Modest performnance mods advice

[zagarus]

so what is a good exhaust piping size for the 1.6TD? from turbo to end.  

P.S  thanks dubcanuck for telling me about this site, i think im gonna learn a lot aboot me car

oh and a 1.9 TDI head gasket fits on a 1.6?  what else can be used from a TDI?  im going crazy thinking of the things to do to my car, just basic enginge conditioning for now.

[935racer]

2.5'' is a great size from the turbo back, get a mandrel bent exhaust for the best flow I sell the 2.5" downpipes needed for this. Exhaust should be the first thing you should worry about before modding naything else, you need to get rid of the terrible stock restrictive exhaust. The 1.9 gasket is a 1.9td not tdi, This won't really do anything for you unless you are running a lot of boost, like 35psi or more. However if you do have the head off the metal 1.9 gasket isn't much more so you might as well put that in along with new head bolts. I like the ideas of headstuds but don't seem very necessary as I haven't seen a headgasket blow since I started using the 1.9 gaskets. Our shop is only about 3 hours from kamloops so if you need anything or any work done let us know. Welcome to the board.

[zagarus]

thanks, so the exhaust i should do eh?  Good cause i wanna get my magnaflow DTM exhaust soon, and get all the piping done.  already got a K&N air filter, so the intake is good, now just to do the exhaust, that'll make my car breath easier.  then i'll get some new injectors, any ideas?

ill be doing work on my car in the spring, so maybe ill stop by one day and get that piping.  how about a deal for a fellow diesel addict?

[dubCanuck1]

No problem there zagarus. In the world of IDI engines, these guys have some serious gray matter. It's helped me out tremendously.

[935racer]

Yes definately do the exhaust, I would say this should be the first mod for these IDI diesels. For injectors get the GTD nozzles. I can install these for you and yes there are always deals for diesel addicts getting some work done.  

[Cheesetoast]

hey, pm how much to install the nozzles in a 93 golf td aaz, and how much performance increase woudl they net?

Yes definately do the exhaust, I would say this should be the first mod for these IDI diesels. For injectors get the GTD nozzles. I can install these for you and yes there are always deals for diesel addicts getting some work done.  

[tackered]

I'm gonna second the exhaust... due to age, my Golf with AAZ got a temporary exhaust-ectomy (hey, I like these ectomies), and I got a noticable power gain, and no noise addition... just a change of the sound coming out, at the same level.

[dubCanuck1]

OK. It's time to start. I have a week off after Christmas, so the 1.6 TD's going into the garage for some Holiday cheer.

Here's the shopping list.......

1. 1.9 TD Head Gasket (Is this the copper one? Does it make a difference?). Where would I get this? I remember somewhere someone had a link to it.)
2. New rings (I won't be able to send the block out to get honed, so hopefully it's not too messy in there).
3. Some washers for the governor mod.
4. Audi 5000 Intercooler
5. Intercooler tubing (someone have a good cheap source for this?)
6. EGT guage and thermocouple (in metric......who's got a link for both?)
7. Oil pan gasket
8. Valve cover gasket
9. Boost guage (needed? Opinions....)
10. Turbo examination (I'll send pics to identify which one it is.) and rebuild if necessary (I know one of you has a rebuild kit. I just can't remember who.)
11. Full Synthetic treatment post-new gaskets.
12. Increase boost
13. Fangled new downpipe from the BC boyz.

OK folks. Here's the part I need your help for. I have this awesome shopping list, now I need a list of tools that I need to get it done. I have most of the goodies to turn wrenches, bolts, odd-shaped 12-sided bits, and whatnot. It's the other stuff that I don't know about (spring compressors, ring compression tools, goofy lubes.....let me have it.)

Also, after doing the governor'ectomy, do I have to re-time the fuel pump? What tools would be necessary for that?

Items not on the docket for this round....

1. GTD Injectors (apparently they don't offer much by way of performance at this level  - here comes the debate....)
2. rebuld of anything in the head
3. Injector rebuild (which I should really consider.....)
4. Clutch and lightened flywheel.

[dubCanuck1]

Thanks Andrew,

Do you have a source or website for those? For a lower baffle, I was thinking of getting the lower baffle that came with the Golf Country. I'm pretty sure it would do the trick.

[935racer]

Hey dubcanuck1, we can supply you with the following:
1.9 metal headgasket
audi 5000 intercooler
electronic boost controller
windage pan with integrated rubber oil pan gasket (I think this is what you meant by oil baffle)
rubber valve cover which requires the valve cover studs without the step (We have those too)
2.5" mandrel bent dp along with flex pipe and extra flanges to weld your exhaust system so it is detachable
Turbo rebuild including shaft balance and polish.

These items are available to everyone we just haven't had time to get them up on the website yet.

[dubCanuck1]

Can you PM me some prices? What would delivery charges be like?

[addautomotive]

AAARGHHHH!

Just a couple months ago I posted that I was looking for a 1.9 downpipe upgrade when mine went bad. None were available, so I bought a factory one for $400!!!

Now these things are available... no fair!

[jtanguay]

Hey Dave I might need to buy one of your downpipes...  I have a big exhaust leak coming from the toilet bowl..  Using your pipe I get rid of the toilet bowl right.  But is there a flex joint I need to isntall to take all the vibration?

One more thing.  I know that clearances with this engine are pretty tight... is there any risk with using your camshaft?  Does it improve MPG + power or decrease mpg + improve power?  Just wondering...

thanks!

[935racer]

Yes our DP's eliminate the stock toilet bowl. We are working on finding the perfect flex joint and I think we have found it, it is a stainless braded center peice 2.5''. Also with the flex joint are 2 extra T3 flanges and hardware to bolt them together so your dp is easily detachable from the rest of your exhaust system. Price will likely be $40-50 more, this includes the 2 extra t3 flanges and the nice stainless braided flex joint welded to the dp. This isn't final yet I'll try to get some pics up ASAP.

Dubcanuck I'll send you an email this afternoon.

[dubCanuck1]

Dave, check your mail.