Paper Engine Build project

[greggearhead]

OK, so I am selling my 16V pickup and will be selling the 1.6NA pickup shortly thereafter, so I will HAVE to get going on my TD engine  for my last pickup.  (Yeah, that is 3 total).  

Anyway, I am trying to figure out what engine to build and how.  I am at a crossroads in determining if I should go 1.9 or 1.6.  The 1.9 should have a much better head, but the crank problems (and required work to fix) worry me.  Moreso, I have heard from people they really rev like molasses.  TDis are great, stock 1.6TD seems fine, I haven't driven a 1.9TD so it is hard for me to make a decision.

I have an 8V T3 turbo manifold that mounts the turbo fairly low.  I am not sure on what size T3 to get, (partly because I am not sure of which engine yet, and partly from never sizing a diesel engine for a turbo before).  Any suggestions?  I know it should be small, but...

Because of the lower turbo, I can use any normal 8V intake and should be able to benefit from that.  Simple pump & injector mods, medium IC size, 2.25 or 2.5 exhaust, maybe propane.  Maybe methanol.  If it is a 1.6 I know I can port the head to benefit.  If it is a 1.9, not sure, but probably.  

Goals would be around 130hp (more if reliable and not out of the realm of decent $$$) and 40-45mpg.  Like to research first and flesh out potential problems before I spend money and get waist deep and decide to change my mind.  Thanks.

[vwmike]

I don't know why the 1.9 would really be bad in terms of revving higher. It has the same bore and stroke as the TDI and I've never heard anyone complain about the TDI. The restrictive K14 turbo is probably a big contributor to the behavior of the engine.

[935racer]

This is my reccomendation:
1.6 bottom end
1.9 flowed head
headstuds with metal 1.9 gasket
tuned injection pump
t3/t4 turbo
air to air FMIC
6lb flywheel
4 sprung center clutch
Those would be the basics for a performance 1.6 that I would reccomend, there are all sorts of other goodies you could mix up in there but that would be one sweet combo.

[greggearhead]

Thanks - that's the type of input I was looking for.  Having driven lots of solid & sprung hub puck clutches, I will pass on that.  Almost all my vehicles get lightened flywheels, so that will happen.  

I think (& I haven't done TDs, so it is just thinking) that a T3/T4 would be too large.  I am not looking to make huge power or have huge boost threshold/lag.  Would rather have a healthy, though more driveable powerband.  Maybe slightly larger than the stock T3/K24, but not much.  

Would love a BB GT series turbo, but just can't justify the cost.  I may also have to go with a 1.9 bottom end - who does the crank nose modification?