Jetta project 200

[TurboJ]

Back at work!

Actually, I have been working on the Jetta nearly every day for the past week, but it always seems the progress is much slower than the count of hours spent working..
I still have a good feeling about this, although there is obviously very much work ahead me. At least I finally have some spare time on my hands. Or would have without
this project

Anyway, it was time to do the fuel lines since the sender unit was now complete:




I was lucky the sender unit came to be the right height... If it had been too short, fixing that may have proven to be a real issue.
Replicating the original unit's sitting depth with the spring action and all was not easy.
But there it is!




I used similar kind of nylon line the factory uses, but 8mm inner diameter instead of the original 6.
The necessary bends were made possible by the use of a pipe bender and heat gun. It did take some testing to get it right and still I'm not
completely happy with the result. The return line has an unnecessary extra bend and it doesn't really sit right. But it has to do...

I made the fuel feed line out of white nylon pipe - it's almost transparent to help locate any leaks. And with the help of a flashlight,
all possible bubbles can easily be seen.




The mess in the engine compartment:




After I finish with the intercooler/radiators fitment project, it'll be time to do the fuel filter along with the air filter housing...

[TurboJ]

Speaking of intercoolers and radiators, here's some parts I have gathered up for the pipework:




And here are the radiators themselves...



The first two are obvious really. The I/C will be modified a lot before it's ready, but the rest will go on the car as they are.
So why do I have four radiators? Well, the small ones are for the oil and fuel respectively.

The fuel cooler isn't huge (it doesn't need to be). It will be fitted directly to the injection pump's return line.




According to someone's research, in this power range the fuel cooler may be worth ~5-7 hp on a warm day.

[TurboJ]

The venerable VR6 top mount and an Aki-made strut bar mount.

[TurboJ]

The rear axle was mated to the anti-roll bar:



The 'basic' 25 mm H&R bar should be the wise choice - I don't want too snappy handling. The car may even see some winter use after its first years.
Maybe. I'm already thinking about a next project, and I think that one will be a full toy

Then it was time to learn the hard way how the brake lines should be routed.



...that was the wrong way as I later found out...


Apparently this works better with the axle mount:




I'm trying a set of Black Diamond braided steel brake hoses. I hope they stand the test of time.




The left side brake line was pretty tough to make fit. I also had managed to sell myself the wrong length pipe at work 




Powerflex rear axle bushings...




All new brake pressure regulator parts too. But now I'm giving myself a hard time for not painting the bias valve! Yes, I know, I know!




And there it is at last!

[TurboJ]

Today I got my new tires too.




BTW; what are your experiences on wheel spacers?
I'm thinking I might try a set, since the Ronals' offset isn't exactly right, near though it is.
Are spacers really a safety risk? And do they stress the wheel bearings a lot more?

[TurboJ]

Time to start fabricating the radiator supports.

I'm using zero original mounting points - the intercooler fitment necessitates that and while I'm at it, I might as well do it right.
So the plan was from the beginning to basically redo the radiator support frame completely.

Putting these parts on the car for the first time in four years!




The finished paint work had to be covered before the cutting could begin.



Next time I start a car project I will definitely do the paintwork LAST. 


Test fitting the intercooler.




The right side top mount would have been to low with the standard sheet metal. So I started to cut it down...




Unfortunately this heap is only the beginning of the cut-up process.




The first parts of the new metal work to be welded onto the frame:




Too bad I don't have a welding device at my disposal right now. I'll have to figure something out... For the radiator frame I'll
have to have someone do some spot welds for me tomorrow. Hopefully I can find a nice MIG welder soon!

[nathantheengineer]

looking good as usual!! Can't wait top see this run, you must be getting excited now??!!

[TurboJ]

Yes, I definitely am!

These days I just can't wait to get to the garage again and when I'm there I just wish time would stop.

Now it's all fun, which can not be said about the body repairs and such...
But this journey has been extremely educational too. I think my next project will turn out real nice.
Now I just have to find out a way to make some more money

[carrizog60]

paint for last is better yes...

but with extra care all can be done!

[TurboJ]

Yesterday I got a nice, heavy package from Aki 





It's a Schwitzer S2A with a modified turbine housing, using the smaller T25 flange style. I don't have all the specs right here,
but the inlet and outlet are 38mm and 50mm. This should spool pretty well I imagine!

The downpipe:




Exhaust manifold is made out of an AAZ manifold IIRC. Collector modified and T25 flange welded on.
The EGR outlet has been reassigned to waste gate duty
All once again sand blasted and ceramic coated for maximum efficiency...



If you have read your 'Maximum Boost' you will cringe at the sight of the wastegate oulet, but it has been carefully chosen.
The priority of this manifold by far is to use the exhaust heat energy as well as possible, helping the turbo to spool up.
The waste gate would have significantly increased the collector volume if fitted to the usually preferred spot - not good
for our IDI engines. And the good thing is this wastegate location has been thoroughly tested and there is no boost creep.



Here's how the T25 flange sits on the collector:




And as you can see the flow path of the manifold itself is not bad at all:




There are also connectors for an EGT probe and an exhaust gas pressure gauge.




This is what I will be using for a wastegate:




...to be mounted something like this:

[TurboJ]

The intake manifold is now better matched to my aggressive camshaft.
I don't think there are many OE VAG manifolds with shorter runners than this!




A nice heat shield on there:



I will soon test fit everything and see how I can manage the radiated heat as well as possible.
I will also be making a sturdy support system for the turbo, waste gate and downpipe.

Also a nice little plugin for a boost signal line.




And of course it is a twin plenum design 




The AAZ injectors have now been tested and set up. Ready to fire up then! (The injectors, not the car, just yet...)




But of course, I don't want them to look old and rusty!
So, bring on the hammerite!






I also got my new motor mounts and decided they won't get rusted any time soon either...

[Powered by Spearco]

Wow Janne. I love the coffee maker in Tial Waste gate photo.

So the intake, is that from a D24T? Looks mighty interesting. Kinda what I'm wanting to do.

[TurboJ]

Then it was time to continue working with the radiator support frame:




I already put in some steel tubing to strengthen the frame.




Looking at it from the front side it was looking like this:




After the added strength the middle section could be opened up for better air flow:




Oh how many holes there are to weld up!
I just hope all the necessary parts will still bolt up how they should after all the shaving.. There are always risks when you don't have complete pictures about everything.




Another mockup stage:




At this point the lower frame was still like the factory intended. The old, rusty front engine mount is only for mockup purposes!




OK, so I was planning to use the stock 1.6 TD radiator, but then I did some research at work and noticed it's one of the smallest radiators
for the space there is available. So I decided to switch to another unit.
I checked which suitable radiator would be the biggest one that still fit my bay, and found out that a Passat one is the best for this purpose.
The specs are Passat 3A2 TDI-110 Automatic with A/C. It's BIG Will post pictures later when I get the change...

Anyway, the switch of radiator meant I had to redesign the lower frame too. So let the cutting begin again!




...like so:




And here you can see my logic - I made a hole in there with the exact measurements of the Passat TDI radiator.



The new rad is exactly 6 cm taller in height than the mk2 rad, so changes were necessary.
I still have to figure out how to do the actual radiator mounts, there are a couple of little issues with that.

Making a new bottom to the lower rad mount:

[TurboJ]

Wow Janne. I love the coffee maker in Tial Waste gate photo.

So the intake, is that from a D24T? Looks mighty interesting. Kinda what I'm wanting to do.

Heh, the Coffee maker is my wife's baby  ( she liked your comment )

Actually, I just can't remember what engine this intake is originally. The D24T should have oval ports, should it not?
I will check when I hear from Aki again! He has so many intake donors around that I really don't remember which is
which always...

and BTW, thank you for your pics and vid you sent me! Nice stuff you got there!

[TurboJ]

One more picture just because I love this heap of parts so much