~My 91 GLI to 1.6TD conversion build up~

[53 willys]

well....I came across a smoking deal on a installed but never used NOS system..they guy bought it for his show car and never even filled it with nitrous!
probably should have bough a radiator instead....BUT I have been wanting some drugs for awhile so I could not pass it up....probably blow something up for sure now...lol
this build is slowly getting less and less daily driver friendly....hahaha
waiting on some more injector heat shields...then i can update my cooling issues..

[deepgrooves74]

Hey man... what did you do about your gas tank with the diesel?

[ODwyerPW]

Though I live in Guaymas, Sonora, Mexico...I maintain a post office box in Tucson Arizona (my legal US address..no more upstate NY).  There has been the odd occasion I've driven up to retrieve something from my box, only to find I have to wait a day.  Well, my box is on Valencia Rd, so why not kill a little time and drive on over to Davis Mothan AFB....the bone yard is incredible.  There is also a guy in one of the industrial parks close by that has a number of MK1 Diesels in his yard.  But, he's never there when I stop in.

Ok, that said, I've been following this GLI to 1.6TD conversion from the beginning.

[foxracer1]

Any progress? Ever find the turbo specs? When does full boost hit? Do you still have your cast manifold?

[53 willys]

well I finally got around to doing some more tuning and tweaking...
had to put a lighter weight spring in my wastegate..it was never opening....now I got it set to 20psi so I can break everything in..the more I drive the T-3 ball bearing turbo the faster it spools..it getting really nice.
the 11mm pump is REALLY REALLY smoky..and at 20psi it's STILL ROLLING COAL...lol I'm gonna start backing the fuel down so I can clean it up.


as for water temps..I took the ac condenser out..and all the tubing..I also put a super low temp t-stat in and now even when I romp it hard it wont go past 185*(temps outside were 45*)
I'm not sure the ac will go back in or not???


I also have 1 injector that keeps leaking..I cant really tell if its the small nipple on the return line or the flanged nut/seal...more checking on that..


I will get some vid up ....but I want it running right before I take the time to film it....it's really really close right now!!



I still have not installed my Volvo oil cooler either..i somehow lost the filter nipple extension when I moved a few months back...now I gotta go find another junkyard Volvo and get the nipple off it..but pulling parts in a Pick n pull in the snow is not something I'm in a hurry to do...lol

[53 willys]

53 willys I am soo impressed with your build!! I was told about your head gasket since I wanted to go above the 20 lb mark w/o blowing my head gasket... I still need to measure the piston protrusion above the deck so I know what thickness of a gasket I need. I had a 3 notch before I rebuilt the short block.
Any way... I have been pickin' away at your thread with the 5 minutes here and there... Man I am excited to see it finally working!! This has been like one of those good books that you get to read, and once you get to a certain point you don't want to put it down... I am runnin' late for work so I could finally finish the thread. Would've been sooner, but I just didn't have the time to read!!

Just to join the rest... uuhhh where's the video?

Zukgod... I wanted to talk to you on the phone... can you IM me your cell? I wanted to ask you a couple of things about my project... (sorry to ask that on your thread 53...) It's about my pump... and Giles...

thanks for the kind words deepgroves!!

[fatmobile]

You can buy those fittings.
 I was searching info on volvo oil coolers,
 over on the vortex when I was installing mine.
,.. and they had thread sizes and links to the fittings.
 Seems like summit had them.

 I probably have a spare around, since I used AN fittings on one.

[theman53]

as for water temps..I took the ac condenser out..and all the tubing..I also put a super low temp t-stat in and now even when I romp it hard it wont go past 185*(temps outside were 45*) 
I'm not sure the ac will go back in or not???

I happen to need a condenser and all lines for my 86. Let me know if you will not be using them as I would probably find a home. Good luck on the rest of your project and video...can't wait to see it.

[53 willys]

You can buy those fittings.
 I was searching info on volvo oil coolers,
 over on the vortex when I was installing mine.
,.. and they had thread sizes and links to the fittings.
 Seems like summit had them.

 I probably have a spare around, since I used AN fittings on one.

thanks for the help...but I need the oil filter nipple not the oil cooler nipples...I think I got it figured out though...I gotta do some lathe work to make one of the adapters I had laying around work.

[53 willys]

as for water temps..I took the ac condenser out..and all the tubing..I also put a super low temp t-stat in and now even when I romp it hard it wont go past 185*(temps outside were 45*) 
I'm not sure the ac will go back in or not???

I happen to need a condenser and all lines for my 86. Let me know if you will not be using them as I would probably find a home. Good luck on the rest of your project and video...can't wait to see it.

I'm gonna keep it...I still would like to keep the ac and make it work..but just not gonna mess with it at this time.

[Rabbit on Roids]

as for water temps..I took the ac condenser out..and all the tubing..I also put a super low temp t-stat in and now even when I romp it hard it wont go past 185*(temps outside were 45*) 
I'm not sure the ac will go back in or not???

I happen to need a condenser and all lines for my 86. Let me know if you will not be using them as I would probably find a home. Good luck on the rest of your project and video...can't wait to see it.

why didnt you tell me this a while ago? i would have saved all my a/c components and gave them to you. but instead i kinda destroyed some of the stuff getting it out.

[zukgod1]

I sure am getting old waiting for you to finish this Mark 

[the4ork]

wow just saw this thread...

i gotta say, i am completely envious, and the funny thing is tonight i got on the site to do a search if anyone had tried one of these turbos yet...

i was actually looking at a .60 trim T3 but im very curious to see where your 50trim  spools at. i assume you have a tach so you can tell?

your build is very very similar to what i will be doing this spring. btw, is that just an 11mm home-modded pump or is it a full giles?

Very nice setup, i hope it lives up to your expectations and mine as well and very very nice workmanship 

[theman53]

How about the videos??? I want to see and hear this thing. It will give me inspiration to work on mine again. Help a fellow Veedubber out.

[53 willys]

wow just saw this thread...

i gotta say, i am completely envious, and the funny thing is tonight i got on the site to do a search if anyone had tried one of these turbos yet...

i was actually looking at a .60 trim T3 but im very curious to see where your 50trim  spools at. i assume you have a tach so you can tell?

your build is very very similar to what i will be doing this spring. btw, is that just an 11mm home-modded pump or is it a full giles?

Very nice setup, i hope it lives up to your expectations and mine as well and very very nice workmanship 

whats your altitude???....for the altitude I drive in I wish I could have got a 45trim..witch is what they originally speced me on and then told me they had discontinued the 45trim...

i'm at 4000-5000ft above sea level most the time and my turbo spools pretty fast but not as fast as I like...the real nice thing I find with the BB turbo is not much boost lost on shifts so you can keep it spooled once you do get it there...


now that I have another few tanks on this 11mm pump I really feel it's too hot and smoky for my app...I can turn it all the way down and it still smokes pretty dang hard...I think a 10mm or even a 9mm might work better...?


my car is still a work in progress and it has been a long hard road but I do like the way it runs....it's getting better everyday it breaks in more.....
thanks for the complements.

Btw Zukgod1 on here is the man who did my pump...he's the man.