mcmyk-
Are the LT vans not 5 cylinder?
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For that Audi 80, they got the 2.5 block from a T4. Presumably normally aspirated in it's native habitat
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2.5 litre T4 engine with decompression plates seems to be the lump of choice. Given the boost levels I'm assuming the decompression plates are about an inch thick.
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Vw t4/lt/crafter all use 5 pot diesels, different models but the 90s ones generally more sought after.
Have the same engine in my 90s volvo, just done bottom end after it needed piston rings (gummed from using veg oil), decided to replace crank and rod bearings (with factory spattered type), after 260k and 22 years they were fine. Some measurable wear but not terrible, nice and even, no scouring, no anything really. Polished the crank journals and put new ones in along with one grade higher of bolts.
The high power guys are running massive steel plate girdles across the main bearing caps (20mm thick steel!), double squirters, forged h beam rods (forgot brand), a chunky decompression plate and then very serious heads, they've been chopped up, dissected and bits somehow welded in to increase everything, amazing really.
Cast iron all the way!
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Merak
el_presidente
Brommers
BrickMan
Here’s a data point, based on what a friend of mine has done. He started with a 996 Turbo- IIRC 420 bhp as standard. He’s taken that to 1,100 bhp and it’s cost him £60,000. That’s starting with a 40k car that is fast in the first place. Starting with a lower horsepower number means (in general) a higher cost to get to bigger numbers, although the Audi boys using a £100 van bottom end probably helps them in this department.