Building AAZ motor; meet Harley

[RabbitJockey]

i like the non over flow rad, but they take up more space by the radiator

http://www.ebay.com/itm/VALEO-ENGINE-RADIATOR-FOR-VW-GOLF-SCIROCCO-171-121-253-F-/261643656911?pt=Motors_Car_Truck_Parts_Accessories&hash=item3ceb2d5ecf&vxp=mtr

and an aluminum version, i think jegs or summit sells a version of this

http://www.ebay.com/itm/CUSTOM-ALUMINUM-ALLOY-RADIATOR-VW-GOLF-MK1-CADDY-SCIROCCO-GTI-SPEC-1-6-1-8-/121159309560?pt=Motors_Car_Truck_Parts_Accessories&hash=item1c35a858f8&vxp=mtr

i think the one lucas showed you is a really score though, for size cooling capacity, and especially price.

[RabbitJockey]

jegs

http://www.jegs.com/webapp/wcs/stores/servlet/KeywordSearchCmd?storeId=10001&catalogId=10002&langId=-1&Ntk=all&Jnar=0&itemPerPage=60&Ne=1%2B2%2B3%2B13%2B1147708&searchTerm=scirocco+radiator

[JASGTi]

Gives me hope that one day I'll finish my project.

[CrazyAndy]

Gives me hope that one day I'll finish my project.

Well thanks, but hopefully you won't drive yours only 150 miles and then let it sit after your driver side axle walked it's inner CV bolts off, like I did.  She was going like crazy until just before Christmas when it happened.  It's too freaking cold to give a damn right now, so I'm going to get her a car cover, throw some old socks full of coffee grinds in the floor boards to keep the moisture out, and wait until March to get back on the horse.  I'm really in no mood to wrench on it anyway; work is going dismally, and the axle walking off didn't do any better for my mood.  At least my 4 point lower stress bar will be here by then, and hopefully so will some nice Bilsteins followed by a good set of wheels.  And a bigger rad, too.

And P.S.:  The temp sender for the oil temp gauge is wonky; goes from bottom to pegging the top in 8 seconds.  Damn cheap JOM crap.  PARTS FOR THE PART GOD.

[92EcoDiesel Jetta]

What happened to the inner CV bolts? I am about to replace my axles and don't want that to happen.

[CrazyAndy]

You know what, I'm not exactly sure.  Either I didn't tighten them enough, or the aftermarket axle is too long and it pressed itself off little by little.  I'm going to need to reattach the axle, depress the suspension in that corner, and check for proper axle movement.  I don't know where to get a true 16v Scirocco axle, so I'm kind of screwed if that is truly the case and the axle is too long; I might even need to get the shaft shortened somehow if I can't find a real 16v axle if I need one.

[92EcoDiesel Jetta]

Did you apply loctite?

[RabbitJockey]

i think the stock ones are stretch bolts or they get stretched over time, they kept coming loose on my rabbit until i replaced them

[92EcoDiesel Jetta]

When I swapped from avx to acn, I reused the old bolts. I don't remember if I loctited them or not. What are the symptoms of them coming loose? I was planning on doing the same thing, i.e. reuse the old bolts on the new axles.

[theman53]

I just had the drivers side on the MKIV come loose a couple months ago. I searched on other forums and many of the same stories...use Loctite. Torque for them is right at 30ft/lbs IIRC

[RabbitJockey]

When I swapped from avx to acn, I reused the old bolts. I don't remember if I loctited them or not. What are the symptoms of them coming loose? I was planning on doing the same thing, i.e. reuse the old bolts on the new axles.

you hear a bunch of weird noises when moving, and if u get out and pop the hood u can see the axles loose, i usually re use old bolts, that set just happened to be tired.  loctite is another good solution.

[92EcoDiesel Jetta]

Good it gives some audible warning! I had a 69 type 2 bus many years ago while driving it suddenly stopped moving no response from throttle engine still running. Crawled under and found all the axle bolts came loose on one axle. I didn't have any tools with me so just threaded them in by hand and drove home. I tightened them with tools and it happened again! I didn't know about Loctite back then. Maybe being rear engine rear drive I didn't hear any noise before the axle came off?

[RabbitJockey]

Good it gives some audible warning! I had a 69 type 2 bus many years ago while driving it suddenly stopped moving no response from throttle engine still running. Crawled under and found all the axle bolts came loose on one axle. I didn't have any tools with me so just threaded them in by hand and drove home. I tightened them with tools and it happened again! I didn't know about Loctite back then. Maybe being rear engine rear drive I didn't hear any noise before the axle came off?

that could easily be, it wasnt very loud on mine, i actually kept driving on them the one time and bent a bunch of them and had to retap some of the holes in the flange, that was when i got new bolts and the problem went away.

[CrazyAndy]

Welp, some good and more bad news.  Got the axle back in and loctited the bolts in for insurance.  Took it out for a drive and it did fine, but noticed that the vacuum pump had almost come out!  I pushed it back into the hole and loctited it's retainer bolt as well. 
Fast forward a week and I tried to install a manual boost controller made with a combination of a pressure regulator and pressure relief valve in line as per here: http://www.autospeed.com/cms/article.html?&A=111348 .  Wow, did NOT like that!  First test drive was just a small turn in on the regulator, but the first time I tried a 2nd gear pull, there was a loud BUMP/POP followed by grey smoke and the engine nearly dying, sounding like it was only running on a couple cylinders and bogging down when I tried to give it any pedal.  After about 20-30 seconds it returned to normal idle and acceleration operation and I soft-shoed it home.  There is no coolant loss, and nothing is leaking around the head mating are that I can see right now.  It's a repeatable fault, as I have demonstrated earlier this afternoon.  What's more, I looked under the hood and saw the vacuum pump doing a little twirly jig in it's hole!  I'm going to have to pull it back out and see if there's any oil pump shaft, intermediate shaft, and/or vacuum pump damage.  As far as the power loss incident, I am actually at a loss of what it definitely might be.  I'm obviously thinking it's something to do with the boost controller I made, either causing a few things to happen:
-The LDA is seeing too much signal boost and the pump dumps too much fuel
-The timing is too advanced and a cylinder pre-ignited
That is really all I have right now.  I'm going to be removing the controller and go back to just the wastegate for now.  I don't like these valves, and will most likely go for a more proven boost control setup down the road rather than this hodgepodge air tool junk.  I will also need to check out the vacuum pump situation, as well as get an eye in the turbo compressor as well as around the exhaust area; she wasn't as willing to spool after the first incident.  I can only hope my stupidity and impatience hasn't caused major, expensive damage yet.

[CrazyAndy]

Okay, so I figured out the vacuum pump concern; it was sitting wrong in it's hole and the clamp was sitting wrong on the pump base.  Easy fix.  I also found out I installed the valves on the DIY controller were turned the wrong way; they have a direction they have to set for the pressure relief function to work and I pointed the arrows in the wrong direction.  I'll fix that and re-install the controller later.  For now, see these videos on how she operates on wastegate pressure.  Not too bad if I say so myself.
https://www.youtube.com/watch?v=VTL8jiuSybo
https://www.youtube.com/watch?v=WLoiolGeTbw