1.6TD higher performance build

[rabbit GTI/GTD]

Planning on building a 1.6TD for power, Complete rebuild, Balancing crank, rods, pistons. the hole she bang, intercooler, giles pump(maybe), wondering if i was to go with mercedes injectors(i can get a lot, pop tested, for cheap) which ones to use, or is it a bad idea. and with this said, what kind of power should I expect?? will it feel way better than my honda civic si v-tec(feels like a turtle on cheap steroids) and better than the car it is going in, 84 Rabbit GTI?? open to all suggestions about anything, what parts to use. where to get them, part #'s, and so on. will be posting pics(if i can figure out how) when i start the build, progress, etc, if anyone is interested anyway. thanks for any help/suggestions.

Chris

[Audi80]

170 crank hp is pretty easy to get :wink:

Good (12mm) pump, vnt turbo (gt20,v gt22v), big intercooler and 2,5" exhaust is all you need. Porting head and better manifolds would always be better.

[jtanguay]

remember... torque wins races  :wink:

i dont know what's all the hype with honda engines that can rev to 8000 rpm or 9000 rpm... sure its nice, but think of all that wasted fuel!!!  :lol:

go diesel and make use of insane low rpm torque  :twisted:

[rabbit GTI/GTD]

For sure, low end torque rules(i race short oval track), plan to port and polish, but as for intakes?? i only have stock handy, so, dunno about that.  and vnt turbos as well, i have 2 stock turbos for the 1.6 td, never looked at what they are(on the engines) and a blown 1.9 with a KKK 24 i think it is. where can i find 12 mm pump heads, or, how to i make the stock one bigger, if possible, if i can build a pump myself that will be satisfactory for now, i will, then i can save slowly for a giles unit. thanks for now, keep everyone who is interested posted, pics to come soon, when i get the car. and is a pump head for a 1.9 pump bigger than a 1.6, how do i know what size it is(how can i measure it, or tell).

Chris

[burn_your_money]

for an intake manifold a ported gas mk2 intake should work nicely. You could use a mk1 manifold but it faces the DS of the car (which might be better for the IC)

[Dr. Diesel]

I wouldn't worry about injectors. I don't think anyone has actually proven them to be a bottleneck in the system yet. People making big power are trying to figure out how to prevent it from escaping through the head gasket. I have yet to see evidence that there are any problems with getting enough fuel (definitely 12mm Giles pump) or air. (VNT is cool, but not neccessary. K24/K26 hybrid is just about perfect for anything up to 35 psi)

Your main concern, if you decide to venture into the upper reaches of diesel power, will be containment. The solution appears to be in O-ringing the block and head, using a copper gasket and, to quote QuickTD, "put up with the oil and coolant leaks."
If you are doing a 'power rebuild', you'd be wise to consider this option, and upgrading to 13mm studs.

[rabbit GTI/GTD]

thanks for all the fast replies, i dont plan on making huge power, or the most that i can squeeze out, my main goal, well for now, is to make it faster than it is now with the gasser in it, its an 84 rabbit GTI 8V. money is limited, so i cant go nuts, can i get like 120 - 130 h/p with reliability, as its going to be a daily driver. maybe i'm dreaming. heres all my plans for now,

complete rebuild, overbore if need be, port/polish, intercooler, 2.5" exhaust, 1.9 head gasket, arp head studs, best bearings available(mains, rods, intermed shaft) get the crank balanced, balance the rods, pistons, and rings myself(my dads built tons of high performance chevy small blocks, he's helping a bit), w/e the most but safest boost and fuel is to run. any other suggestions?? or is this going to be unreliable?? So the intake off the engine that i get in the car will fit with the turbo exhaust manifold?? if it will i'll take it off the gas engine and away we go, lol.

[zukgod1]

for an intake manifold a ported gas mk2 intake should work nicely. You could use a mk1 manifold but it faces the DS of the car (which might be better for the IC)

I've heard you can use a gasser intake but I was hesitant.

Is it a direct bolt on as far as to the head goes?

Sothe mk1 faces the drivers side ehe? That sounds like a better set up like you mentioned if using an intercooler


dan

[burn_your_money]

It will physically bolt up, you will need to grind the manifolds a bit to get them to fit together. Don't quote me on which way they face, I don't like gassers

[rabbit GTI/GTD]

i may be trying that out, and it does face the DS, that would be awesome for the intercooler.. cant wait to sell my civic and get started

[SMOKEYDUB]

i figure about 120 horse or so is still reliable..... My car however is not

[rabbit GTI/GTD]

Well, hopefully with what i am doing to the engine i can squeeze that out of it, whats a safe boost pressure to run with just the upgrade to a metal HG?? whats your car making for power smokeydub?

[SMOKEYDUB]

my car gteched 130 i think it measures net wheel hp.the car weighs 2250 with drive so it prety fun.

[rabbit GTI/GTD]

cool, mine weighs 2150lbs, less once i strip it a lil :twisted: ,   , i think this car is going to be very fun, lol. any idea where i can get an 11 or 12 mm pump head and plunger, anyone??

[SMOKEYDUB]

ebay off of a pegueot or sometihing or i got mine from giles when he did my pump.