Author Topic: ~My 91 GLI to 1.6TD conversion build up~ (Read 100823 times)

53 willys · « **Reply #240 on:** January 14, 2009, 11:07:50 pm »

Quote from: "Vincent Waldon"

Very nice work... nothing like that first fire-up, is there??!!

Guess which part I like the most

Yup, the glow plug wiring !!

LOL thanks Vince!!...I love the GP wiring aswell!! great idea!

yes it's a good feeling to have it running again..

I also got my new water temp gauge installed..IN THE TOP HOSE housing.....I was kinda disturbed when the fans did not kick on until about 220* :shock: ....I think I'm gonna order a cooler fan switch from GAP...
seems way to late to try and cool this baby down when the head coolant is at 220*

I really don't like the VW cooling systems

does not seem like the ideal set-up...

:roll:

Smokey Eddy · « **Reply #241 on:** January 15, 2009, 04:50:01 am »

You and me both buddy! Hahahah
Perfect timing

we have identical EGT sender mounts. Like i don't think they're more than 5 degrees out from each other there on the manifold hahahahha

Augh im so envious of that downpipe and probably done out IP.

What is the use of the manifold pressure?

foxracer1 · « **Reply #242 on:** January 15, 2009, 10:21:10 am »

Good to hear its going back together. I agree on the VW cooling system i feel several VW engines would still be around if the cooling system would have been a little better. I plan to install a coolant temp gauge to see where it actually is during regular beatings.

The same with the drive pressure gauge. Do you have a list of all the parts you used for the drive pressure gauge?

53 willys · « **Reply #243 on:** January 15, 2009, 10:45:13 am »

lots of headgaskets die in the diesel world from extreme cylinder pressures...when tuning a diesel with a BIG turbo you want to try and get as close to a 1.1 ratio of pressure between the turbo pressure and the exhaust pressure.....
so I installed a drive pressure gauge so I can "tune" my turbo to be least abusive on my new head gasket as possible.
I did the DP gauge so I can FULLY tune this beast...although I do need a wastegate to make the most of this set-up..but times are tight so the wastegate will be added later....

thanks gents...

I will add a list of my DP gauge parts soon as I get back...

zukgod1 · « **Reply #244 on:** January 15, 2009, 10:51:09 am »

Well good thing your turbo has a waste gate built in huh???

Easy to tune as well.

Looking forward to some test rides once again. I dang near stopped by last night to freeze with ya for a min but, Wednesdays = Scouts so i had to boogie on through.

Sure is looking good Mark.
You driving it to work today?

53 willys · « **Reply #245 on:** January 15, 2009, 12:36:05 pm »

Quote from: "zukgod1"

Well good thing your turbo has a waste gate built in huh???

Easy to tune as well.

Looking forward to some test rides once again. I dang near stopped by last night to freeze with ya for a min but, Wednesdays = Scouts so i had to boogie on through.

Sure is looking good Mark.
You driving it to work today?

thanks Dan...I blame you for all this money pit and diesel fun!! :lol:

I pretty much did not plan on using the stock gate...the stock gate does not have that much adjustable does it Dan???
if it does maybe I will tune it with that??
I dont work today..hope to drive it to work tomorrow tho...

53 willys · « **Reply #246 on:** January 15, 2009, 12:41:03 pm »

some guys are asking what parts I used to make my DP gauge..so here goes..
3' of 3/16" steel brake line..coiled around my "2 D mag light"
1 90* 1/8NPT to 3/16" compression fitting
1 male 1/8NPT to 3/16" compression fitting
the other two compression fittings came with my gauge..
I made the soot filter with some solid aluminum bar stock(homedepot) I drilled it out for some 1/8" npt..pretty simple really.

clear as mud??

foxracer1 · « **Reply #247 on:** January 15, 2009, 12:49:44 pm »

Thanks for the list. It looks like a good setup so thats why i asked i plan to make one similar to that.

I believe that several headgaskets have died from extreme cylinder pressures. But i'm talking about daily driven stock VWs that people just drive and it gets hot and ruins the head.

All in all can't wait to see how your HG works. Also am interested in how the hybrid turbo runs. Keep us posted.

zukgod1 · « **Reply #248 on:** January 15, 2009, 01:46:12 pm »

Quote from: "53 willys"

Quote from: "zukgod1"
Well good thing your turbo has a waste gate built in huh???

Easy to tune as well.

Looking forward to some test rides once again. I dang near stopped by last night to freeze with ya for a min but, Wednesdays = Scouts so i had to boogie on through.

Sure is looking good Mark.
You driving it to work today?

thanks Dan...I blame you for all this money pit and diesel fun!! :lol:

I pretty much did not plan on using the stock gate...the stock gate does not have that much adjustable does it Dan???
if it does maybe I will tune it with that??
I don't work today..hope to drive it to work tomorrow tho...

I think you could use the OE WG. Just install an adjustable T fitting in between the manifold and WG so you can adjust when it opens.

When it's completely unhooked as your and mine are we don't even need to adjust that screw all the way as as we did. You can adjust that for along with the T fitting to get the WG to open when and how much.

Plus we can take one, cut it open for larger springs ect and just make a ring to reassemble the 2 half's once done.

WAY less than an external WG.

Smokey Eddy · « **Reply #249 on:** January 15, 2009, 02:49:42 pm »

I wonder what the ratio would be with no controlling it... the Drive pressure and boost pressure that is. ie. a set up like mine where you get as much boost as fuel you push through it with no BOV or waste gate.

53 willys · « **Reply #250 on:** January 15, 2009, 06:23:31 pm »

Fail!!!
Details when I'm not so efing pissed.....

Smokey Eddy · « **Reply #251 on:** January 15, 2009, 06:32:46 pm »

Fail?

zukgod1 · « **Reply #252 on:** January 15, 2009, 06:41:57 pm »

I'm coming over man!!

Be there in 45 min..

Kudagra · « **Reply #253 on:** January 16, 2009, 01:46:54 am »

Guess I should log on more often..

Ive been spending time doing the same swap. Down to the G60 v/c, same FMIC and its even a solid lifter 85 engine.

Cept mine is a 90 GLI and its BLACK.

I almost bought a haggard 89 Helios for $400 to do the swap into. The Vortex would have imploded.

Im going to send you a PM about those gaskets (ill need 2) when I hear that all is better.

53 willys · « **Reply #254 on:** January 16, 2009, 11:30:22 am »

well I got it put togather last day before yesterday...I warmed it up and retqed it yeterday...took it for a ride..10psi was the most I pushed it..
came back home feeling great!!
look under the car and see red coolant dripping down...at the back of the engine!

grab my inspection mirror and start looking...the damn head gasket is seeping coolant on the back side of the head and block!!!! :cry: :evil: :cry: :evil: :cry: :evil:
so after punching a few holes in my garage walls!!!!(jk)
I started to take the car back apart to see why...after I got it apart I pretty much came to the conclusion that I did not get the gasket FULLY smashed...I clean the surfaces again..and this time I applied some permatex Aviation form-A-gasket sealer...and put it all back together.....head off, cleaned, inspected and reinstalled in about 2.5 hours!!! I'm getting good now! lol

I took the studs to 95ftlbs...I'm gonna warm it up and go to 105ftlbs

if this SOB does not seal now..well I dont know what I will do!!!!!!!!!

to be continued...........