Looking to build a 1.6

[diesel smoke]

Hi all,

Well, I'm looking to get back into the IDI game since my old one gave up the ghost. I found a '88 Golf D in Red Deer for a good price. It has a bit of body damage, but I know a good body guy. The engine is toast since the guy's girlfriend ran it out of oil. But that is ok since I got 2 TD blocks sitting here waiting for rebuild. What I'm wanting to do is buy the car and swap in one of my rebuilds.

HOWEVER! What I'm wanting to do is build the engine as strong and redundant as possible with a bit of performance, and I'm wanting a point in the right direction. What I'm wanting to do is rebuild it right from the bottom up, new bearings all round, polished crank, forged rods, block bored out .5mm oversize with .5mm oversize pistons (since my blocks are worn), rebuilt head, Giles pump, intercooler (got that one already), upgraded turbo, and straight pipe (unsure on size still). 

I'm fairly confident on all of it, except where to go with the pump and turbo. I know there is the T3 turbo, but I'm hearing that they got bearing issues. I'm looking for the IDI equivalent to the VNT 17/22 turbo for the TDI. Something more durable than the stock one, but flows more and is capable of higher pressures. (I know the old IDI ones use a waste gate and the new TDI ones are VNT, but you get my drift)
I'm also not sure what I should do with the pump in regards to what I should tell Giles so he can make it work with the turbo.

So can someone point me in the right direction and offer some guidance? Maybe something else I should be doing while I'm in there?

Thanks. 

[vanbcguy]

Just use a VNT off a TDI?  There's a bunch of folks who've done just that...  If you want to stick with an IDI pump (which also takes care of sorting out the vane control issues) you've got a few options depnding on what you want to do:

K03 - Fast spool up but limited max boost.  Won't go much over stock boost levels - I'd probably keep it around 9-12 PSI if you want it to live.

K14 / T2 - Moderately fast spool up, can go to the high 'teens boost wise.  If I was buying a turbo today and didn't have the cash for a VNT I'd probably go this route.

K24 / T3 - Slow spool up, can go in the mid-20's boost wise.  I've got one on my car now and run it at 15PSI currently.  If I had an intercooler I'd be running it more like 22PSI or so.

As far as Giles is concerned, just decide what you're going to use in terms of a turbo and intercooler and how much boost you're planning on running.  He'll set the pump up go go with your engine.

[GEE-BEE]

OR A K03/KO4 HYBRID TURBO WITH A AAZ INTAKE AND EXHAUST FITTED WITH A 2.5 DP

GEE-BEE

[diesel smoke]

Hmmm, I don't think I want to go the VNT route. Wouldn't know where to start for controlling it. I'm liking the sound of the T2 and T3, but how durable are these turbos and where would I get one?

[vanbcguy]

Don't know that there's anything particularly better one way or the other between the Garrett turbos (T2 / T3) and the KKK turbos (K14 / K24) - I personally have a K24 and it seems my boost comes on sooner than people with T3's... Likewise it seems people with K24's can run 'em higher than the people with T3's can before they grenade.  But that's not based on any personal experience with the others.

T3 or K24 came on 1.6TD's (Mk II's)
T2 or K14 came on GTD's (not really any in North America) or some AAZ's (Mk III's)
K03's came on other AAZ's (Mk III's)