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Author Topic: ~My 91 GLI to 1.6TD conversion build up~  (Read 99782 times)

Reply #45October 10, 2008, 03:23:46 pm

53 willys

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~My 91 GLI to 1.6TD conversion build up~
« Reply #45 on: October 10, 2008, 03:23:46 pm »
Well I made some exhaust this week..I spent about $200 total for  the 3" mandrel bent turbo back system.
of coarse all the labor is me witch is the only way I can afford my projects :lol:

it not a tig welded PP down pipe....but I am kinda proud of this one.


painted with some 1500* flat.......yeah I know it will probably burn off.. but the same stuff lasted over a year on my cummins....


downpipe



downpipe connection


over the axle arm



4" gloss black turndown..
 :twisted:




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Reply #46October 10, 2008, 03:27:44 pm

53 willys

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~My 91 GLI to 1.6TD conversion build up~
« Reply #46 on: October 10, 2008, 03:27:44 pm »
engine in!


G40 valve cover back from powdercoat




glow plug relay base..




glow plug wiring...in place of old ECM...
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Reply #47October 10, 2008, 04:12:14 pm

zukgod1

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~My 91 GLI to 1.6TD conversion build up~
« Reply #47 on: October 10, 2008, 04:12:14 pm »
Well at least you've been busy taking pictures  :lol:  :lol:  :lol:



















Looking good man!
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dan

99 Golf TDI (now CNG powered) , 82 TD Caddy
Reply #48October 10, 2008, 06:33:52 pm

53 willys

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~My 91 GLI to 1.6TD conversion build up~
« Reply #48 on: October 10, 2008, 06:33:52 pm »
yeah progress has been slower then I want....all the little things have been sucking up my days...I got most the little things figured out this week so I should be starting it up and driving it next week!! :twisted:
the oil drain and supply and also the coolant supply and drain have been tricky.....
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Reply #49October 10, 2008, 10:02:28 pm

blkboostedtruck

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~My 91 GLI to 1.6TD conversion build up~
« Reply #49 on: October 10, 2008, 10:02:28 pm »
thats an odd valve cover all of mine have the oil fill on the normal passenger side where yours is opposite! and i have 3 of them!
wher you find that one at?
other wise looks good!
keep the pics. coming!
Duane
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injector rebuilds call  414-840-1395 for faster service not on line much!
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Reply #50October 10, 2008, 10:21:07 pm

cyrus #1

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« Reply #50 on: October 10, 2008, 10:21:07 pm »
Congrats!  That is one of the cleanest engines I've seen.  :shock:
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Cody

2002 Jetta TDI
2000 Jetta TDI - R.I.P.
1990 Jetta 8v-Eventually to be 1.6TD
Reply #51October 10, 2008, 10:55:40 pm

53 willys

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~My 91 GLI to 1.6TD conversion build up~
« Reply #51 on: October 10, 2008, 10:55:40 pm »
Quote from: "blkboostedtruck"
thats an odd valve cover all of mine have the oil fill on the normal passenger side where yours is opposite! and i have 3 of them!
wher you find that one at?
other wise looks good!
keep the pics. coming!
Duane


yeah I dont know whats up with that cover?? I bought it from a guy on Vortex... the ad had no pics...anyway I am glad it has the oil filler on the drivers side cause my intercooler piping would cover the oil fill cap if it did not come on the drivers side.......some one said it was a G40 polo cover??? but I have no clue??? :oops:

thanks for the kind words 8)
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Reply #52October 10, 2008, 10:58:25 pm

53 willys

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~My 91 GLI to 1.6TD conversion build up~
« Reply #52 on: October 10, 2008, 10:58:25 pm »
Quote from: "cyrus #1"
Congrats!  That is one of the cleanest engines I've seen.  :shock:


thanks...I need to post some before cleaning and after cleaning side by side shots!!!
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Reply #53October 10, 2008, 11:35:02 pm

cyrus #1

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~My 91 GLI to 1.6TD conversion build up~
« Reply #53 on: October 10, 2008, 11:35:02 pm »
I just looked at the pics again.  Did you paint the injector bodies?
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Cody

2002 Jetta TDI
2000 Jetta TDI - R.I.P.
1990 Jetta 8v-Eventually to be 1.6TD
Reply #54October 10, 2008, 11:52:33 pm

53 willys

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~My 91 GLI to 1.6TD conversion build up~
« Reply #54 on: October 10, 2008, 11:52:33 pm »
Quote from: "cyrus #1"
I just looked at the pics again.  Did you paint the injector bodies?

no they are just new china injectors with merc tips....
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Reply #55October 11, 2008, 11:06:49 am

foxracer1

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~My 91 GLI to 1.6TD conversion build up~
« Reply #55 on: October 11, 2008, 11:06:49 am »
Which clutch disc did you use? And did you get your flywheel from clutchnet? I was thinking of getting the 6 puck or the organic disc.
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Reply #56October 11, 2008, 11:13:29 am

53 willys

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~My 91 GLI to 1.6TD conversion build up~
« Reply #56 on: October 11, 2008, 11:13:29 am »
before cleaning

after cleaning




pretty big difference! what a PITA it has been cleaning all these parts...
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Reply #57October 11, 2008, 12:11:28 pm

dillenger1

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~My 91 GLI to 1.6TD conversion build up~
« Reply #57 on: October 11, 2008, 12:11:28 pm »
this is a fantastic build!!Good flippin job ,man!After its all done,you will reap the rewards.
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Reply #58October 11, 2008, 01:01:05 pm

53 willys

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~My 91 GLI to 1.6TD conversion build up~
« Reply #58 on: October 11, 2008, 01:01:05 pm »
Quote from: "foxracer1"
Which clutch disc did you use? And did you get your flywheel from clutchnet? I was thinking of getting the 6 puck or the organic disc.


well I am running the 210mm flywheel from the 16V trans(2Y)...I cut the ring off myself..so its just a lightened stock 210mm flywheel.
I got this clutch disc..it is the smaller 24 spline to fit my ASF trans I converted in....AND it has the 210mm diameter to fit the bigger 16v flywheel.
http://www.clutchnet.com/product.php?productid=18192&cat=0&page=1
then I used this pressure plate...again it's for a 16v since I have the 210mm flywheel....
http://www.clutchnet.com/product.php?productid=20986&cat=0&page=1

I called them to make my order just to make sure I was getting the right stuff...they are easy to deal with so it's no big deal...
 8)
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Reply #59October 11, 2008, 01:03:16 pm

53 willys

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~My 91 GLI to 1.6TD conversion build up~
« Reply #59 on: October 11, 2008, 01:03:16 pm »
Quote from: "dillenger1"
this is a fantastic build!!Good flippin job ,man!After its all done,you will reap the rewards.


thanks buddy... :D
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