Building my mk2 1.6TD

[zukgod1]

Did some playing around last night.





Pulls good, and keeps it right @ 30psi where as to before I could hit 40psi under a hard pull.


I'm going to search for a better front bumper then spend more time trimming so it looks/fits better then I think I'll take some stretched metal and bend it the shape of the bumper then have it powder coated black.

[Baselyne]

nice front mount, I really like how clean it looks up front

Is there a link to the place you bought the cooler from?
the progress on your rides coming along so nicly
keep it coming man, im anxous to see what your doing with the bumper...

but overall very nice build
what EGT are you seeing now/ there must have been a drimatic drop in temps from before and after install
good work and very exciting to read
props

[zukgod1]

Thanks for the comments.

I didnt notice a dramatic drop in temps but it's better for sure. I can hold the peddle to the floor longer. Can still hit 1400deg on a good pull.

Normal cruising was about 900 deg @ 75 mph and 6-7 psi.
Now @ cruising it's 750-800 same speed and boost.

Defiantly has more power in the bottom end though.

Planning on stretched metal to replace the area I had to cut out and having it powder coated in black, bend the same shape as the area removed (I hope) and bolt it on. Still need to get the flares and side skirts on as well then get the black part of the bumper's painted.

Intercooler link http://cgi.ebay.com/ebaymotors/ws/eBayISAPI.dll?ViewItem&rd=1&item=250219901631&ssPageName=STRK:MEWN:IT&ih=015

And the piping kit I used, I added a 45 deg pipe, 2 90 deg silicone boots, a couple hump hoses and a few extra clamps also.
http://cgi.ebay.com/ebaymotors/ws/eBayISAPI.dll?ViewItem&rd=1&item=250226585237&ssPageName=STRK:MEWN:IT&ih=015

[zukgod1]

Figured this thread was SO old I would add an update.

I had long ago removed the 10mm pump and installed a fresh 9mm pump.

Well after a long internal debate I decided to build another 10mm pump.
I used one of my TD pumps i had and tore into it. It all looked good so I bead blasted the case and pressed in new bushings. 53willys reamed them to spec for me then I assembled it with a new AAZ cam and a 10mm pump.

Was able to get it all installed in a few hours and timing set to 1.07mm.
I had blkboostedtruck set my new injectors to 165bar thinking that when they settled in they would end up around 160bar or so.
Anyway, went for a drive to Sears and could smell diesel when I got out. I didn't even want to look so I didn't till I got home and sure enough the one cover you cant do anything with when it's o the damn car was leaking, cold start advance cover. So I removed the pump again and just replaced the cover. Re installed then set the timing the next morning yet again. I also set eh internal pressure to 40psi @ 1000rpm.
Runs butter smooth now all the way the RPM range. I also installed a very aggressive fuel pin. Damn thing will pass 30 psi now  :twisted:
Time will tell but with the new pump and new injectors it's a entirely different car once again.

[zukgod1]

Some recient pics.