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#225 by TurboJ on 24 Mar, 2009 17:44
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1500-2000 maybe... rings are already broken in as they were used for 15 k km after last rebuilt. Other than that, I don't see much benefit in a very long breaking-in period.
Modern motor oils are so good anyway, that the engine should be pretty well protected from the start.
Besides, I want to get the engine dyno-tuned as soon as possible, so I'll know it's running at optimum performance. Bad pump settings, for example, can cause more harm than 'forgetting' to break the thing in! -
#226 by DYNOMAX on 25 Mar, 2009 18:22
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A healthy engine needs only a very short running-in period.
The mainbearings etc allready got their clearance. -
#227 by subsonic on 26 Mar, 2009 12:40
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What injectors are you planning on using? 1.6td, 1.9n/a single stage, or 1.9td dual stage?
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#228 by TurboJ on 26 Mar, 2009 16:43
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1.9td dual stage.
Aki told me they're the best OE alternatives and I trust Aki in everything diesel related!
BTW, I've just spent some of the most insane days of my life, putting the Jetta together for the paint shop. There were a lot of nasty surprises in the last few yards, so I've been working like a madman.
Now I have to get some sleep, in 5 hours I'll take the car to the paint shop.
Those gleamy new suspension parts really make it all worthwhile...
I think this thing is going to be loads of fun already when I start fitting all the goodies on it! Let alone drive it as 2.2 bar of boost pressure...
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#229 by subsonic on 26 Mar, 2009 18:01
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Just think, you are almost done and will be able to take a break and rest!
Will you be using the stock aaz nozzle in the injector? Will you keep the pop / breaking pressure of the injectors at oem setting? -
#230 by TurboJ on 27 Mar, 2009 04:06
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Quote from: "subsonic"
Will you be using the stock aaz nozzle in the injector? Will you keep the pop / breaking pressure of the injectors at oem setting?
Yes on both counts
Apparently the limit of OE AAZ injectrors is around 70-80 hp, so I won't need special injectors or nozzles at this point.
When I upgrade the engine in the future, I might get some biodiesel injectors, they're supposed to be the new hotness.
The car is finally at the paint shop, so maybe I really can take a little break now!
Thanks for all the input and comments, fellows! -
#231 by TurboJ on 30 Mar, 2009 13:36
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Time to update again
Like I said, I worked very hard the last two weeks to get the bodywork ready to be painted. There were lots of nice little surprises as the work went on...
The inner fenders had to be rust proofed of course:
I think I'll add a couple layers more, as the plastic inner fender guards won't fit, I'm going to need a lot of protection for the wheel wells.
The front fenders had to be lined up to fit the front doors:
Both sides needed cutting, forcing and bending to make them fit.
Still they're not perfect - I really should have stuck with original front fenders. We'll see how it looks when it's all painted.
Speaking of the nice surprises that I found:
..and remember, this was less than 24 hours from the moment when I was to take the car to the paint shop.
So I needed to repair the multiple new-found holes.
Luckily these holes won't be visible to the outside of the car, so I didn't need to make the repairs pretty...
The next surprise came when I tried to finish the windshield wiper holes.
One that we had welded up earlier, gave up when drilling the new hole, and the other just had too thin metal around. I was in a terrible hurry at this point, so I just welded on a couple of washers there, and called it a day! (or should I say night...)
The next morning the Jetta was on its own four feet for the first time since last July:
Speaking of feet, there they are:
Cheapo Raceland coil-overs and Passat 16V hub carriers.
I just hope the new and recently repainted suspension parts don't get covered in Tornado Red paint mist after the paint job!
Onto the trailer:
She ain't pretty yet, but she does look better than two weeks ago.
And soon I'll post some piccies of the new paint job
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#232 by zukgod1 on 30 Mar, 2009 14:56
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Coming along nicely
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#233 by subsonic on 30 Mar, 2009 21:05
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Have you ever figured out how many man hours you and Aki-76 have into this project total? You guys are just going at it like men possessed! I love it! I wish you guys lived next door to my house!
I have a turbo question for you. Did you ever consider a VNT style turbo? Something like a GT2256v, 2259v or 2260v? I don't rember the turbo you said you are using, I will have to go back and do some reading of your early posts. Do you thing the ones above would be big enough for what you want to do?
Jim -
#234 by TurboJ on 31 Mar, 2009 02:12
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Thanks for the feedback!
subsonic, I never considered a VNT turbo, because at my power level, the low-down torque would just be too much. Con-rods wouldn't stand a chance.
I think if I ever do an Evo II build, I will look into compound turbos instead, or perhaps just upgrade my current turbo a bit further.
The turbo I have now is a Schwitzer S1BG with 39 mm and 46 mm inducer / exducer respectively. It's currently at a turbo shop being modified to a 42 mm inducer. That should give it around 230 hp capacity, if our calculations are correct. Experience from people who have put these turbos to 1.6 TDs tell me that it should act much like a well tuned N/A gasser - very smooth power and torque curves and no spikes to hurt the rods. That is exactly what I'm after. This turbo is originally form an agricultural tractor, so it's pretty heavy duty despite its smallish size, and it can withstand constant boost of 2 bar + ( 30 PSI + ).
About the turbos you mention - I really wouldn't know as I haven't looked at VNT turbos at all for this project. Someone with personal experience will know how those would work.
About the elapsed hours of work - well, since last July I've worked on the car every week, and at least 10-15 hours a week, so that should give a rough estimate! I never expected it to take so many hours, but the bodywork had so many hidden surprises in store that it just happened.
Meanwhile, Aki has been working on my engine quite a bit, and a couple of my other friends have frequently stopped by to help, so I guess there have been quite a lot of man hours involved! But the work has to be done, otherways the car will never run...
I hope the car will be up and running before June, but there's definetely a lot of work to be done still! -
#235 by Dirtrag2 on 31 Mar, 2009 08:37
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Turboj,
off topic here but I'm curious... what is your favorite Beer ? prety important for a tear down/ rebuild like this :lol:
keep it up I can't wait to see videos of a running car. :wink: -
#236 by TurboJ on 01 Apr, 2009 09:19
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To keep things German, I would have to say dark Erdinger Weissbier!
Yesterday I cleaned up the garage so it's less dusty when the body gets back from the paint shop ( you can imagine how dirty it was after 9 months of grinding, cutting and welding )... So I have done something else besides drinking beer!
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#237 by RabbitJockey on 01 Apr, 2009 14:50
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i am curious what you or one of your friends thinks of the holset hy35w turbocharger if i end up going through with my 1.6/1.9 id like to use this turbo because they have an internal wastegate and are cheap and plentiful from the dodge cummins turbo diesel trucks.
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#238 by rallydiesel on 01 Apr, 2009 15:10
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Once you go unfiltered wheat beer, you never go back to regular beer!
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#239 by TurboJ on 02 Apr, 2009 14:51
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Quote from: "Trev0rbr"
i am curious what you or one of your friends thinks of the holset hy35w turbocharger if i end up going through with my 1.6/1.9 id like to use this turbo because they have an internal wastegate and are cheap and plentiful from the dodge cummins turbo diesel trucks.
Someone had one on an AAZ, and it was too big - didn't really spool up at all.. But what are the dimensions? There are different HY35s. A smaller one could work just fine.
