Plans for a 1.6 GTD????

[regcheeseman]

Having just picked up a GTD engine for very little money (poor ebay ad), I've some time to sort it before it's intended chassis is ready, but what to do....

I'm thinking of doing the following....

Adjustable Boost controller
EGT pre turbine
2.5" downpipe
Intercooler (not the original)

Gov mod - do I replace the primary spring with a spacer OR pre-load the secondary spring OR both? Seen many versions on here.

Pin grind + pump tweaks

AAZ gasket and ARP studs???

I'm looking to run 15-20psi max

Does this sound OK? Have I missed anything or any further recommendations?

Oh I've also got an AAZ spare - should I swap the bits over? I've also got an 11mm TDI pump, can I use this?

[1outof5]

sounds like what I would like to do on mine.

I don't want to go crazy on power so don't know if the 2.25 or 2.5 exhaust makes that much difference ?

I've read that the AAZ head flows better than the RA/JR but haven't taken anything appart to see if the exhaust header is the same which then brings up the question of turbos. Are you keeping the T2/K14 with the watercooling?

If you find a good place (understand good price) for the ARP studs, I'm interested  

[TurboJ]

Definetely put the AAZ head on. It does flow better, and when you want to port the head, there's more room for that on the AAZ head. Also use AAZ injectors, they are the best stock IDI injectors for performance.

Bottom end - 1.6 and 1.9 both work well. The 1.6 revs better, the 1.9 has better torque. The 1.6 has a more reliable crank wheel connection, and the 1.9 has lower compression (slightly) that helps with boost.
If you use the AAZ head on the 1.6 block, you should drill extra coolant holes in the block to match the AAZ head. You can see the pictures on my build thread ( Jetta Project 200 ). Then you can use the AAZ head gaskets which are vastly better than the 1.6 ones.

When running a high-power TD, a full rebuild is most important. After that decision, you get to choose which parts you wish to use.

[regcheeseman]

Definetely put the AAZ head on. It does flow better, and when you want to port the head, there's more room for that on the AAZ head. Also use AAZ injectors, they are the best stock IDI injectors for performance.

Is there not a port match issue between the AAZ head and 1.6 manifolds?
AAZ injectors better than GTD injectors?
Have heard about merc injectors and even hybrid injectors - is this worth looking at?

Are you keeping the T2/K14 with the watercooling?

I intended too - any reason not to?

[1outof5]

Are you keeping the T2/K14 with the watercooling?

I intended too - any reason not to?

nope , was just a question.

the smaller turbos boost faster (lower down)

[regcheeseman]

I like the usable low rpm boost of the smaller turbos too, I wondered if you had any insight on the merits of the water cooling.
Some people disconnect it, some run it constantly and I use it as VW (KKK?) intended (thermo switched)