1980 Caddy TD Build

[rabbid79]

That color in the pic of the Rabbit is "Inari Silver".  My rabbit was the same color and I loved it.

[dh13]

This is the color that I am referring to. Bali Green. 




Although I love this color. I don't know the factory code for it. If someone knows, please share.



We will see. I am still searching for the perfect color.

[Powered by Spearco]

The brown one is called Agate Brown.
Nice color.

[dh13]

The brown one is called Agate Brown.
Nice color.

Do you know the letter/number code for it?

Edit: I'm sure a Google search would turn up an answer.

Also I assume that this car


Is the same color code? Agate Brown?

Did volkswagen ever have a metallic brown?

don't get me wrong I love this color and will most likely go with it.

[dh13]

Finally I got my engine back from the machinist. I will be dropping off the head today to get a shave and some crane valve springs installed and a valve job. I did some mild porting to it so that is already done, like I said it was mild but should flow better.

Here are some pictures of my shiny new parts.





Blingin D-crank nose.




Balanced Clutch and Flywheel




ARP Rod bolts and rebushed rods










Here is what I had done.

- Hot tanked block
- Magniflux block
- Polished crank
- Balanced crank, clutch, flywheel, and harmonic balancer
- Machine crank for TDI sprocket
- Bored 0.020 (0.5mm) over
- ARP rod bolts and resized rods
- Re-bushed rods
- Line bored 
- Set and check bearing clearances
- Install Intermediate shaft bearings

That is about all. I will post more when I get the head back and start building. 

[dh13]

First of all, for all those who are searching for answers I will make some clear here.

I will explain in separate sections. I know this will help at least one person. I will explain the options I went with.

*CLUTCH
For my clutch I decided to go with the 210mm setup using stock parts, with an upgraded (HD) disk.

1. 210mm 16valve Flywheel. Stock not lightened
2. 210mm 16valve Pressure Plate. Stock weight.
3. 210mm 8valve disk. HD model. (I will explain)

So this option gives you a heavier than stock pressure plate and a bigger diameter clutch 190 or 200mm stock, to a 210mm 16 valve clutch. The use of a 8valve disk is for those who are running standard 8valve 020 transmission with small spline. This the way you are able to run a 16valve clutch with an 8valve transmission. This option will give you more pressure from a heavier pressure plate, but will not be too abusive on your thrust bearings as would a race pressure plate.

Also for those who care about the physical weight of their clutch I will post the weights of all these parts.

Stock 190mm Flywheel - 13.2 lbs
Stock 190mm Pressure Plate - 7.0 lbs
Total - 20.2 lbs


16valve Flywheel - 10.8 lbs
16valve Pressure Plate - 9.2 lbs
Total-20.00 lbs

The difference of 0.2 lbs will not be noticed too much. I did not want a lighter clutch because lightened clutch + diesel engine = No good. The extra weight of the clutch slows Rev time, but it helps with smoothness.



*Crank Nose
What is needed

1. AHU TDI crank sprocket
2. New Bolt

Have your machinist or (yourself) machine a flat on the crank nose 180* from stock key slot. The flat on the crank should be machined so that the crank sprocket is a mild press fit. 

I hope this helps someone.

[dh13]

Well I finally started building.

I started by cleaning the block and cylinders. I wanted to make sure it was fully cleaned. After cleaning it was time for some paint!

Ill let the pictures do the talking!
















I started assembling the bottom end. Ill I have left is to install the pistons.

Piston meet Rod


Random Main shot


Installed the Oil Squirter's with new allen screws




Lubing up the bearings


Cranks in






Thats all for now. I have all four pistons and rods connected and ready to install.

[dh13]

Well I finally got my head back today. I spent way too much money on random little items today, but it is all stuff that I need to get this thing together.

Here are some pictures

First piston and second pistons in






Soft Plugs in


















More to come.

[morgoon]

Awesome

[katakura silk]

Great build.

[dh13]

Well finally got some more work done.

Don't feel like typing much so here are some pictures for now.

G60 rubber gasket and stud kit


36mm oil pump and oil pan baffle installed


Head Studs installed


Head installed and torqued to 100 ft-lbs


New (well fully rebuilt) injectors


Injectors installed and new glow plugs installed


Test fitting turbo and manifold


AHU intake manifold test fit.




Turbo drain fitting





Thats about all for right now. Ill post some more soon.

[kaneb]

Looks great!

[GEE-BEE]

Get a PD130 Intake and racepipe from Nick at Streettoys2000.com

Need some egt wire sleeve  ? 1/4 i.d.

let me know...

GB

[katakura silk]

Great build!!!

[dh13]

Get a PD130 Intake and racepipe from Nick at Streettoys2000.com

Need some egt wire sleeve  ? 1/4 i.d.

let me know...

GB

The AHU manifold for now will work. I cut the egr valve off and will be welding up the manifold. If i feel that the manifold is not performing as well as the rest of the engine I will get something better, but as of now I thing the AHU will work.