Bigger valves and better cam

[theman53]

Its for motocross engines, they don't tend to last very long

ahh, that makes sense..

i wonder if you can get dimpled valves in a size that fits our diesels?!

That and I bet even in high rev racing conditions the valves probably get gunked up and the dimples fill in a bit. Then it would be like a normal vavle again. Our diesels even more so than the gassers would tend to carbon up a little.

[theman53]

So it's better to have a semi rough intake and a polished exhaust?

I think with my turbo setup and choices ill have problems keeping my head on the block. Has anyone figured out a way to keep these bolted down?

I wouldn't say rough, just not mirror. IIRC 120 grit finish is where mine was at. It isn't smooth, but it isn't rough. The 120 grit surface seems to grab your fingerprint a bit not much, when running across it. 80 I know was too coarse. I will see if I can post a pic of my intake I made as the welds were cleaned up with the same grit as the head.

[theman53]

Old head pics

[Jetmugg]

Beautiful work on that intake.   Did you do the fab & welding yourself?

Steve.

[theman53]

no. I haven't had much experience with a tig. A guy I have a customer I sell to and he did the welding, but I did all the fab and porting. I guess you could say I built it. I am more of a hammer guy and my tig customer is more of an artist. If you look at my sig there is a 'round 2' and page 2 that explains how it was built. SAUSAGE STUFFERS!!!

[R.O.R-2.0]

So it's better to have a semi rough intake and a polished exhaust?

I think with my turbo setup and choices ill have problems keeping my head on the block. Has anyone figured out a way to keep these bolted down?

run a different turbo that makes less drive pressure..

drive pressure is what kills these, not boost..

[Hoble]

Both turbos are pretty efficient and running 44mm wastegates. What's the best way to monitor that pressure?

I'm actually running a 1.8l 8v intake with the ports modified to fit the 1.9 D intake ports. Need to cut off the original tube and weld on something better. I am the active tig welder at the shop I work at. When it's done I'll post some pictures.

[RabbitJockey]

Both turbos are pretty efficient and running 44mm wastegates. What's the best way to monitor that pressure?

I'm actually running a 1.8l 8v intake with the ports modified to fit the 1.9 D intake ports. Need to cut off the original tube and weld on something better. I am the active tig welder at the shop I work at. When it's done I'll post some pictures.

if u have that intake with and with proper sized turbo u shouldn't have any issue.  just drill and tap a fitting in the exhaust manifold and watch your emp's just like u would watch boost pressure.

[RabbitJockey]

So it's better to have a semi rough intake and a polished exhaust?

I think with my turbo setup and choices ill have problems keeping my head on the block. Has anyone figured out a way to keep these bolted down?

I wouldn't say rough, just not mirror. IIRC 120 grit finish is where mine was at. It isn't smooth, but it isn't rough. The 120 grit surface seems to grab your fingerprint a bit not much, when running across it. 80 I know was too coarse. I will see if I can post a pic of my intake I made as the welds were cleaned up with the same grit as the head.

yep, i finished mine with 120 grit then the machine shop i had do all the valve work sand blasted all the ports


here is mine u can see i didn't remove much of the hump around the valve guide, i guess i should have judging by how lucas's looks.:



and here is my exhaust manifold tapped for emp gauge, and a coil of copper to help keep the hose from getting hot

[R.O.R-2.0]

Both turbos are pretty efficient and running 44mm wastegates. What's the best way to monitor that pressure?

I'm actually running a 1.8l 8v intake with the ports modified to fit the 1.9 D intake ports. Need to cut off the original tube and weld on something better. I am the active tig welder at the shop I work at. When it's done I'll post some pictures.

1Y manifold is JUST what you need.. already has the D ports, and it is shaped almost identical to the mk2 1.8L intake mani..

no welding required, unless you want to completely remove the EGR accommodations..

[Jetmugg]

no. I haven't had much experience with a tig. A guy I have a customer I sell to and he did the welding, but I did all the fab and porting. I guess you could say I built it. I am more of a hammer guy and my tig customer is more of an artist. If you look at my sig there is a 'round 2' and page 2 that explains how it was built. SAUSAGE STUFFERS!!!

Don't know how I missed your "Round 2" build thread before, but I was missing out.     The sausage stuffer tubes look like they worked well for the transition pieces.

I like your idea & need to see how to approach my own intake project.  I just bought an ABL intake, I believe from a 1.9 Vanagon.  I'm planning to use that as my starting point.

Steve.

[carrizog60]

i have a 1y intake and it looks way better than gtd ones...
well i have 1Y all around and when i started the build i was told that they had the 7mm stem valves from stock...

[Hoble]

I have more time than money and I would at a machine shop. Making an intake is easy for me. It would be harder to go find a 1Y intake an buy it and ship it. Plus this way it's all custom to what I want.

Side note, got some Alu pulleys made up for my motor at work, do you know the crank bolt hole pattern isn't really a pattern? They aren't in a circle at all and not symmetrical at all. Just kinda weird VW did that.

[TylerDurden]

Side note, got some Alu pulleys made up for my motor at work, do you know the crank bolt hole pattern isn't really a pattern? They aren't in a circle at all and not symmetrical at all. Just kinda weird VW did that.

IIRC, they just offset one hole a few degrees...?

[Jetmugg]

That's good to know.  I assume the bolt pattern is indexed like that so the pulley only goes on one way, thus allowing the timing alignment marks to be used.

Steve.