i need your advice...

[2mAn]

... in a few weeks im going to have a local shop install a 1.6TD in place of my NA 1.6D. at the same time im having them install the 2.5" passenger performance downpipe, and also a 2.5" exhaust. id like him to modify the stock setup so that i can run 1 bar of boost.

 im also looking at installing some vdo gauges (egt & turbo)

#1
http://store.summitracing.com/partdetail.asp?autofilter=1&part=VDO%2D150052&N=700+115&autoview=sku

OR

#2
http://store.summitracing.com/partdetail.asp?autofilter=1&part=VDO%2D150063&N=700+4294925227+115&autoview=sku

and this is the pyrometer gauge i want to use

http://store.summitracing.com/partdetail.asp?autofilter=1&part=VDO%2D310953&N=700+115&autoview=sku


* to make it easier for you, i moved all my questions down here in hopes that they will all get answered, thanks*

 what mods need to be done so that i can run around 1 bar of boost? is this something i can do on my own?

im obviously going to double check this, but the egt gauge looks like its a whole set, can anyone verify this? will i need anything else? which boost gauge would be better? why?

the downpipe had a flange welded to the DP and also a flange to weld to the exhaust, but there is no bolts, nuts, or gasket to attach them. what should i use? also since we are on the topic of exhaust, im under the impression that straight through is the best? as of right now im plannin on buying straight 2.5" piping and some j-bends and making it go straight through, no mufflers or anything and it will come out in front of the rear wheel on the driver side...

i also want to install a clutch, any recommendations?

sorry if im asking a lot of questions, but i really want to do this right the first time. once this is all setup ill be getting it ready for an intercooler and more boost. and just for making it this far ill throw in the most recent pic of my ride.

[jtanguay]

hmmmm go with aircraft spruce's gauge & thermocouple.  its less than VDO's $99 gauge.  doesn't look like that gauge comes with a thermocouple...

go with the boost gauge that doesn't have vacuum.  your motor doesnt have vacuum .

to run 1 bar of boost you need to block off the BOV.  some use plates, others stick things into it to jam it shut  :lol:  and for the wastegate, you could probably mess with the wastegate lever to adjust for 2 extra psi.  if you ever want to go higher than that, you should get a manual boost controller.  they splice into the air line that goes to the wastegate.

[jtanguay]

hmmm i stand corrected  

i havent bought a boost gauge yet, but i will get one witha vacuum gauge too then.  would the vacuum part be good enough to tell me when i need to buy a new air filter? that would be pretty neat

[Benjamin]

I'd say go with a boost gauge that DOES have vacuum so are warned if you ever have the rare and possibly engine damaging event of an intake restriction, e.g. bad air filter.

Andrew

good thing  

An old engine got a bit vacium also, well, thats what some say.
Do you think you can read it with a gauge?

Greetz, Benjamin

[veeman]

Benjamin...  

I've got boost gauge #2 and the EGT that you pictured.   Some people have said that the VDO EGT doesn't respond quickly and that the boost gauge was cr_p, but I've had good luck with both.   They match my caddy's interior and seem to work well. The EGT kit you listed is indeed the kit with the thermocouple and wiring.

For the boost gauge, I bought the boost line signal adapter to "smooth out" the pulses or "fluttering" in the needle at higher boost levels.  I've posted here about it in the past.  Several places like ECS tuning carry that and it makes a big difference in how the gauge reads.

That said, I think it'd be worth a try to go the Aircraft Spruce route.  Sounds like a good alternative.

but there is no bolts, nuts, or gasket to attach them. what should i use?

I'm sure you can check with PP on this, but maybe you could use a triangular exhaust gasket and some stainless bolts.  I hate messing with rusted out bolts on the exhaust.

im under the impression that straight through is the best?

Depends on what you want to listen to...  The TD's don't really need any kind of restriction after the turbo, so 2.5" should be fine.  I've got a full 2.5" exhaust with one single cherry bomb resonator near the back.  It's pretty quiet and still allows the nice turbo sound to be heard.  I daily drive my caddy and it hasn't bothered me to the point of wanting to change it, however, without a real muffler it tends to drone a bit at highway speeds.

i also want to install a clutch, any recommendations?

I've always liked using the 16V pressure plate and a good Sachs 8V disk to create a sporty clutch setup.  Seems to work fine....next time I'll add a lightened flywheel though.

sorry if im asking a lot of questions, but i really want to do this right the first time.

No problem...that's what the forum is here for.  Remember that the search function is your friend.  There's a TON of info in there and I find that most of my questions have been asked before.  

once this is all setup ill be getting it ready for an intercooler and more boost.

I just got doing that and I can tell you that the IC and some more boost REALLY woke up the engine.  The IC brought down the EGT's and made the car more "consistent" in the power.  I like it.  Careful... it gets addictive.

[RabbitJockey]

all you need to do to run 14.7 psi is put a dial rod in your bov, which takes like 20 minutes, and install a boost controller which takes another 20 minutes...

[2mAn]

all you need to do to run 14.7 psi is put a dial rod in your bov, which takes like 20 minutes, and install a boost controller which takes another 20 minutes...

when i first saw this i thought you said a 14.7 quarter mile :shock:

[935racer]

Dont use the VDO EGT gauge or thermo couple, its response is too slow and the higher the temperature your exhaust reaches the more inaccurate the reading on the gauge face reads. I have had to reinstall ispro or autometer in place of VDO gauges several times. One of the last times we did a good side by side test of an autometer EGT and thermocouple and the VDO currently installed. We couldnt get the vdo gauge to read above 1150 with the current fueling, and it need to "warm up" when you started the engine from cold. Also once the engine was warmed up if you stomped on the go pedal and were seeing lots of black smoke and you knew your egts should be soring it took just over 4 seconds for the vdo gauge to hit its top of 1150 (on a 1600 degree setup mind you)

Now switch to the autometer gauge, there is no "warm up" it starts reading as soon as it gets power, and the response is very fast, faster than a tach and almost as fast as the boost gauge. Funny thing is with the same fueling on the same engine this gauge read up to 1600 degrees under WOT where the vdo only went to 1150, this is of course a major problem.

I havent tried the aircraft spruce EGT yet but I have heard good things about it and for the price its certainly worth at least trying.

While you have the engine out of the car remove the turbo and drill and tap for the thermocouple in the exhaust manifold, put it in the bottom right before the turbo so that you are getting flow from all 4 cylinders.

For the downpipe you dont need any gaskets, just tighten the flanges down and you will be good to go. For bolts any hardware store can help you out, and if they try charging you more than $1USD they are hosing you, go somewhere else.  Might as well keep it metric, get (4) m8x35mm bolts and matching nuts. Use some heat resistant copper antisieze on the bolts to keep from seizing up on you.

For the boost controller there are a lot of theads about this on this website, but to some it up you need to block off the blow off valve on the intake manifold and use some sort of boost controller to control the wastegate.

For clutches I sell performance 4 puck setups. But as mentioned above the 16v pressure plate and 8v disk is not a bad setup either, the 16v pressure plate will not fit the 6 bolt 190mm flywheels, they only fit the 9 bolt 200 and 210mm flywheels. Figure out which flywheel you have than buy the right clutch.

Looks like a pretty clean mk1 jetta 2 dr there. Glad its getting a TD



 

[veeman]

Dont use the VDO EGT gauge or thermo couple, its response is too slow and the higher the temperature your exhaust reaches the more inaccurate the reading on the gauge face reads.

So... do you think the problem stems more from the probe itself than the gauge?  Jake reports good results with the Aircraft Spruce probe while still keeping the VDO cockpit style gauge in the thread about it.

If that's the case, I could try the 1/4" NPT version and hopefully find an adapter to go from the 1/2" hole I drilled for the VDO bung to the 1/4" style used for the Aircraft Spruce version.   It'd be easy to do back to back tests.