Author Topic: ~My 91 GLI to 1.6TD conversion build up~ (Read 99785 times)

53 willys · « **Reply #30 on:** September 19, 2008, 10:19:09 am »

I punched out the gas tank to fit diesel nozzles this week..I used some 1.5" DOM tubing and heated it up with a propane torch...punched out the little metal flapper...I was nervous if it would work but it actually worked better then I expected!
forgot to take the camera over so all I have is phone pics..and I forgot to snap a pic of the tank opening.

fatmobile · « **Reply #31 on:** September 20, 2008, 02:55:08 am »

Yep, wasn't sure if I was just lucky the little metal flapper came out so easy, glad it came out so easily for you too.

Quantum TD · « **Reply #32 on:** September 20, 2008, 03:25:13 am »

So, I guess I'll still be the voice of reason (or dissent in this house). Shame what you're doing to that GLI. It's an exhilarting ride. No diesel can touch the RPM whooosh of a 2.0 16v. It's a different type of thrill that starts in the guts, and moves up to the brain. Diesel is all torque, but the 2.0 16V was vws first really sexy engine, and it lived up to the billing: quick throttle response, high revving, and seat of your pants performance.

Despite my misgivings: at least, it looks like you're doing it with class. So, I guess the back-handed compliment is: looks good, despite the molestation. I guess those failure-prone motronic control modules and the hybrid CIS/motronic ECUs are enough to turn off even the most avid VW nut.

Smokey Eddy · « **Reply #33 on:** September 20, 2008, 06:27:59 am »

53 willys , your TD is gonna be faster than any 2.0 16v

at least that's my goal

53 willys · « **Reply #34 on:** September 20, 2008, 10:07:24 am »

Quote from: "fatmobile"

Yep, wasn't sure if I was just lucky the little metal flapper came out so easy, glad it came out so easily for you too.

hey buddy I need to thank you for the great advice on do this fuel tank mod!!
I probably would have pulled the tank...put a vacuum in and drilled the filler neck out :lol:

thanks for the sweet trick!

53 willys · « **Reply #35 on:** September 20, 2008, 10:11:23 am »

Quote from: "Quantum TD"

So, I guess I'll still be the voice of reason (or dissent in this house). Shame what you're doing to that GLI. It's an exhilarting ride. No diesel can touch the RPM whooosh of a 2.0 16v. It's a different type of thrill that starts in the guts, and moves up to the brain. Diesel is all torque, but the 2.0 16V was vws first really sexy engine, and it lived up to the billing: quick throttle response, high revving, and seat of your pants performance.

Despite my misgivings: at least, it looks like you're doing it with class. So, I guess the back-handed compliment is: looks good, despite the molestation. I guess those failure-prone motronic control modules and the hybrid CIS/motronic ECUs are enough to turn off even the most avid VW nut.

hahaha I driven enough 16v 2.0 vw's....nothing special.

this is why I cant post it on vortex....Die hard purists!
Diesel power for the win :lol:

zukgod1 · « **Reply #36 on:** September 20, 2008, 08:49:06 pm »

Quote from: "Quantum TD"

So, I guess I'll still be the voice of reason (or dissent in this house). Shame what you're doing to that GLI. It's an exhilarting ride. No diesel can touch the RPM whooosh of a 2.0 16v. It's a different type of thrill that starts in the guts, and moves up to the brain. Diesel is all torque, but the 2.0 16V was vws first really sexy engine, and it lived up to the billing: quick throttle response, high revving, and seat of your pants performance.

Despite my misgivings: at least, it looks like you're doing it with class. So, I guess the back-handed compliment is: looks good, despite the molestation. I guess those failure-prone motronic control modules and the hybrid CIS/motronic ECUs are enough to turn off even the most avid VW nut.

Why dont you buy the 16v from him? Sounds like you like them maybe you need one? :roll:

53 willys · « **Reply #37 on:** September 27, 2008, 02:44:38 pm »

got a pic of the governor mod..
I use a steel roll pin for mine...it fit the shaft real nice and allowed the spring to stay on there for some slight give...

also got my ARP studs installed

stock 2 notch gasket...1mm over bore pistons

I replaced some more seals on the trans...while I was doing that I decided I would change that bushing in the end of the shaft...I had to make a tool to pull it out...I ended up using a tap welded to some nuts..then the nuts attached to the slid hammer...worked great!

the engine is put together for the most part...I should have it installed by middle of next week(my next days off)
if I can get my coolant hoses by then I may even drive it next week

Vincent Waldon · « **Reply #38 on:** September 27, 2008, 02:49:26 pm »

Lookin' good man... keep those pictures coming... we loves us our build threads !!

53 willys · « **Reply #39 on:** September 27, 2008, 03:01:27 pm »

Quote from: "Vincent Waldon"

Lookin' good man... keep those pictures coming... we loves us our build threads !!

thanks Vince!!

these are some older pics I had from my phone...I got a lot more done to is this week...I will have some more pics this coming week....I will also have some pics of your glow plug pimping..little different version but the idea is yours

53 willys · « **Reply #40 on:** October 02, 2008, 11:21:29 am »

well I have got the turbo mounted and pretty much got the supply and drain lines figured out....
I had to make a spacer for the turbo so it would not hit the intake manifold...it worked really well and was super easy to make.

more spacer shots...you can also see my BOV eliminator cap...Zukgod1 gave me the idea....you take a VW strut cap turn it down till it fits in the same spot as the stock BOV and I also weld in a 1/8" NPT steel fitting for my boost gauge...

here you can see the oil drain....

I cut the stock metric threads off the pan and welded a -AN fitting (10) to the old metric pipe fitting....I LOVE -AN fittings so I wanted to change so I dont have worry about finding weird fittings or threads for a drain.

-AN oil supply and and -AN water supply too...

53 willys · « **Reply #41 on:** October 02, 2008, 11:28:38 am »

Clutchnet.com race sprung hub clutch and lightened flywheel

pretty much got everything ready now!!!
this here is a beautiful thing!!!!

kinda cleaned up engine bay...I still gotta gut the stuff I dont need out og the harness...

got my new gauges installed too!!!

zukgod1 · « **Reply #42 on:** October 02, 2008, 12:01:36 pm »

I'm stopping by to see this sexyness tonight!!

That turbo spacer looks really good there man..

I wish I would have had one of those so I didn't have to grind the livin piss out of my compressor..

May need one to clear the new intake manifolds though

Not to sure how excited I am about building a new oil drain and down pipe though.

arb · « **Reply #43 on:** October 02, 2008, 03:42:20 pm »

Has anyone put a small electric radiator fan near the turbo? Ideally it would run only at low speeds / stops as I would think at high speed you have enough airflow back there. Or, maybe run it all the time.

zukgod1 · « **Reply #44 on:** October 02, 2008, 03:47:21 pm »

Ya know with a after run pump you could actually plumb in a heater core mounted in the fender and just run a separate system all together.
Something to consider I guess.

Author Topic: ~My 91 GLI to 1.6TD conversion build up~ (Read 99785 times)

53 willys

53 willys

53 willys

53 willys

53 willys

53 willys

53 willys

arb