16v Callaway Turbo Motor
The Zonker's engine featured the only 16v turbo ever developed by Callaway. This system was in testing for future cars. But was never put into production. 2 kits were all that were made. This is the only working one.
Callaway Turbo Rebuild Story
The Zonker has always been referred to as the 16v Callaway Turbo GTI Syncro. The turbo is one of the two reasons that makes the car so unique. And let me tell you how unique.
After getting the Zonker home and taking it out on its maiden drive. It was not performing, as it should have. After some testing we found that the boost from the turbo was at 2 lbs. Not what we wanted to see so off comes the turbo, down pipe (that's another story) etc. You would think a Garret turbo with the part # 107100-0 and serial YJ-L0103 would be a call to the turbo shop to get a rebuild. HA! Now I know what one of a kind means. After that failed I searched the web talking to anyone who would listen, calling every company that had turbo in their name.
Finally I found Jeff at Turbo Auto in Tennessee. After receiving the turbo Jeff sreaching the Garret number. He found that it was made for Callaway. By who? Well working backwards Garret, Roto-Master, Rajay. As best as we can tell the turbo turned out as a Rajay Compact, used in formula racing. Jeff completed the rebuilt and in testing what do we find? The waste gate is setup for 25-30 lbs. of boost (this is what most of the 2 liter formula cars ran in 1988 25-35 lbs.). Now the big question is has this turbo ever worked? Callaway's 2-stage turbo system only claims 10-15 lbs.
The Zonker's Garret, Roto-Master waste gate part # 300118-05 serial # VJ-L0103 is setup for 25-30 lbs.?
Down Pipe Story
The Zonker has always been referred to as the 16v Callaway Turbo GTI Syncro. The turbo is one of the two reasons that makes the car so unique. And let me tell you how unique.
After getting the Zonker home and taking it out on its maiden drive. It was not performing, as it should have. After some testing we found that the boost from the turbo was at 2 lbs. Not what we wanted to see so off comes the turbo, down pipe (that's another story) etc.
The original down pipe was a combination of VW stock pipe and modified pipes also built with no flex pipe.
The new down was fabricated by Turbo Power in Cameron Park, CA. As you can see we went from a twin pipe 1.5" configuration to a signal pipe 2.5" configuration, added a flex section. Also added a rotating flange to the turbo end of the down pipe.
The down pipe was made by Turbo Power, if you need turbo work or exhaust give them a call 1.800.887.2648 or visit his web site www.turbo-power.com