Author Topic: Jetta project 200 (Read 132252 times)

jtanguay · « **Reply #180 on:** February 17, 2009, 06:22:19 pm »

Quote from: "TurboJ"

Remember there are two engines talked about here.

The head porting pictures are of my 1.6 engine with AAZ head,
the pistons are from Aki's twin turbo engine.

As for the ceramic coating, both our engines will have that. (Piston tops, combustion chambers, exhaust ports and manifold, possibly also insides of the pre-cups).
Now I hope I had bough those uprated con-rods after all.
The rods are now the only thing that prevent me from going seriously over 200 hp. Well, there's always next time...

watch out on coating the swirl chambers... the design of the motor requires them to be quite hot to ignite the diesel effectively. i would think that coating them to limit the heat transfer to the head might actually work though... if anything, you would want a coating that would enhance heat transfer inside the swirl chamber, but i think its already good enough.

TurboJ · « **Reply #181 on:** February 22, 2009, 06:55:48 am »

OK, finally a little update.

Like I said, I have been very busy lately, so I haven't been able to work on the Jetta as much as I would have liked.

The bodywork is still under way, but I like to think it'll be done in a week or so.

The door surrounds are complete. The welding luckily didn't distort the panels, so the doors and trim went back on beautifully after the work was done. Of the windscreen surround I drilled only the sides and the upper part, as the lower part had aready been welded pretty much through when repairing the rust damage. Next will be the engine bay, and then the reinforcings are done.

I test fitted the front wings and cut the arches to allow more room for the wheels. The wings became really flexy after removing the inner lip from the arches! Then of course the plastic arch trims also needed attention...

Old trusty dremel tool proved useful in trimming the plastic arches.
I hope the openings are big enough, since the arches and wings are now at the paint shop. Not going to be easy to further modify them after they are painted. And no - I'm definetely not painting them body colour! The plastic parts will get a nice matt-black coating to make them look like they did when they left the factory.

When I took all the parts to the paint shop, I noticed that my original arch trims had some serious damage, and even some pieces missing.
So I had to find some replacements. That was not easy!
New arches cost 100€ + apiece at the $tealership, and used ones I came by, were all even worse than those I had.
Finally I found a set that did have broken parts, but different parts to my set. So I combined 4 arches from a set of eight. As a result, I only had to repair two bigger cracks. Here's the picture:

Soldering iron fixed the cracks in no time, and after the arches are grinded smooth and painted over, no-one's gonna know.
Sure beats paying 600€ for a full set of new side trims!!!

All the parts that came off, were taken to the paint shop this week.
The paint guy started the work right away. I should be getting all these back in a few days, and in about three weeks' time the complete body should be done. This means a lot of work to be done in the following days.

Expect some nice engine footage after next weekend - I'll be going to meet Aki at his garage and we're going to be working on my engine.
Aki's told the AAZ head should be ready by then. I can hardly wait!

Aki-76 · « **Reply #182 on:** February 28, 2009, 10:04:54 am »

my own twin turbo crankshaft just arrived balancing..

http://i434.photobucket.com/albums/qq68/Aki-76/moottorin%20osia/IMG_3806.jpg

weight is 1,2 kg lighter vs. orginal :twisted:

ryanp · « **Reply #183 on:** February 28, 2009, 10:48:36 am »

aki, I Sent you a pm re. the 1Y diesel engine, did you get it?

crank looks

i'd love to build a big power motor!

cheers!

TurboJ · « **Reply #184 on:** March 04, 2009, 09:18:42 am »

Things are moving on, and as promised, here are the latest pictures.

The bodywork's reinforcement weldings are now done.
All together it took about 600 welds.
Spot welds on the door frames and the wind screen frame, and some seam welds on the front shock turrets.
I'm not sure how much all this has affected the rigidity of the body,
but just by jerking the inner fender panels by hand,
you can definetely feel a difference after seam welding all the
(plentiful) factory seams on the turrets.
The complete feedback will of course only be available once the car is driveable once more,
but then, all suspension components have changed too, so it will be difficult to spot which upgrade has the most effect.
If you have personal experience on a spot-welded bodywork, let me know!

TurboJ · « **Reply #185 on:** March 04, 2009, 09:32:36 am »

When I ordered my stress bars through the eBay, I got the wrong bar for the front turrets, so I sold it on and Aki volunteered to fabricate a custom stress bar to fit the Jetta with the modified 1Y intake manifold.

Compared to the usual commercial offerings, these turret-top plates are really heavy-duty. The plates are some 8 mm thick and the bar itself will be much straighter than on the usual kits, so this thing should really help improve the front end's rigidity. A coat of paint to match the engine bay's hue is coming along.

A lesson here: Never buy cheap aftermarket A-arms.
To this point, I have already had to buy three sets of new A-arms, and still not fit one set.
I have the Prothane polyurethane bushing kit, and the bushings all have the the same dimensions as OE stock arms. So, none of the cheap aftermarket arms would work with these bushings, since the arms had all the wrong size mounting points.
Now I bought a set of German-made Lemförder A-arms, and obviously, they are of the right dimensions. I will NEVER ever buy the chinese crap anymore, be it not intercoolers or door handles :lol:

After removing the rubber bushings from the crappy Chinese A-arms, I noticed the different dimensions. The two arms from the same factory even had 2mm difference between them!!!

I had also bought a brand new aftermarket subframe, which had the same exact problem. That, luckily, I was able to return for a full refund. Then I got a rust free OE subrame for 1/10th of the price. Sometimes you DON'T get what yoy pay for...

TurboJ · « **Reply #186 on:** March 04, 2009, 09:52:39 am »

The cylinder head is ready apart from ceramic coating and re-assembly:

The head was almost new to begin with, so I should have a good starting point in terms of potential head failure.
The inlet ports were enlargened quite a bit, the exhaust ones a bit less just to be safe. The head has been re-planed (how do you say that in English?)
and the valves are mounted deeper into the head to allow for the increased lift of the performance cam.

The valve guides have also been re-shaped:

It's a venturi shape of sorts, one that apparently works quite well on VW 8V heads.

The valves themselves got some attention too.

The valves have a full angle, lapping and polishing job.
We sanded the valve heads to 400 grade. Not mirror-smooth by any means, but a big improvement none the less. Besides the valves were almost new to begin with. The angle job should improve flow quite noticeably too.

As you can see, the valves sit quite deep in the head.
That and the 3-notch H/G (it had a 1-notch originally) will help the valves keep as smooth as they are.

There's almost 1 mm difference on how deep the valves sit compared to a stock AAZ head. That will also lower the compression ratio, which is no bad thing considering how high it is on a stock engine. You can also see how the combustion chambers and pre-cup openings have been re-shaped on the first picture.

This week I will be getting my bumpers, doors and plastic trim from the paint shop. The complete body goes in next week, and within a month I should be able to start putting it all back together. Actually, I only need a clutch now, and some little detail parts, then it's just fitting and finishing ( I WISH...

)

Anyway, the beast should be ready to hit the street just before summer, so I hope no more nasty surprises.

BTW, this is how we left the Passat that gave us a TD-spec 02A gearbox:

With the 0.71 5th gear, I'm aiming to reach a top speed of 150 mph.
We'll see how that goes!

Once more, thank you for all the great work and help, Aki, Marko and Esa!

arb · « **Reply #187 on:** March 04, 2009, 11:51:09 am »

Very nice head !! Has anyone powder coated theirs when its this clean ?

truckinwagen · « **Reply #188 on:** March 04, 2009, 11:57:20 am »

nope, but I might when I do my next one as I will have some time to do it.

great idea!

RabbitJockey · « **Reply #189 on:** March 04, 2009, 05:26:19 pm »

wow wow wow u guys are really doing it and going all out damn.

TurboJ · « **Reply #190 on:** March 06, 2009, 01:27:43 pm »

Thanks for all the positive feedback!

Anyway, I'm currently in the process of repainting my 'new' subframe and steering rack. What's curious is that the subframe has 'made in Mexico' or the equivalent Spanish words on it, and the steering rack (power steering) has USA on it.
They both came off a German import Golf GTI 16V.
Did they really put American made parts on German-built Golfs?
Just wondering, I thought it was strange.

Furthermore, will the US-made steering rack be interchangeable with my original TRW rack?

RabbitJockey · « **Reply #191 on:** March 09, 2009, 11:18:52 pm »

i am cruious about a few things that the finnish may know since you guys seem to tune these engines much more than many other countries, will a 2 piece plastic sdi intake clear a 1.6td injection pump? i don't have my td car anymore since the body shop has had it captive for ages now and i am just really curious if i have a nice upgraded intake or a paper weight. i have it bolted it to my 1.9 head but i just cant tell it is too close to tell.

also how is the 20v tdi coming along?

TurboJ · « **Reply #192 on:** March 10, 2009, 04:13:01 pm »

Aki's doing an AAZ twin turbo first, 20V TDI is next

As for the intake, AFAIK it should fit fine. No experience on my own, but that's what I've been told.

BTW, What do you mean the body shop's keeping your car captive?
You ARE getting it back, right?

RabbitJockey · « **Reply #193 on:** March 10, 2009, 05:14:58 pm »

i better get it back its a mk1 jetta coupe, mk1s are hard enough to find around here, a jetta coupe is even worse. it took him a year to get it done and i want him to fix a few blemishes and i think he is just ***ing around about fixing them so that i will throw a fit and just come get it.

RabbitJockey · « **Reply #194 on:** March 10, 2009, 05:31:58 pm »

i got a chance to look at my dads mk2 td i really doubt it will fit now that i have had a chance, i sat my bare head with the sdi intake on it in the engine bay to compare, the lda is just too high it looks like it will hit in many places. maybe it would work on an na motor or a td with a jx pump. it looks as though even the injector lines could cause issues