Jetta project 200

[RabbitJockey]

What are the torque values on numbers like that with a diesel of our stroke and bore?

Torque means just as much to me as BWHP does

on daves car the peak torque was around the same number around 190, not that they are comparable in that way.

[Smokey Eddy]

Would anyone agree that with a built 1.6td the hp is on par with torque or what seems to be the trend? I would have imagined the torque would have been 200ft.lbs+ with 150hp

[rallydiesel]

Are you going to stitch weld the body or reinforce it somehow to handle all the extra power and not flex into oblivion?

[RabbitJockey]

Would anyone agree that with a built 1.6td the hp is on par with torque or what seems to be the trend? I would have imagined the torque would have been 200ft.lbs+ with 150hp

i think it all really depends, all the dynos i've seen on here seem to be different, it seems like people with smaller turbos have a way high torque number, not that this is surprising

[TurboJ]

Torque is dependant on what rpm range the engine makes its power in. We are expecting about 350 Nm ( 260 lb-ft ), but with VNT turbos there have been 1.6 TDs with more than 500 Nm ( 370 lb-ft).
We're not after the most possible hp  ( again, 250 hp has been done with a 1.6 ), but a usable engine with nice power.

We are confident it will hold in one piece, since most of the other engines have, that have been built with similar parts. The most important part is not putting it through too much low-down torque.

The 1.6 TD like the 1.9 TD, have pretty weak bottom-ends. The con-rods in particular are extremely weak, a LOT of these have bent or cracked on Finnish turbo projects.  This is the very reason why we need to limit low-down torque. As I try to limit my costs, I won't be getting H-profile rods, but try to do with stock ones, albeit balanced. This is why we use a girdle and steel sockets, so that the stock parts have the best possible change of holding together.

In this engine, all parts are similar as the ones used on my friend's 260-hp twin charged TD, only my turbo is smaller. This should mean that my engine will be just as reliable, if not more, than his was. After all, on a 1.6 the internal loads should be lighter than on a 1.9 as the stroke is shorter and there's more metal between the cylinders.

As for the head and head gasket problems, well, we are using a special inlet manifold that allows even flow to each cylinder, along with a reground camshaft that improves flow dramatically. This reduces the strain on the head a lot. As for the head gasket, we have special custom built studs and nuts which absolutely do not stretch ( much, much stronger than ARP ones), and we also re-torque these studs to higher-than stock torque after initial warm-up. On all the engines we have been associated with, no problems have been present with head gaskets.

[rallydiesel]

What upgrades are you doing for handling? Strut tower reinforcing bars, chassis seam welding, etc?

[TurboJ]

GTI front and rear anti-roll bars, all bushings replaced with polyurethane, height adjustable coil-overs with helper srings all round.
We're not reinforcing the body shell at this point, but if that later seems necessery, we will. I may be fitting strut braces front and rear if I find a good price.
Does the 'rally' in your nick tell you have some racing experience with mk2s?
If so please let me know if you find strenghtening the body work is essential.

[rallydiesel]

I wish it did. I am just going from the body flex that is noticeable from jacking the car up. Since you have the body completely stripped, now would probably be a good time to reinforce the seams.

Anyways, could you explain how your friend makes the custom head studs and did he also make the girdle?

[TurboJ]

The girdle was made by another guy I know.
Making the head studs and nuts: It's special high-strength steel that's used on some high-end tools. It's machined down to the exact size wanted and then heat-treated. Apparently they work really well, as we have no problems with head gaskets not sealing properly.

[rallydiesel]

Would your friends make some to sell?

[TurboJ]

I'll ask when I next meet them  

[rallydiesel]

This build makes me reconsider building an mTDI. TDI stuff is still so expensive. An IDI actually seems like a better hobby project. For me, the affordability of IDI performance is why I was hooked in the first place.

Now I just have to convince myself my precups won't fall out.

[MJF]

Precups wonīt fall off. Those fall off from gazillion times overheated&wrong used (beating cold engine, not cooling hot engine etc) engines. Just keep the temperature at normal, there is no problems with head. When people started building superturbo Mercedes, there was "knowledged" people who kept telling: "head doesnt last in stock engine, it cannot be souped" Well, stock engines still keep cracking heads, but not superturbos :roll: Itīs not the power that makes problems with head, itīs heat.

I had no problems with head or hg with my Scirocco engine, before it blew. It threw a con rod and I know what went wrong with it. I was at 230-240hp (crank) range at that time.
Those girdles are made by me. I had these made a bunch, sold them all.

[carrizog60]

and the head studs?
what would be tha price for those?

[truckinwagen]

first off awesome project, you are a inspiration to us all.

do you have the cad file on that girdle?
if so would it be possible to get it so a local machine shop could make one for me?

how thick is the girdle and what kind of steel is it(mild/alloy)

I am working on a sequential turbo setup, and that girdle looks like the solution I have been looking for to hold the bottom end together,
I also have a few buddies with gassers that are interested in the girdle design to make their high HP motors more reliable.