The GTD RETURNS!

[RabbitGTDguy]

Thanks for the comments...now I need nozzles and I may have an excuse as I think these ones are on their way out the door...so to speak.

Anyways...unlike alot of people I've seen that have vented the breather/ccv to the atmosphere, I still have mine plumbed to the intake tube.

Yah...can't wait to get the CTN in...the FN is really limiting in what I can use of the power band...and boost, especially in 1st and 2nd.

Joe

[Audi80]

Hmm, does Matti have more of those clutch cable kits?  

 :lol: I could get a couple more  :lol:

Hey Joe, what car are those shifters from? I have a Passat shifter in Scirocco and the cables are a bit too long :? I was thinking if Golf or Corrado cables are same length?

[hillfolk'r]

LOL , I don't think so...but it could be asked.

On the turbo. I'm not running a stock t3 from a 1.6 TD. Its larger on the exhaust side, a .48A/R at the moment with a .42 50 trim compressor. Its not what I ideally "want" on the car...but we're working on that for this winter as well.

Joe

hey joe,hows the response on that turbo????im tryin to figure out a new one for my setup

[RabbitGTDguy]

Matti,

Oh no...I may have inadvertantly gotten you into a business Matti! So nice though that I'm not going to have to run the damn hydraulic clutch setup. Its not the fabbing involved with the system...its just the idea of the wet clutch...i dislike. I may convert the b3 to cable clutch as well in the future here...hmm, maybe I should have gotten another! Anyways...

Matti,  particular box is from a MKIII VR6 GTI. The box itself is slightly more "slender" in design, slightly shorter and is more curved towards the back compared to the 'rado or passat boxes. However...I thought about cable length as you were saying and sat my very nice passat cable shift box I have here for my swap next to the MKIII GTI one....no difference in cable length from what I can discern. I've heard in the MKI the best way to solve this problem (of the cables being too long), or rather, the best install and what I intend to do is to mount the cable shift box TOP SIDE on the shift tunnel and run the cables through the firewall vs. expanding the existing opening and mounting it up through the bottom.

hillfolk,
On the turbo. I'm working on getting a tachometer setup in the car, I really need to get it in to see where the turbo is spooling up, etc. My optical tach setup is having issues, so I think I'm just going to go with the Dakota Digital convertor (was going to try the tach conversion, but can't find the right electrical components). My impressions...well, mind you...I still have .216's in the car and the FN tranny which essential doesn't allow anything to get going in 1st or 2nd just because of the gearing...However, the turbo does respond quite nicely I think and I've had it up sustaining 30psi here. I haven't run it out because I don't have the water system installed yet for the intercooler, but that should happen today/tomorrow. With R520's and the low end fueling I can pull from them with the pump setup, I'd expect it to be ALOT more impressive. The turbo itself was used, so I may need to rebuild it this winter but overall I'm happy with things. Though...there have been GT units I've been considering and possibly a holset...but doesn't sound like that is working well for you. I think there are merits with a slightly larger cold side (say .50 A/R, .53) and the .48 turbine side. However, it does effect spooling...but top end response is better with the larger turbine side A/R. Fueling makes  a big diff though too. It'd be nice to find something like a .53 A/R cold side and a .42 A/R hot side honestly. It keeps the "smaller" turbine side in check for quicker spooling, but gives more top end breathing (more so than the .36/.38 stock IDI TD T3 units) but doesn't take it too large to hurt low end spooling depending on your fueling.

Joe

[hillfolk'r]

i dont wanna jack your  thread joe,,,,what about this turbo??id use the .48 turbine housing i would think.......
http://cgi.ebay.com/ebaymotors/Garrett-T-3-Turbo-Turbocharger-60-trim-T3-Ford-SVO_W0QQcmdZViewItemQQcategoryZ33742QQihZ016QQitemZ260133364336QQrdZ1

[ezekiel]

hillfolk,

I moved my post over to your other thread so as not to jack Joe's thread.

Joe,

what is the name of the stuff you used to tape off the block for painting?  I've been looking all over for something like that after I read that's what you used.  Liquid masking tape?  I've found it online, hoping I can find it at a store somewhere.

thanks

[RabbitGTDguy]

Honestly, what I used to "prep" the block was alot like a petroleum jelly that you'd just buy in the store. It worked great and on the "flange" areas really made the taping off process alot easier...other than that, it was masking tape and alot o' shop towels...

On the turbo above, I think ezekiel's post in your thread on the problems with the holset turbo is right on....especially consider size, flow, temps, etc. etc. I'll post more over in the thread...

Hopefully AWIC installed tomorrow or by the end of the weekend (if it doesn't get done tomorrow because I have the day off...then sat. night/sun will be the next time I get to work on it). Looking good...just tight finding spaces in the MK1 to make things look "clean and neat"

Joe

[RabbitGTDguy]

Well...the AWIC is finally completely plumbed in, filled with water and working. I have a few refinements that I'll "make as I go" here, but the fact of the matter is that it is up and working, which I'm very happy with.
so... a few pics...

Here is when I first started plumbing in the lines for it... I used some really nice Ag sprayer hose made by Goodyear for the job...nicely sized as well at 3/4" ID throughout the entire system. All total, once filled today it topped off close to 5gal of water.


One thing that took a while was finding decent grommets to fit the body where I made the holes for the water lines to come up through...
ended up in the "HELP" section of the local auto store and pondered...finally, came across a HUGE GM grommet...but it fit PERFECTLY for the hose and the body!!!

Installed one compared to the other line/hole...

Here is what the keg that I used finally looked like after searching through McMaster for the aluminum bungs for it... and my homemade brackets which seem to work really well and keep the setup looking "clean" in the hatch...

So...the final product as it stands at the moment.
I ended up using a Ford lightening/VR6 style aux. water pump as the RV unit I had wasn't up to the task...it was a diaphrapm style and got to be loud once in use for quite a while...
Keg mounted, system filled/bled at this point...I've also made a "mount" for the pump if I want to make it stationary to the spare tire well if need be. I'll also eventually here in the next few weeks be mounting my battery on the opposite side from where the keg is and that'll leave the spare tire well open.


Here is what you can see of the plumbing of the intercooler from the outside of the car...its not much, and I didn't want to run them down the center of the car of course because of the exhaust...


I'm so glad that with all these additions to the car in the way of drilling, cutting, welding, etc. that I have not done the bodywork yet. Its nice because when i go to do it this winter, I'll have everything "set" the way I want to, be able to weld anything I don't want back up and have a nice clean "ready to install" setup for once I get the paint and bodywork done here. Its a good feeling. Do it once...do it right.
This winter the keg will get a good polishing, as well as the intercooler itself and I'd like to eventually replace the intercooler pipes with some nice aluminum or stainless if I can find something at a decent price...or someone with scrap in the size I need and long enough...
I also am working on figuring out how to make filling the system easier. Originally I wanted to keep the look of the keg "clean" to keep it "keg" looking...so I was going to install a small aluminum res. for filling that would be the highest point in the system either in the back hatch of the car (t'ing off the return line) or installing it up in the front of the car.
Well...as you can see...room in the engine bay is getting hard to find and the piece I got off of EbAY really sucks IMHO and I don't want to use it. I may install a radiator neck/filler neck on the intercooler instelf, or could do it on the keg as well. Still up in the air about it. We'll see.
It is working though and is a nice setup. took it out for a good run after I finished things up and after the run you could easily touch the pipes and tell a distinct difference in temp before and after the intercooler.

Anyways...so....R520's...please come soon and I need to find someone to rebar my injectors!!! Preferably while I'm on the honeymoon so they'll be here when I get back!

Think I might work on upgrading the filter system (fuel) and hiding it (don't like where it is in the engine bay there...) and may try to relocate the pump back closer to the tank if I can find room....its kinda "large" though...we'll see... I'd like to clean up the bay a bit


Joe

[RabbitGTDguy]

Well, honeymooning in the Outer Banks of N.C. right now! It'll be great to get back home to the mTDI though as its neatly tucked in the garage at the moment. Haven't seen any MK1....spare the cabriolet that was in the VW caravan at my wedding and my friends 16v 2.1 ITB bunny...and another 'vert down here...nothing else...

Nothing interesting diesel wise either with exception to the MASSIVE numbe of Duramax and Powerstroke diesel down here for 4x4'in in the sand North on Highway 12....VERY NICE!!! Makes me want a truck!

Anyways...missing the bunny...hopefully nozzles will be in order when I get home!

Keeping my eye out for bread vans/4bt's while I'm down here too in hopes to snag another pump for the b3 project coming up.

Couldn't ask for better whether though! Maybe next year the trek will be in the mk1 !!!!

Joe

[RabbitGTDguy]

Heh...Heh...Heh

Look what came today!!!


Working on the install now in some 220 bodies I have...

Joe

[zaprzal]

Heh...Heh...Heh

Look what came today!!!


Working on the install now in some 220 bodies I have...

Joe

I think you'll need bigger turbo again  

[RabbitGTDguy]

LOL...maybe, we'll see. mine is not the 1.6TD unit, I've had several ask about it...its the merc 300D unit. .42cold .48 hot. I've toyed with different ideas for this winter but haven't decided on anything concrete. The selection of the turbo I've found to be one of the most difficult choices on this particular project as I can't settle on one it seems *but haven't tried multiple others*.  The lag that you pull from the .48 A/R hot side one here that I'm using isn't dramatic...but does seem to take away that characteristic idle "whistle" through the tailpipe that I had with the standard 1.6 TD garrett unit on the old IDI TD project. Kinda like with the VNT 15 /17 sitting at idle on a stock TDI with mufflerrectomy...kinda miss that sound.  This unit does work rather well but considering the t3 design is 20+ years old there are a host of other turbos out there that are more efficient. So...we'll see. The search continues for the "best" combination IMHO. I don't think I'd go much larger on the hot side at .48 A/R but the cold side could use some work...maybe it'll be making a hybrid turbo this winter out of a merc. hot side and something a bit more fun on the cold.

She will do the 30psi  and I can't tell you how dramatic the difference is in the intake temps with the AWIC installed. Its quite an amazing system. I've done several runs, pulled over after...felt the boost tubes...WOW. what a difference between the inlet and outlet pipes...and the fact that the intake manifold is just "warm" to the touch...even better Its really doing the job nice and I'm not even completely finished as to "how" i want the setup yet!

Joe

[zaprzal]

maybe vnt? gt2256v or bigger

[RabbitGTDguy]

It'd have to be a VNT that I'd setup up mechanically...but I've thought that route if possible. Its the one thing that I'd like to bring back that I can't really do with the wastegated unit (with exception to feeding more fuel down low...but it goes against this purpose and doesn't do it the same as a vnt would), is pull back that lag with a VNT.

I feel as if I'm still in that "perfect" turbo search which is why I didn't spend a bundle on the merc turbo in the first place... gt2256....hmm...

I've had thoughts of  GT series in my head....a holset....so many options...

Joe

[RabbitGTDguy]

So...updates...

Well...found a Inari Green parts car that I was able to get the doors and hood off of! So...she finally has a pretty straight hood and the new d side door installed...

THEN:


NOW:


You can't tell from the pics in great detail, but the d side door was pretty "ding'd" up. In several places and it would have taken a door skin from another door to repair it correctly. Same with the D side rear door, but I'll have that on here shortly as well. The PO had the car repainted at one time. "Inari" but, it came out much more of a silver color than the OEM Inari color. Now if I could only find a MINT Inari hatch!
It was interesting with the doors. They came from a 78 and my car is a 79. There were some differences between the doors that needed addressing. Namely, the 78 and earlier doors have a metal weatherstripping channel attached to the front of the door whereas the later doors simply have the weatherstripping "clipped" to the body of the door in the same place. This wouldn't clear with the door mounted. So the channel had to be removed, weatherstripping re-clipped. Also, it had the "early" hinges as well...which wasn't that difficult to swap. Ended up swapping in all of my "good" vent wing window stuff from the "bad" door as the PO had glue the vent windows shut ruining what I thought were some pretty nice seals (despite the fact that they ALL leak).


Well,  more decisions body and interior wise for winter...

Body:
Since I'm going to have the engine out to do the 02a swap/setup, etc. I think I'm going to remove the raintray from the car. At the very least, the engine bay will hopefully be detailed this winter...with the final bodywork, paint coming in the spring. Deleting the raintray to me will open up the bay a bit more and make it look "not so crowded". I plan on retaining the heater blower, but building a "box" for around it so it can still pull fresh air.  We'll see....

Also...welding in a new D side rocker panel on the car because the current one is quite "crusty" and has gone through in a few area

Plan on removing all the sealant in the engine bay area as well, around the strut towers, etc. and then doing some stitch welding with my MIG in those areas too. There will also be a slight repair to the front core support as well as the installation of a core support reinforcement bar as well.

INTERIOR:

Well..continuing to work on getting the seats I've been working on for quite a while ready. The plaid material is awesome and will go great with the Inari paint and I just picked up some really nice black onyx microsuede that I'll be using to recover the door cards which will also have the "plaid" inserts on as well. I'm also considering doing a early MK1 dash, the one really nice one I have...possibly in the fabric (has a few cracks...not major though, so don't know if I want to do that to such a nice early MK1 dash) as well. Contemplating building a false floor in the back of the car to bring the AWIC res/keg up a bit higher in level and also hide the battery which now resides in the trunk.

MECHANICALLY:
Cleaning this up as mentioned above. I'd like to possibly play with a different turbo of similar size to the one I'm running, or rebuild the current one so I can say "EVERYTHING" is new. Also, a new intake setup is in order, playing with Jake's use of the PRM system.
Of course...the 02a swap and I think I'll be using WRD mounts for it as getting them from across the pond will kill me in shipping alone
May downgrade my lift pump that I'm currently running which is basically a "Holley Red" fuel pump. Its a nice unit...really nice, but may be overkill for its needs on the mTDI setup. What bothers me worse, is the noise. Its pretty loud and can be heard above the sound of the engine itself! Leaning towards installing it on my 72 westy that could benefit more from it (has dual dell 36's) and run something more similar to a smaller, quieter facet pump hidden back by the tank on the mTDI. Also plan on relocating the fuel filter to the inside of the p. side fender.

This is all barring I have the time to get it done! Student teaching for grad school this winter too....so...we'll see, and there is a possibility of us buying a house in the next month that we've been eyeing....with a VERY nice garage!!! 4 car too!!! So much better than where we are at now! Did I mention, heat, water, electric and cable...LOL.

Anyways...thats an update. Right now, its just enjoying driving the car and staying out of trouble with it. Taking it easy on the 020 and all that good stuff. I have a squeak coming from the accessories somewhere on a cold start, or low rpm "cruise". Its not the crank serpentine pulley (i replaced the stock 1z/AHU one with the updated one) so its either the alternator, h20 pump (but no leaks) or the tensioning mechnism itself.
Its just an annoyance...

Thats good for now!

Joe