Author Topic: Lightened flywheel and stretch bolt questions... (Read 4158 times)

larry104 · « **on:** August 24, 2006, 08:03:42 pm »

I'm installing a 16V flywheel and pressure plate on my 92 Eco, among other mods, including a Giles pump. I've read on the board about lightening the flywheel. Where and how much material do you remove? I'd expect an improvement in acceleration, but is it really worth doing? Any downsides?

Secondly, I installed a new stock 3 hole head gasket and stretch bolts like those used on a TDI. The head is straight, and I took great care to clean the sealing surfaces without damaging them before installing the gasket. The motor has 127,000 miles and ran perfect before (no smoke, started easily). The previous owner changed the oil every 2,500 miles. Spotless inside. I plan to run 15 psi boost with the K14, an intercooler, and a free-flowing exhaust. Anything I need to worry about here?

Thanks.

vwmike · « **Reply #1 on:** August 24, 2006, 08:24:59 pm »

The material is removed from the inertia ring behind the ring gear for the starter.

Also, what head gasket did you use? A TDI gasket is not compatible with a 1.6 engine.

hillfolk'r · « **Reply #2 on:** August 24, 2006, 10:38:55 pm »

i take that sucker(flywheel) down to the ring gear :shock: it pretty much cuts its weight in half
its the big chunk of metal that extends from the ring gear and goes towards the engine,thats the "chunk" you need to remove
i do em on a lathe
i think it weighed like 13-13.5 or so,and after its cut its like 6.5 or so i think,roughly

15 psi?yea you would probably be ok with stock head bolts,but you will see
you WILL want more boost,and now the stock bolts could be a problem
but 15 psi? itll be alright

larry104 · « **Reply #3 on:** August 25, 2006, 04:45:49 am »

Quote from: vwmike

The material is removed from the inertia ring behind the ring gear for the starter.

Also, what head gasket did you use? A TDI gasket is not compatible with a 1.6 engine.

It's the correct 3 hole (hydraulic head) IDI gasket. Thanks for the help.

larry104 · « **Reply #4 on:** August 25, 2006, 04:59:49 am »

Quote from: hillfolk'r

i take that sucker(flywheel) down to the ring gear :shock: it pretty much cuts its weight in half
its the big chunk of metal that extends from the ring gear and goes towards the engine,thats the "chunk" you need to remove
i do em on a lathe
i think it weighed like 13-13.5 or so,and after its cut its like 6.5 or so i think,roughly

15 psi?yea you would probably be ok with stock head bolts,but you will see
you WILL want more boost,and now the stock bolts could be a problem
but 15 psi? itll be alright

Removing that much material, doesn't the idle get lumpy? Vibes worse? Hard to launch without revving the heck out of it?

About wanting more boost, yeah, I know what you mean. On my motorcycle, which ran great before, I wanted more power :twisted: , so I shortened the cylinders to boost compression. Well, it became a cantankerous pain to start, and I couldn't get it to stop pinging, even with 93 octane and 30% toluene in the tank. I sort of learned a lesson from that... well maybe... :mrgreen:

We'll see how it goes. Next time it's down, might look into a K24, some head studs, and a metal head gasket.

Kudagra · « **Reply #5 on:** September 01, 2006, 06:36:20 am »

So what is the largest Clutch surface flywheel that fits in our transmissions? I know of a aluminum VR6 flywheel I can get cheap but I think its the wrong configuration

hillfolk'r · « **Reply #6 on:** September 01, 2006, 04:02:52 pm »

yea its fun to cut em on a lathe,we have contests to see how far we can make the chips fly
the vr6 setup would require a trans swap,etc

burn_your_money · « **Reply #7 on:** September 01, 2006, 05:39:04 pm »

Could someone takea picture of one on a lathe? I have a friend at a machine shop and want to make sure I do this right

DieselsRcool · « **Reply #8 on:** September 02, 2006, 05:45:28 am »

How are you guys balancing them after cutting?

Kudagra · « **Reply #9 on:** September 02, 2006, 07:35:44 am »

Quote

the vr6 setup would require a trans swap,etc

well I figured that but I was asking what the largest flywheel we can put in our transmissions? 210mm 228mm?

Where the hell did this come from??

hillfolk'r · « **Reply #10 on:** September 02, 2006, 10:52:30 am »

Quote from: DieselsRcool

How are you guys balancing them after cutting?

um i balanced one once,and it was so close to begin with(1 gram) ,i wouldnt even bother next time i do one
i took an old crank and clutch setup to work to balance it
the one im runnin now isnt balanced,and ibet ive put 50k on it
you are removing the weight evenly for the most part,so it shouldnt really change much
im all for precision and stuff,but if ya have a buddy with a lathe,have him cut it,then slap it on
:wink:

hillfolk'r · « **Reply #11 on:** September 02, 2006, 10:59:41 am »

Quote from: Kudagra

Quote

the vr6 setup would require a trans swap,etc

well I figured that but I was asking what the largest flywheel we can put in our transmissions? 210mm 228mm?

Where the hell did this come from??

210mm :wink: