Jetta project 200

[theman53]

The acryllic urathane should be ok. It is more the aresol solvent based stuff that is 70% or more solvent. I guess it eats into the zinc a bit too much and lessens its effectiveness. I did the same as you and waited several days to do more work on top of it and mine isn't rusting yet.

[TurboJ]

Thanks, all of you!

I'm finishing the frame right now and when the spray filler has hardened, I'll start cutting up the intercooler pipes.
Then the coolers will be off to a radiator shop for pressure testing and some TIG-welding. Hopefully this will all be done soon sp I can get working with the technical parts!

As for the ALH Polo - no link yet, but I can tell you it's running a modified Schwitzer S200 turbocharger (single turbo).
Aki has been closely involved in the build for some time and has made many of the parts. I will share more information when I have some!

[Alcaid]

Good progress, TurboJ! Looking forward to hear all about your first startup of this monster Jetta!

As for the ALH Polo - no link yet, but I can tell you it's running a modified Schwitzer S200 turbocharger (single turbo).
Aki has been closely involved in the build for some time and has made many of the parts. I will share more information when I have some!

Single turbo?!? Sounds like a lot of lag and alot of RPMs on top?

[745 turbogreasel]

I was wondering  if you can comment on reasons for choosing this manifold http://i232.photobucket.com/albums/ee303/TurboJanne/Jetta%20II%20TDIC/Valiaikainen%20yhteiskansio/IMG_2298.jpg
instead of that?

[TurboJ]

Good progress, TurboJ! Looking forward to hear all about your first startup of this monster Jetta!

As for the ALH Polo - no link yet, but I can tell you it's running a modified Schwitzer S200 turbocharger (single turbo).
Aki has been closely involved in the build for some time and has made many of the parts. I will share more information when I have some!

Single turbo?!? Sounds like a lot of lag and alot of RPMs on top?

Sorry for not replying when you posted this...
Aki and his friend have been working on the Polo some more, and after another turbo evolution (still S200 based), power has increased still, and now with wider power band.
No 'real' dyno numbers yet after the 340 hp, but torque is apparently over 600 Nm (440 lb-ft +).
It's really interesting just how far a 11mm pump can be taken.
It's been a long road for Aki, some legendary builds and also a huge amount of challenges to overcome.
Now everything is coming together on that ALH engine. I will post info when we have some more of it.

[TurboJ]

I was wondering  if you can comment on reasons for choosing this manifold http://i232.photobucket.com/albums/ee303/TurboJanne/Jetta%20II%20TDIC/Valiaikainen%20yhteiskansio/IMG_2298.jpg
instead of that?

Sorry for this delay in replying!

Do you mean why did I choose a short-runner intake instead of the one on your picture?

If so, I chose it because the SRI (short-runner intake) is better suited to my camshaft profile.
I had a 1Y -based (1.9 D N/A) long-runner intake before, but since Aki made that one, a lot of experience has
accumulated on these IDI engines, and some important information has been found regarding camshafts.

On a stock, or nearly stock camshaft profile (also on high-lift ones) a long-runner manifold seems to work best.
On a more aggressive camshaft, such as mine, an SRI works best.
The only thing I'm wondering about is if my plenum is too big - it's a 1.6 liter engine after all. The plenum has to be more than 2 liters on mine..

Here:

[TurboJ]

I'll post some pictures about what I've been working on lately.

As of today I have abandoned all hope of the car running this autumn.
It could be done, but at a too high cost. I have my work, my studies and a young wife that I need to attend to, so I'm cutting back my garage hours for now.
New plan is to make it all ready in good time for next spring - should be much more relaxed that way without a great big hurry.

Anyway, as you guys might have noticed, I have been asking questions about fuel filters.
I made a new filter mount:













Too bad I'm not going to be able to use this one. Story of my life - I build all sorts of parts for the Jetta only to notice when they are ready, that they
don't work on my application. I'm going to need a really big heavy truck filter, and that's not going to fit this spot.
Luckily I already have an idea on how to make one fit..  More on this in the future!

[JBG3]

Too bad I'm not going to be able to use this one. Story of my life - I build all sorts of parts for the Jetta only to notice when they are ready, that they
don't work on my application. I'm going to need a really big heavy truck filter, and that's not going to fit this spot.
Luckily I already have an idea on how to make one fit..  More on this in the future!

this is the one im using-

w

it has a flow rate of 60 gallons per hour.  Could that work for your application?  It doesn't really fit in the engine bay without cutting through, but its ridiculously easy to change

[TurboJ]

Some more sanding on the rad frame:





Spray filler, several coats of it:





Meanwhile, sanding again and again...




Finally, proceeded to applying the primer:





Lower and upper rad support parts:





The lower part ended up like this, ready to be joined to the front cross member:

[TurboJ]

JBG3, thanks for the tip!
I'll look into that.
Your filter setup looks really professional-like, good job!

[TurboJ]

The G60 brake master cylinder and the TD booster heat shield fitted.

[TurboJ]

The engine rear mount and transmission mount:



Rear mount is G60 spec, the transmission mount is mk3 VR6 spec.
I'm having my doubts about this G60 rear mount though. It seems really soft, you can twist the top part by quite a lot using only fingers.


Here's my new(est) water flange.
Of course I had already refurbished and painted one aluminum cyl head end flange before I realised I'm going to need an extra water temperature sender mount...

[TurboJ]

The radiator frame is finally looking approximately how I wanted:





The I/C sits quite comfortably there:





Flexible rubber strips to cover most of the gaps between the air baffles and the I/C:





...as well as between the grille and I/C:





...and even between the lower scoops and the bumper:




I also put rubber insulating strips on the water radiator baffles, so now I've done most that I can to make air go through the radiators as effectively as possible.

[TurboJ]

Then I was finally able to start working on the intercooler pipes.

I shortened the pipe connectors of the I/C to make room for curved inlet and outlet pipes.
The path for each pipe curve was VERY tight!




I had to grind down those little screw bosses on the radiator. I hope there won't be any warranty issues, then!

These are supposed to become my boost pipe set:





It was a surprisingly difficult job to make both pipe connections fit. This has been by far the most challenging intercooler fitment I have ever done.





Finally the first two bends are ready for welding. Incredible, it took like three hours and the end result is just these two little pieces 




Tomorrow morning I'll take these to a TIG welder along with the intercooler, and then I can start working on the auxiliary cooler lines and the radiator fan fitment.
The fan is not going to be easy.. I wish I could find a quick solution for it! But I'm afraid it will take a great deal of fabrication and alu welding too...

Hopefully soon there will be more to report!

[745 turbogreasel]

If so, I chose it because the SRI (short-runner intake) is better suited to my camshaft profile.
I had a 1Y -based (1.9 D N/A) long-runner intake before, but since Aki made that one, a lot of experience has
accumulated on these IDI engines, and some important information has been found regarding camshafts.

On a stock, or nearly stock camshaft profile (also on high-lift ones) a long-runner manifold seems to work best.
On a more aggressive camshaft, such as mine, an SRI works best.
The only thing I'm wondering about is if my plenum is too big - it's a 1.6 liter engine after all. The plenum has to be more than 2 liters on mine..

Interesting.
Id think your volume would be still relatively in proportion, as you have removed  2 cyls from it, though who knows what VW optimized it dfor or how much effort they put into it.