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Author Topic: Golf MK1 with 1.6 TD (CY) --- Diesel race car project  (Read 32703 times)

Reply #30February 01, 2010, 06:06:31 pm

Alleslowbuged

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Re: My Golf MK1 with 1.6 TD (CY) swap to 1.9 TD (AAZ)
« Reply #30 on: February 01, 2010, 06:06:31 pm »
Dear all,

i get my ported and polish 1.6 mechanical head back, also the valve seats has been mashined to a slightly bigger diameter
I will use the LT28 intake manifold, modified to a dual plenum intake and also with ported chamber (same as head intake ports).
Here is a picture, with pipe direction to the wrong side (non driver side):










Here the new gaskets:


I have also take my 1.6mm MLS gasket to mark the additionally "steam holes", then
i have drilled 4mm holes.






Best Regards
Clemens
 

 
VW Golf Mk1 (Typ 17) 1981 with 1.6 TD
BMW E28 524 TD

Reply #31February 03, 2010, 04:27:35 pm

Smokey Eddy

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Re: My Golf MK1 with 1.6 TD (CY) swap to 1.9 TD (AAZ)
« Reply #31 on: February 03, 2010, 04:27:35 pm »
Fantastic port job.
Ed
Blacked out mk2 AAZ Jetta RIP. You are missed.
White 1999.5 ALH Golf 2dr. Low & wide. Rammed off the road RIP.
Blue 2009 CR140 Jetta CBEA/CJAA. Malone stage 2. EGR/DPF/Exhaust-valve deletes. 2.5" open exhaust. ADP Turbo swap. 1-stage nitrous kit. THROWN ROD

Reply #32February 03, 2010, 04:47:00 pm

rallydiesel

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Re: My Golf MK1 with 1.6 TD (CY) swap to 1.9 TD (AAZ)
« Reply #32 on: February 03, 2010, 04:47:00 pm »
Nice build. What happened to the 1.9 plans?
2006 Jetta TDI - gtb1749v, Malone 2, Frank's Titan 2 cam, VR6 clutch....
1991 Jetta TD - sold :(
2001 Golf TDI - Son's
1981 Rabbit - BEW tdi swap project

"ONCE YOU GO CLACK, YOU NEVER GO BACK"

Reply #33February 03, 2010, 05:08:19 pm

Alleslowbuged

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Re: Golf MK1 with 1.6 TD (CY) --- Diesel race car project
« Reply #33 on: February 03, 2010, 05:08:19 pm »
Hello,

i have just the title of this thread, as also the car the change from my old mk1 street car
(which should get a 1.9td swap) to the yellow race mk1 with 1.6 td engine.

As compensation for the other mk1, i have bought a mk2 with aaz engine which is actual
broke down. Here is the link:  http://www.vwdiesel.net/forum/index.php?topic=24407.msg186924#msg186924

Best Regards
Alleslowbuged
VW Golf Mk1 (Typ 17) 1981 with 1.6 TD
BMW E28 524 TD

Reply #34December 30, 2011, 04:46:05 pm

Alleslowbuged

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Re: Golf MK1 with 1.6 TD (CY) --- Diesel race car project
« Reply #34 on: December 30, 2011, 04:46:05 pm »
Hi,

i did not have wrote here for long time and to be honest i did not have make big progress, but it is still an actual (waiting) project.

here is a picture, what happens if stupid person (the same who has made the hopefully good port job) don't listen and make what
he wants, after years of waiting. The pipe-part is cut out again, but the manifold is still waiting for new effort.



Next step was to make a stand-alone outer part of the shaft drives. The parts a needed to pre-stress the front wheel bearings,
otherwise the bearings will be scrap if the have to carry the full weigth of engine and chassi.



So after this was done, i could put the whole front axis together and put the car on its own wheels (first since it is mine):







Whith the 14" rims it is pretty tight with the brakes:



Next was the brakes itself, i have bought a set of "stahlfelx" (i don't know the english word) flexible brake hoses and
will install them inside the car:













The actual status is, that the two hoses to the rear brakes are in the cabin and i have drill two additional holes in the back domes
to bring them out to the brake again.

I will go ahead with special Ø256mm rear brake disks and stock (MKII) Ø38mm brake caliper. Here are some pics of the installed
disks and adapter together with the new rear shock damper:





As the 14" rims do not fit with the rear brake, i put the car on a set of 15" rims:


I have bought a new honed (first oversize) SB engine block with new pistons will go ahead with that.
To use my mechanical cylinderhead i still have to close the additional oil return hole. But more unlikely
is, that the guy i bought the engine from was a 100% specialist, who put all bearing covers together
in a box and used for each cylinder the one which was first to catch. After that he was wondering, why
the engine could not rotate, but he tried to rotate it, which results in some unpretty marks in the new pistons.

Anyhow, i have measured all parts, find their correct place and came to the conclusion that everything can
still be used.

Here is a scratch at the upper part of the pistons:


and to pistons with scratch at the lower part:




I have shown the pistons a proffesionell engine rebuild shop and they meaned that it is not that bad, so i have
regrinded the spots.

Today i have swapped the stock conn-rods to a set of china H-beam con-rods:




Best Regards
Alleslowbuged    
Last step was today t
  
    

« Last Edit: December 30, 2011, 04:55:58 pm by Alleslowbuged »
VW Golf Mk1 (Typ 17) 1981 with 1.6 TD
BMW E28 524 TD

Reply #35December 30, 2011, 09:49:57 pm

410

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Re: Golf MK1 with 1.6 TD (CY) --- Diesel race car project
« Reply #35 on: December 30, 2011, 09:49:57 pm »
I love pictures. :)
Toyota truck 4x4 with Mtdi, M-vnt gt1749va, 11mm pump, fmic, smog .216 nozzles.  Sold!
Working on 1993 4runner mtdi, gtb1756vk, 11mm pump, smog .216 nozzles, custom 1" thick adaptor plate, pd150 intake manifold.

Reply #36December 30, 2011, 10:45:49 pm

rabbitman

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Re: Golf MK1 with 1.6 TD (CY) --- Diesel race car project
« Reply #36 on: December 30, 2011, 10:45:49 pm »
Wow, dude that is such a cool lookin' car!!!!

Any idea what the scratches in the piston are from?
'82 Rabbit, I put on a euro vnt-15, 2.25" DP, 2.5" exhaust, the result.....it whistled.

I removed the turbo, made a toilet bowl 2.5" DP, the result....it was deafening. Now it has a homemade muffler up front and a thrush in the rear, the result.....less loud.
Watch: AGENDA, GRINDING AMERICA DOWN

Reply #37December 31, 2011, 12:30:08 am

Powered by Spearco

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Re: Golf MK1 with 1.6 TD (CY) --- Diesel race car project
« Reply #37 on: December 31, 2011, 12:30:08 am »
Nice shift linkage. The same as I use on my 02J but with an 02A tower.

Nice little car.
'87 Syncro Transporter Single Cab "Now TDI"
'78 Rabbit..Gas Weekend Racer
'81 Caddy..Diesel 1.6/1.9 TD hybrid 275HP 349TQ "Retired"
'90 MultiVan, 2.5 Suby Swap, Porsche Brakes
'76 Scirocco TD dragster project
'13 Golf R:. Tuned
'98 Puch G320

Reply #38December 31, 2011, 04:45:18 am

Mark(The Miser)UK

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Re: Golf MK1 with 1.6 TD (CY) --- Diesel race car project
« Reply #38 on: December 31, 2011, 04:45:18 am »
Wow, dude that is such a cool lookin' car!!!!

Any idea what the scratches in the piston are from?

Neither of those sets of marks look like they were created during engine operation. Down at the skirt looks like a bench clamping issue.

Top gouge is one way only and probably comes from someone slipping out of the ring groove whilst cleaning with a piece of ring...

No to-ing and fro-ing affirms this 8)
Mark-The-Miser-UK

"There's nothing like driving past a bonfire and then realising; its my car on fire!"

I'm not here to help... I'm here to Pro-Volke"

Be like meeee: drive a Quantum TD
 ...The best work-horse after the cart...

Reply #39December 31, 2011, 06:44:23 am

Alleslowbuged

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Re: Golf MK1 with 1.6 TD (CY) --- Diesel race car project
« Reply #39 on: December 31, 2011, 06:44:23 am »
Hi,

@Mark
you properly right, the engine rebuilder says the same. Regarding the upper scratch he also means that as long as the ring is totally free to move,
this would be no issue, as dark black smoke will close the extra space from the scratch rather quick.

Greets
Alleslowbuged

P.S.
What means to-ing and fro-ing?
VW Golf Mk1 (Typ 17) 1981 with 1.6 TD
BMW E28 524 TD

Reply #40December 31, 2011, 11:55:27 am

Mark(The Miser)UK

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Re: Golf MK1 with 1.6 TD (CY) --- Diesel race car project
« Reply #40 on: December 31, 2011, 11:55:27 am »
Hi,

@Mark
you properly right, the engine rebuilder says the same. Regarding the upper scratch he also means that as long as the ring is totally free to move,
this would be no issue, as dark black smoke will close the extra space from the scratch rather quick.

Greets
Alleslowbuged

P.S.
What means to-ing and fro-ing?
Chuckle brothers would say "to me, to you".
Perhaps backwards and forwards, or shuffling, 'working' it's way down, up and down, 'in and out'... ;D
Mark-The-Miser-UK

"There's nothing like driving past a bonfire and then realising; its my car on fire!"

I'm not here to help... I'm here to Pro-Volke"

Be like meeee: drive a Quantum TD
 ...The best work-horse after the cart...

Reply #41January 01, 2012, 02:46:17 pm

mtrans

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Re: Golf MK1 with 1.6 TD (CY) --- Diesel race car project
« Reply #41 on: January 01, 2012, 02:46:17 pm »
ccc....puzzle again.
I`ll improve my English

Reply #42January 06, 2012, 12:27:40 pm

baldone

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Re: Golf MK1 with 1.6 TD (CY) --- Diesel race car project
« Reply #42 on: January 06, 2012, 12:27:40 pm »
what kind an intake manifold have you used?

Reply #43March 04, 2012, 04:49:07 pm

Alleslowbuged

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Re: Golf MK1 with 1.6 TD (CY) --- Diesel race car project
« Reply #43 on: March 04, 2012, 04:49:07 pm »
Hi,

as short update, i could finish the rear brakes today:

left:




right:




So at least i have to fill it up (brake system) und deaerate it.

Best Regards
VW Golf Mk1 (Typ 17) 1981 with 1.6 TD
BMW E28 524 TD

Reply #44March 04, 2012, 08:22:00 pm

CrazyAndy

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Re: Golf MK1 with 1.6 TD (CY) --- Diesel race car project
« Reply #44 on: March 04, 2012, 08:22:00 pm »
Nice shift linkage. The same as I use on my 02J but with an 02A tower.

Nice little car.

Yeah, I've seen that setup before.  You got it from Claus von Essen Chassis Works & Golf 1 Special Parts didn't you?
http://www.clausvonessen.de/pi38/pd648.html

Totally gonna get that setup myself.  What's the diff-mounted relay lever off of, or is that in the kit too?

Finally nice to see a working pic of it on a car, and the Corrado/Eurovan clutch actuator; this looks to be a seriosly good car.  8)

Thanks for the progress pictures!