftermarket turbo kit

Necassary gaskets and oil lines

Intercooler

This first project involves a stock N/A (naturally aspirated) diesel Rabbit and a aftermarket turbo kit. The Kit I will be using was made in the early eighties by BAE (Bob's Automotive Engineering). This kit was designed as a bolt on system for the VW rabbit and Dasher diesels. It utilizes a Rajay turbo charger with low 7psi boost compared to the 15psi generated by a factory vw turbo diesel. The Factory turbo diesel engine is made with heat tolerant materials, oil cooler and oil squirters to cool the pistons. The stock N/A diesel is not built to meet the demands of a powerful turbo but with some extra measures I think the Rajay will do pretty well.

Unfortunately the kit I purchased is not complete and will require quite a few additional componants. I will use this as an opportunity to add a personal touch. The BAE intake manifold is missing and a modified gas rabbit manifold is in its place which will actually offer some advantages.

In addition to finding and fabricating the missing parts needed I also plan to add an inter-cooler, oil cooler and possibly larger exhaust. The intercooler will cool the air between the turbo and air intake to create more density for better combustion. The oil cooler is off of a factory turbo-diesel but is also found on vanagon diesels. It is good to use exhaust pipe larger than the output of the turbo to allow unrestricted expantion of the hot exhaust leaving the turbo. The down pipe included with the kit is only 1 7/8 so I don't know if I will bother w/ 2-2 1/4 right away.