I have solved the clutch slip issue
With ACT Heavy Duty Pressure plate. ACT says these are good for 357 ft/lbs of torque, which gives me plenty of room to grow
I considered going with their modified sprung disc (no pucks), which is rated at 279 ft/lbs, but I decided better safe than sorry.
It is going to take me a little while to learn to drive this thing. I have stalled it twice, and I can't remember the last time I felt like I couldn't drive a stick
Sometimes I get it right and it is a smooth take off, but often I just lurch it. The rivets on my ring gear are not going to last long like this. I think in a week I'll have it dialed in.
I'm pretty sure my old clutch got some coolant, oil, water, or some combination all over it because it was kinda greasy and did not look happy
This guy isn't even that old it is a Sachs 210mm 16v'er clutch
And it made quite a mess in here. I cleaned the flywheel when I did the swap. This is after 1,000 miles!!! I cleaned it really well with some brake cleaner before I reinstalled it.
I have come up with a few explanations for the problem. First I did not have a timing check cover. The car did not have one when I bought it, and I could never find one. I found one on the german autoparts website, so that issue has been addressed.
Second I installed the engine with the galvanized metal cover that came with the AAZ, which was apparently for an 02A and left the bottom of the pressure plate exposed. So when I changed the clutch I swapped it for the 020 one that was on my 1.6D
02A is on the left, 020 on the right.
The end result is that the clutch no longer slips and this thing is a beast! I took it out on the highway and floored it on the on ramp. I am amazed at how quick it is. I was making 25PSI so I swapped the softer spring into my boost controller and did a few runs to get it dialed in around 20PSI max. EGT's build to 1200ºF pretty quickly with the pedal on the floor, and obviously it makes a little black smoke. When I let off to about 3/4 pedal though they drop down to around 900ºF and I am still accelerating.
It is a lot quicker than I thought it would be. I feel that I have achieved my goal of making this thing as quick as my sister's MKIV 1.8T Jetta, of course now she is trading it in for a Japanese subcompact so I will never get to confirm this.
Next I am going to relocate my air filter under the hood, because I can't take the noise anymore. Also I have come up with a way to connect the hockey puck to the intake as part of the same modification. I will have to relocate the fuel filter to do this, so I got some new fuel line to accomplish this. Pics to come soon.
Also the radiator is leaking pretty badly, so I bought a new one. I got the kind with the integrated reservoir to clean the bay up a bit, but I can see that mounting it will take some rigging. I will post up picks on how I work it out, when I do.
Finally I decided I would upgrade to the USRT shift linkage, when I did the clutch, but my kit is missing a piece. It makes me crazy when you pay good $$$ for parts and they show up with pieces missing. Do I just have bad luck, or is this the accepted standard? So anyway it will have to wait, and I don't know when I am going to have time to get to it.