Author Topic: My build sheet, 1.6l franken motor (Read 4577 times)

thedeezel1 · « **on:** January 06, 2009, 06:15:14 pm »

Hi guys, I am back after six months of remodeling my house for 8 hrs a day and doing my normal job 8 hrs a day.

In that time frame I have come up with what I hope is a good mix of parts for a reliable, powerful IDI for my 81 Rabbit 2 door.

Here it is.

91' 1.6l TD block
1.9l AAZ head, rebuilt + ported/polished
Kolben. pistons, coated
1.9l injection pump, stock
1.9l injectors, stock
k24/k26 hybrid turbo, using cold side from k26 and hot/center from k24
modified intake manifold
Stock exhast manifold, cleaned up inside
FMIC
Looking at 20-25 psi boost

The car is getting everything new, all the suspension and steering, fuel system and wiring and brake system will be replaced.

I plan on reusing the 1.6l crank and rods and getting the block bored out .5mm.

I will be getting a new clutch, which is my biggest unknown at this time as I am unsure which clutch disc and plate to use to hold the HP and TQ.

Any input would be greatly appreciated.

TurboJ · « **Reply #1 on:** January 06, 2009, 07:33:23 pm »

How much power are you after?

In any case, with that hybrid turbo, the stock 1.9 fuel pump will not cut it. You need either a completely different pump or modify the 1.9 pump extensively. A bigger plunger head, modified LDA and governor at least.

Then when your pump meets the needs of that turbo, your gearbox will begin to feel the strain. You may want to look into replacing the gearbox with one of the 02A type - they are stronger and you can find cheaper, strong clutch options for them. Any 35i Passat, any Corrado or Golf G60, Golf mk3 GTI / Vr6 will have a 02A gearbox.

You're also going to need a new exhaust system. The stock one is far too restrictive. Make it at least 2.5 inch from the downpipe, 3" being even better.

BTW, the Mk1 Rabbit is a very good platform for your franken motor since it's so light! Now if you make the engine really pump out power, it's bound to be really fast

thedeezel1 · « **Reply #2 on:** January 06, 2009, 07:47:00 pm »

I am planning on a 2.5 inch exhaust with no muffler out the back.

I was thinking of changing the plunger to a stock 1.6td as I have a 1.6td pump also, or would it be better to just use the 1.6 pump. The 1.6 pump needs to be rebuilt and the 1.9 is off a recently great running car.

I am hoping to get 125 hp out of it, and do it reliably, as this will be my daily driver. I drive an 06 TDI now and it is just too boring, I miss my old MK1 so I building this one.

spencebm · « **Reply #3 on:** January 06, 2009, 08:22:22 pm »

mid 14's!!! I don't know about that but a stock pump will spool that turbo I bet if you mess with the pump. sounds like fun

thedeezel1 · « **Reply #4 on:** January 06, 2009, 08:54:21 pm »

I am not planning on taking it to the strip, but I'm sure doubling the stock HP will make it fun to drive, I might autoX it if I have time.
I have thought about having Giles do the pump, but that may have to wait until next year, I am already looking at putting 3 grand into a body shell I paid $200 for.

boosted_diesel_84 · « **Reply #5 on:** January 06, 2009, 09:48:17 pm »

check with SPEC for clutches, they make some great ones to hold up to a lot of power, i am currently running a SPEC stage 2 on my build, and i really like the way it engauges, not to harsh but deffenitly a lot stronger and quicker than a stocker,

monomer · « **Reply #6 on:** January 09, 2009, 05:09:21 pm »

Quote from: "boosted_diesel_84"

check with SPEC for clutches, they make some great ones to hold up to a lot of power, i am currently running a SPEC stage 2 on my build, and i really like the way it engauges, not to harsh but deffenitly a lot stronger and quicker than a stocker,

I ordered a stage3 from them.

I cant wait until it's finished...

Krazy · « **Reply #7 on:** January 09, 2009, 08:58:49 pm »

Can you run A/C on this engine in this model?

TurboJ · « **Reply #8 on:** January 09, 2009, 09:02:08 pm »

Yes, but depending on your intercooler setup, you may have to use a custom radiator for the A/C.

Krazy · « **Reply #9 on:** January 10, 2009, 09:05:54 am »

Would you send pictures of the engine in the car?

thedeezel1 · « **Reply #10 on:** January 10, 2009, 10:34:41 am »

As of now the engine is just a pile of parts, the block and head will be going to the machine shop hopefully within a month. I don't have the turbo(s) yet, they are about the only thing I haven't got.
I am also wondering about the o2a tranny, what year and model of VW did that tranny come in? I have a stock 5 speed from a MK1 Rabbit diesel that I was planning on using, but if it will not hold up, I will go with an o2a right off the bat, as I once I put the car together I don't plan on having to tear into every weekend.
The car originally had A/C, but I will not be running it. I have a design I drew up using a small 12 volt squirrel fan and a NACA duct, tubing and a small roung ice cooler to make a cold air system like in NASCAR to blow some cool air my way in the summer, I even thought of using the helmets with the cold air inlet on top and wearing that when I drive it. :evil:

MJF · « **Reply #11 on:** January 10, 2009, 10:57:21 am »

Quote from: "thedeezel1"

I am also wondering about the o2a tranny, what year and model of VW did that tranny come in? I have a stock 5 speed from a MK1 Rabbit diesel that I was planning on using, but if it will not hold up, I will go with an o2a right off the bat, as I once I put the car together I don't plan on having to tear into every weekend.

You´ll find one easiest from ´88-´96 Passat. You´ll also need cable shifter, hydraulic clutch (or cable assy from early Passat), 100mm driveshafts, custom mounts, different speedo cable, 02A flywheel, clutch and starter.

thedeezel1 · « **Reply #12 on:** January 10, 2009, 12:18:28 pm »

Thats a ton o junk to change just for the o2a tranny, I figured the shafts were different, I didnt know about the custom mounts. I dont think the cable shifter would be a big deal, just more cash to throw down, especially when I already have a stock 5 speed.
I could just tone down the motor and hope the stocker will take it, and I wont be drag racing it, so hopefully with a good clutch it will live.

thedeezel1 · « **Reply #13 on:** January 10, 2009, 01:38:09 pm »

Disco potato?

I have been looking into just using a k14 or k24, or a t2/t3 hybrid also.

I am looking for 20 psi max boost, although the motor will be built to handle more than that, the reduced boost should help it be reliable.