whitetail build - advise welcome

[Whitetail]

Hey Guys, I pulled the whitetail in the the garage last night to swap in a 5 speed - add turbo - paint.

TURBO

Picked up a complete turbo and intercooler setup off a 98 tdi, i believe a AHU? I am used to bigger diesels, this thing is teeeny tiny! It look like it should be on a mower LOL

The engine is a 1.6 out of a 86 golf that was supposedly rebuilt 20K ago and has "bigger turbo injectors" on it if there is such a thing.

Should I adjust the wastegate at all? What is a safe PSI to run on a stock build? I will get an EGT gauge and keep it under 1200 and was thinking about getting an oil cooler to help engine longevity.

I quickly figured out the MK1 bay is way too small to use the jetta intercooler and air box. Any recommendations on a cheap universal kit? The way the pipes are oriented I will have to order a tubing kit to loop it from the so a tiny intercooler would prob be a good idea.

AIR in: It looks like I can cut the inlet pipe and clamp a 2" silicone tube on it to rotate it towards the rain tray with a small 2 3/4" cone filter on it.

OIL in: I am thinking about bending flared copper pipe from the oil filter head to the top of the turbo. If you have ever seen a oil fired furnace, this is the style of pipe I am thinking.

OIL out: Will the pressure be enough to push the oil from the bottom of the turbo up to the valve cover or do I need to weld a bung on the oil pan? Any better spot?

OIL Cooler: If I do add a oil cooler should I do it pre or post turbo?

EGR: is nasty, its hard to believe the jetta even ran with all the crap in the intake. Its getting cleaned in a dip tank, when I get it back do I need to do anything to keep it disabled? I plan on leaving it all on there but welding the tube shut from the manifold.

5 SPEED

Its out a 86 GOLF. Plans are to...
modify the 4sp L bracket by welding flat stock to it and raising it one inch.
It looks like I will be able to cut the MK1 and MK2 mounts up and weld them together to make a MK1 body mount with the Mk2 trans pattern
might need to order a 5 sp "shifter repair kit" to swap the linkage

PAINT

going to use auto air "metallic white" and clear
shaving all the running lights and converting to small tails
adding a small duckbill but keeping it black
might paint the metal on the bumpers to match

will keep the post updated with progress pics...

[vanbcguy]

A few thoughts...

Boost level: the AHU turbo won't be good for much over 12 PSI or so. The wastegate is probably set to around 9-10 currently.

Oil in: you don't want to use copper. It will harden and crack from the diesel vibrations. There's a few different braided flexible lines available that will work well though.

Oil out: the oil outlet needs to be free flowing downwards, it can't go uphill even slightly. There's basically no seal preventing oil from leaking in to the turbine / compressor if it can't freely drain out. You'll need to put a hung on the pan.

EGR: just block it off. The same sites that sell the flexible oil lines sell EGR block off plates too.

Oil cooler: you can get a "sandwich" adapter that goes between the oil filter and its mount, that would be ideal. Look for a thermostatic one, you don't want the oil getting too cold.

[Whitetail]

Boost level: the AHU turbo won't be good for much over 12 PSI or so. The wastegate is probably set to around 9-10 currently.

This is good then right? I dont want to blow the engine, just need a little bit more power.

Oil out: the oil outlet needs to be free flowing downwards, it can't go uphill even slightly. There's basically no seal preventing oil from leaking in to the turbine / compressor if it can't freely drain out. You'll need to put a hung on the pan.

OK no prob. Do you know what the pressure is post turbo? I was thinking cut the little braided line off the hose coming off the bottom of the turbo and hose clamp some hydraulic line on down to a nipple on the pan? That should hold 20 to 30 psi.

Breaking the copper line makes sense, any idea what size that fitting is on top of the turbo? I am assuming the little port on the oil filter housing is 10mil machine thread.

Trans update: I got the 5 speed in last night, it looks like I will need to lenthen the L bracket from 4in to 6.25in and the 10.5in rod on top need to be cut to 9.25 because its hitting my downpipe. Rest of the linkage looks ok but wont know till I get the other 2 fixed.

[vanbcguy]

Boost level: the AHU turbo won't be good for much over 12 PSI or so. The wastegate is probably set to around 9-10 currently.

This is good then right? I dont want to blow the engine, just need a little bit more power.

Yep, it'll be fine at stock settings if that's all you're looking for.  The turbo was big enough for 90 HP on the AHU so almost double what a stock NA 1.6 would be putting out.

Oil out: the oil outlet needs to be free flowing downwards, it can't go uphill even slightly. There's basically no seal preventing oil from leaking in to the turbine / compressor if it can't freely drain out. You'll need to put a hung on the pan.

OK no prob. Do you know what the pressure is post turbo? I was thinking cut the little braided line off the hose coming off the bottom of the turbo and hose clamp some hydraulic line on down to a nipple on the pan? That should hold 20 to 30 psi.

There should be no pressure at all - the oil on the inlet side is pressurized, but once it has escaped from the bearings it is at atmospheric pressure.  The drain is just a drain, it needs to be big enough to flow all the oil to the pan without causing any sort of a restriction but there's no pressure to speak of.

Hydraulic hose works great btw, and it's oil resistant.  And yup a hose clamp is sufficient at the pan end.  Just try and put your fitting in the pan as high as possible so it's above the level of oil in the pan, it'll drain better that way.  Starting with the AAZ VW started draining through a hole in the side of the block, I don't think there's a boss there on the 1.6 blocks though.

Breaking the copper line makes sense, any idea what size that fitting is on top of the turbo? I am assuming the little port on the oil filter housing is 10mil machine thread.

Not sure.  There's a few pre-made options, like these:

http://shopping.boraparts.com/product_info.php?products_id=1123

http://www.darksidedevelopments.co.uk/products/darkside-braided-oil-feed-line-for-1-6-1-9-td.html

I have one of the Darkside feed lines on my build, it works great.