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Engine Specific Info and Questions => TDI Engine -General Info => Topic started by: Greasecar on September 22, 2007, 09:18:33 am
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I am returning to the board after a long absence with a new project. I gave away my original Rabbit GTD after it sat in an idle state of restoration in my garage for 2 years (stripped out for body work). Discouraged by the amount of work I had into the car and the amount of work needed to complete it and distracted by numerous other projects and running my business, I handed it off to my friend Jay who is working on building her up on his own.
In the subsequent months I missed my old rabbit project but filled the void with my Golf TDI and diesel Mini, until last month when the Golf went up in flames. Unfortunately the insurance settlement won’t buy me a new Golf but in an effort to turn lemons to lemonade I figured it offered a good opportunity, scrap parts and budget to build a decent Rabbit TDI.
Over the next few months the plan is to salvage what I can from the burnt out Golf and build those modern comforts and power into my first love the MK1 Golf (Rabbit).
I found a decent old diesel Rabbit 2-door near by which I paid way too much money for. When I was originally into this you could get these for a few hundred bucks, my last one was $100 and I even bought an original ’84 Rabbit TD for $900. In any case excitement and impulse took over and next thing I know I’m bombing my new turd 2-door up I-91 with tie-rods rattling, bearings humming and brake lights about the only working electrical item.
Since the plan is to salvage and re-assemble the TDI from the Golf there is little concern about the long-term durability of the stock N/A 1.6l and because it is going to take a few months to get the TDI engine back together and prepped for installation I figured we’d have a bit of fun.
I forget how to properly post a photo but here's my try.
These are the remains of my poor Golf TDI:
http://i225.photobucket.com/albums/dd32/Greasecar/golf005.jpg
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I had three choices in front of me:
-My old BAE kit with it’s big low pressure long lag Rayjay turbo which would add a bit of power at higher RPMs and offer little threat of damaging the stock N/A engine.
-A factory Rabbit/Jetta TD Garrett turbo setup which would offer decent power
-Lastly I had a spare 2001 Golf TDI turbo and manifold set with it’s tiny quick spooling turbo integrated into the manifold.
Since I had already seen what the other two units could do on a 1.6 setup the choice was simple for a bit of quick fun.
As most of you here know, the manifolds for a 1.9 TDI will bolt right up to a 1.6l cylinderhead and there is plenty of room behind the engine to fit the little turbo
The oil pan, oil filter assembly and lines from the BAE kit made for a quick solution to lubing the turbo.
The minimal challenge was fabbing the intake, charge pipes and exhaust. In the past I would order a handful of mandrel bent pipes from JCWhitney and piece something together but since the cost of those items has gone up quite a bit and bends are not available in all sizes I chose a different route. I had used 2 in on my last Rabbit for exhaust so I figured I’d up the ante to 2 ¼ this time around as this is what the TDI turbo is normally set up with. Luckily I found a local shop with a good bender who bent up all of my exhaust and charge pipes for $130. Of course I did end up having to cut and weld a bit here and there but the rear section of exhaust fit much better over the trailing arm than the one I pieced together last time.
The exhaust flange had to be cut and rotated but I was able to use the first bend on the TDI head pipe (nice mandrel bent stainless). The rest was modeled after the original Rabbit exhaust just bigger.
The turbine compressor shell had to be rotated to clear the drive axel and some funky pieces made to go from the 1.5 in outlet to the 2.5 in intake port but nothing a few hours and a box of misc. parts couldn’t take care of.
Photos are on the server computer at my office so I'll post some next week.
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JUSTIN!!! Is it you? Welcome back if so! Have been wondering what you have been up too!
Let me know if you need any help! Another mTDI build on my plate here this winter into my b3 variant as well as continuing work on the mk1 mTDI (02a/j swap, interior,bodywork i hope, etc) :)
Great to have you back!
Sorry to see the demise of the Golf :(
Joe
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Joe-
It is me. I have been keeping an eye on your build and it looks sweet! Glad to see that '79 went to good use, what did you do with your original shell?
Since I have the whole car and a couple of helpers, we are planning to do a full ECM controlled TDI swap. I'd definitely like any suggestions you have on engine mounting.
I'd love to check out your car, let me know if you are ever coming through New England
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Justin,
I just plain ran out of room here with the old shell and just couldn't keep both with my space constraints...and the 79 body wise was the better choice with minor working needing done to the body.
The GTD shell currently resides with a friend and member of this board here, "Fuslit" who has it inside and plans to put it back on the road with an IDI TD swap.
I'm on the hunt for a nice clean 2dr. mk1 or early mk1 rocco...so keep those eyes peeled. We may be buying a house soon, with a VERY nice garage, that would allow me the room! So....
Yes, the Mk1 is def. fun! ALOT of fun. I've been driving it all week this week and then switched to the b3 yesterday and even driving my wife's MKIV 1.8T I fell like I'm in a tank taking a nice sunday drive...
Its a blast with even more to come...
I'm willing to help on any mounting problems, questions, etc. that you have! Let me know what you need. My "mount" for the p side is really simple...and works nicely, its detailed in my thread. I'll be getting my 02a mounts from WRD I think as they are "stocking" them now and look to be really nice units.
Nice idea on the ECM control, especially if your target is more efficiency rather than power adjustability, etc. And if you have the entire harness...its probably cheaper/easier to be honest! If I had a complete ECM and harness, pump for the next build, I'd be doing a eTDI into the b3 instead of the m unit. But, I don't have it...nor do I have the money to piece all of it together $$$ wise..so m is cheaper for me in this route and really isn't that much less "efficient". Quieter, def. not! Either way, it'll be fun. Now on the mk1...hmm...mTDI was always the plan because of the pump I wanted to build, turbo selection and power I was after... something that in addition to finding all the eTDI stuff, plus the cost of reflashing the ECM to run the fuel/power levels I'd want...just TOOO expensive!
Maybe you have seen "lagomorph"'s car on the vortex? Or over on TDI club. I don't think he has posted here yet. But he did a nice eTDI swap with a AHU motor into his car a couple years ago...a '77 MK1, miami blue....beautiful, with minor upgrades nozzle/chip wise... selling the car now. 14k
Congrats by the way! I've been watching greasecar over the last few years here, checking the site every now and then wishing I had a daily setup for the system! Its great to see where you have gone from where it started! I remember!!! Its great to see things are going so well and such and I have to say that the big reason for the b3 variant swap to mTDI (motor build this winter, swap in spring) is so I can finally get a kit in the car and make it truly a utilitarian car!
By the way, I've also made contact with the only guy here locally I know running the true GREASECAR kit...in a 2002 Jetta Wagon. Nice guy, I've helped him out a few times but there are also "kits" being made in Ithaca here too...so, its interesting to see how its growing! But he proudly displays the greasecar logo right across the rear of his car!
Joe
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I think Lagomorph has that car for sale over on Vortex, I'll look out for the build thread, do you remember where it was? Its a real nice car and I was thinking about it, but I can't rationalize $14k on a Rabbit right now
Gongrats to you as well, I heard that you got married.
Here are a few photos just to give you an idea of what I'm working with.
[img] http://i225.photobucket.com/albums/dd32/Greasecar/DSC00012.jpg [img/]
[img] http://i225.photobucket.com/albums/dd32/Greasecar/DSC00011.jpg [img/]
[img]http://i225.photobucket.com/albums/dd32/Greasecar/DSC00007.jpg[img/]
[img]http://i225.photobucket.com/albums/dd32/Greasecar/DSC00009.jpg[img/]
[img]http://i225.photobucket.com/albums/dd32/Greasecar/DSC00015.jpg[img/]
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joe-
do u have a build post or can u talk with me more about the m-tdi in the mk1 bc this is my idea to use in my 80 four door rabbit
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my build thread is listed in the forums here, right on the first page...
http://vwdiesel.net/phpBB/viewtopic.php?t=1956
Justin, Yes...thats lagomorph. Pretty nice guy, I don't know if he'll pull what he wants out of it...but it is a nice car. Was a eurotuner feature car along with a miami blue vr6 (with really cool OEM graphics on it) MK1 that was in there as well.
To post a picture directly its (http:// your image location here )
Nice looking bunny your starting to work with Justin! I haven't seen one "that high" in quite a while! Reminds me of when I had Boge with the HD spring setup on the car! Looks like its a nice shell to start with def. though. Finding them in any sort of "solid" condition in this area is hard to do. Even on the 79, I have rust repair work to do :( Really, I wish it was a 2dr....but alas. Going with what I've got for now.
Anyways...the other pictures that you posted. Are those specific issues you are having with manifold fitment/EGR, etc?
Joe
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Those other photos were just to give an idea of what the current 1.6l with TDI turbo and 2 1/4 exhaust look like. It is really tight behind the engine and it is hard to see the plumbing and turbo from up top. So far so good with this setup and I got my electrical fixed this weekend, now that I have functioning lights I should be able to register and drive it a bit to see what it can really do.
I need to figure out what the best sequence of events is for the build. I am planning on driving the car while the TDI engine is getting put back together but I still have a few things to do to get her up to speed.
-Patch some rust in the floors
-Add a resonator to the end of the exhaust
-Figure out why my brakes are still soft (replaced all wheel cyl and calip. already)
I am planning on attempting an A4 dash and harness swap as part of the engine swap. Shouldn't be too bad since I have the donor car but I certainly plan on having the interior ripped out for at least a few weeks while the wiring and fitting takes place.
Right now my girlfriend is driving my Passat and I plan on taking the mini off the road by the end of November so I need to decide whether to build out this shell or drive it and find a solid stripped out shell that I can pick at over the winter.
Of course, the issue is finding a good one like you said. I missed out on a beautiful '84 rolling shell that had been totally stripped and painted back in 1988 and has been in storage since. It was mint with all sorts of powder coated accessories and totally bare ready to build up as new, but alas, I snoozed and losed out to some young Vortexer who put in a deposit earlier in the day that I decided to go down and get it. It was $3500 which is why I had to think twice, now that I already have that into my current turd, I am kicking myself.
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I can understand you there Justin ( on the "shell" situation). I know what you mean in a build progress too. Honestly, the best way to do it IMHO is if you have engine rebuild stuff you need to do. Get that all done during the winter months. I did my build during the winter, did all my sandblasting of spare parts I had (mounts, etc), did all my idea formation...then swapped in the spring. Took my time on the motor build and built as $$$ allowed at the time, etc. and its still a continuing work in progress. I thought maybe "paint" this year...well, that may or may not happen.
My idea has been that with the setup I've done with the car, I wanted to go through and make sure I had everything mechnically setup the way I wanted to... i.e. intercooler mounting, pump locations, brackets that I'd have to drill holes for, etc. etc. so that when I went for final paint and body...all non-needed holes, etc. would be covered up, rewelded, etc. and then later on once it is painted...I'm not drilling or making holes in good fresh paint!
So...she kinda goes "rat stylz" at the moment. Or OEM -worn :)
The pics do make it tight. You also have to decide...is this a car you'll be driving year round once the swap is done or not? In the "not" situation, you could remove the raintray from the car and open up the bay a bit and still retaining the heater, etc. by building in a close box for it (i'm doing this , this winter)...but I wouldn't recommend removal of the raintray for year round use.
Also, on your MKIV dash swap...it has been done, and can be. There are threads on the vortex detailing it. Its ALOT of cutting with the MKIV dash and most recover them with something else in the process as well. There was also a guy parting a partially finished 1.8T rabbit on there as well, and it had a modified MKIV dash...not completely finished, but it was partly done. There are considerations when you do the MKIV dash swap about what heating setup you'd use, which involves relocating the blower box, all accessories, some cutting, welding, etc. etc.
A different story though if it isn't a year round car.
Another solution for that is what Mr.Dave did. He use the stock MK1 dash and made his own bezel for the MKIV cluster goodies, etc. and it turned out fairly nice as well!
As for your brakes being soft. Check that master cylinder...they can go bad without loosing fluid...i had mine go on the b3 here this past spring and it was a "soft brake" problem.
Doesn't sound like its the booster...but, you never know...
Vac. pump diaphrapm been replaced lately as well? Always nice in making sure the brake system is healthy
Joe
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I couldn't get that (http:// thing to work, I tried with spaces and w/o. what am I doing wrong?I have a new master that I will be putting in as well as some new flex hoses which I'm sure will be needed with the extra pressure. All of the flare nuts are frozen though so I plan on diving it over to my friend's shop with a lift before getting into it so that I can attack all the breaklines at the same time.I have my first question for you: One of my guys is cleaning up the TDI tranny and putting the seals in it. My question is; since we are going to have the drive flanges out to do seals should we be swapping them out for rabbit flanges or modifying them in any way? I haven't gotten that far in my research yet, I have come across the options for cable shift solutions and have found a cable clutch retro-fit kit but I don't know the best route for dealing with drive axles/ flanges. Any ideas? What are the options?The MK4 dash is certainly not the paractical and straightforward choice but since I have it all and want to make this car a bit more special I want to take on the challange. I couldn't find any detailed threads on Vortex concerning the swap just a few that showed before and after. There is one from Belgium or somewhere that shows the swap in a Cabby and made it look pretty straight forward. I have the support drame and everything else from behid the dash so I hope that will make it a bit easier. I saw that one from the abandoned 1.8 project but I think it is sold. I could certainly do what Dave did (we have a CNC here) but if I am going to do a swap which is pretty much becoming common (mk1 TDI) I want to add a little something special.I would love to make the car as functional and practical as possible. I am not planning on putting A/C or P/S on it but I do plan on retaining the heat and trying to make it as weather-proof as possible. The hard part of the 4 season choice is exposing a labor of love to the sand, salt and snow. I can't do that with the Mini because those things would rust as they were sitting at the dealership, a Rabbit on the other hand can be rust-proofed to some degree.By the way, I guess I should post a thread with photos and some info from the mini build, that was a project (ground up build), but still we completed it in about 3 months.Here's a teaser: (finally figured out how to post the photos{warning: they are pretty big})[img]http://i225.photobucket.com/albums/dd32/Greasecar/frankenstein2.jpg)
(http://i225.photobucket.com/albums/dd32/Greasecar/uglyrunning.jpg)
(http://i225.photobucket.com/albums/dd32/Greasecar/fueling039.jpg)
(http://i225.photobucket.com/albums/dd32/Greasecar/fueling046.jpg)
(http://i225.photobucket.com/albums/dd32/Greasecar/TDSstart.jpg)
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I was looking at the Mini on the website...that looks like a def. fun project...
On the dash....I'll see if I can dig and find the info that I had on it. It really wouldn't be that hard if you were planning on "recovering" it after you make your cuts, etc. I'm thinkin about recovering an early MK1 dash I have here that has only a few cracks in it...early....dual round gauges (or come in the "cyclops" single gauges), the original german dash. I have some nice black onyx microsuede I bought to go along with the green plaid inserts I'm making to do the door panels, pillar trim, etc. in...may recover the dash. Also...gives it that ferrari touch! Nice...fabric treated dash.
Anyways...I'll look to see if I can find more info. and post it to you.
As for the TDI tranny and swapping to rabbit axles flanges. Thats a no go...
The TDI trannys actually have a more coveted axle flange. The 02a style TDI tranny from the MK3 and B4 cars run the "02a" casting for the tranny, but have the newer style 02j diff...the MKIV...all 02j. The unique thing about the 02j diff and its axle flanges on the TDI is that they are 1.) bolt on and 2.)they are 100mm
Which makes things nice...you can run 100mm axles from a 16v scirocco or any 85+ MK1 cabby and not have any issues. You'll need to either also get 16v or 85+ MK1 spindles (clearanced for 100mm outers) or clearance your 90mm spindles to clear the axles. Some people have had problems with it, needed to clearance...some say its not an issue. Clearancing 90mm spindles for the 100mm axles though is the best route IMHO or find 85+ mk1 spindles (i'm actually trying to locate a set right now).
So...just unbolt the flanges to replace those seals...and reinstall. The axle orientation, etc. will be fine.
Many 1.8T owners actually seek out TDI flanges when doing big hp upgrades because 1.8T units are 108mm and our TDI ones are 100mm...weird that they stepped down in size but...ok.
Pretty easy there.
For mounting the 02a, you'll need custom mounts. There are many different variations out there and some now that you can even just buy online which is even nicer. However, I imagine with your fab skills that you might go your own route on making some. My welding skills probably aren't to that point yet, so i'll more than likely be buying some...they are available from WRD.
I'm also using the cable acutated clutch setup on my CTN 02a TDI tranny as well. I have all the bits to do it (thanks to another board member here :) ). Since your using the MKIV tranny, the clutch slaves orientation is slightly different than that of the 02a style trans if I remember correctly...but the bolt pattern is the same, etc. so it may be possible for you to use the cable acutated version as well.
I'd post pics, but looks like they are "dead" in my other thread, so I'll have to snap a few, upload them and then post.
Joe
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Joe,
You certainly are a wealth of knowledge.
If there are parts that we need in common (such as tranny mounts) let me know and perhaps I can fab up pairs, that way you can help with the engineering and we can jump in on the welding and machining.
I'd love any info you already have on the tranny swap.
I just to the rabbit for a little blast at lunch and that little diesel 4-speed is about the worst match for the extra power of the modified 1.6. There is a guy near by advertising an FN for $70, maybe I'll drop that in for the meantime (FN seemed pretty good in the last bunny). Thoughts on that?
As far as the dash goes, it looks to me that most of the trimming is on the depth as the width is doable. The swaps I saw looked like they had minimal trimming on the ends and were not sectioning the center. If I can figure out where material needs to be removed ahead of time rather than hacking it until it fits, we may be able to do it without recovering. The whole shing appears to be molded foam rubber with a textured vinyl skin. If you are careful and trim from behind you should be able totrim under the skin and leave a flap to cover the edge once it is to size. All of this is of course based purely on face value as I have no experience doing this.
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Justin,
Yes, I def. wouldn't mind helping and us helping each other out at the same time if it proves to be useful! I believe we have been there before :)
Anyways, on the mounts. There are several different versions out there and I seem to recall someone that put up ALL the dimensions for both the tranny D. Side mount and the lower tranny mount as well. Even so far as to have them in a CNC format if my memory serves me correctly. I'll have to look, maybe I have the graphic around somewhere, but I know they are out there. Just can't remember whether it was here or on the 'tex
Any info you want on the tranny swap, just let me know. There are considerations when going to cable shift in the MK1 for the best routing for the cables (as all the cables are slightly longer than what the MK1 likes, etc. I can tell you what I've thought of, what I plan to do, etc. Other than that...its not too bad of a swap in the end! I can't WAIT to have the CTN in the mk1...its really going to make the car fly quite nicely :)
On your current trans...yes...I'd swap in the FN for now. Would you believe, I'm running the same FN trans that I had in the old IDI TD setup on the mTDI setup currently. Its a tough unit! Granted though, I'm taking it easy on it as I don't want to have to put the car away TOOO early this year...but it is a nice trans for the good ole' IDI motors...NA or TD. Mine is starting to show its age, etc. but still has been in the mTDI for about 1.5years now without issues. Again though...i haven't gone out and really beat on it. Not my style :)
For $75...you can't beat that. You may have to rewire the tranny switch on it as the FN uses the funky plastic "box" switch with the additional pinouts for the upshift indicator, etc. but thats easy enough.
You've got the complete and right idea on the dash. Thats how I'd do it. Most that I have seen that have done the MKIV and the MKIII dash have cut the dash where the "glove box" side/p side of the dash would meet to the HVAC/vent portion of the dash, shorten it there and then use that flap that you mention to make it all one unit again. Many have turned out very nice :)
Even more fun...maybe a TT dash which is more at home in a tight cockpit :) Have seen that done as well!
Joe
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Joe-
Do you have any old photos of what your TDI engine looked like inside when you goti before cleaning it for re-build, I want to see how mine stacks up for condition. Mine has about 60k on it and I am trying to decide whether it is worth taking apart the bottom end or just putting it back together since it looks clean to me.
The main reason I was planning on using the MK 4 dash is because I have it and it almost seems that pulling the whole harness with it for the rabbit may be easier than a whole bunch of cutting and pasting Frankenstein style. It is pretty large for the application though. If anyone knows of detailed threads showing how others have done it I would love to see.
I saw in your build thread that you sourced Corrado cable shift boxes. I have my Golf box but the ends of the cables will need to be replaced. Is it possible to put shorter Corrado cables into the mk 4 box you think or should I just ditch it and go with the Corrado or A 3 box because it will fit better?
For the mounts; if there are DXF files out there or evengeneral dimensions we can probably work with them. For stuff like that it always takes longer to figure out what to make than to actually make it so if the figuring out is already done and known to work we should be ablt to whip it up pretty quick.
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I do have a few pictures...when I started with mine...it had 129k on it, was pretty dirty, etc. I always wanted to start out "fresh" so, a rebuild was the only way to go...especially with some of the things I wanted to do (such as machining the pistons, thermal coating, etc...)
Here is what I started with...no wiring, etc. etc...just a engine with eTDI pump
(http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_1809.jpg)
(http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_1796.jpg)
I've got another 1z downstairs that def. needs a rebuild, its go close to 220k on it I believe and was running on vege when it came out of the car. Again, I'd like to start with a zero miles unit...so, I'll be rebuilding. though, much more mild on this one.
I understand what you are saying about the MKIV dash, I'm sure it'll work well. Many people upgrade the MK1 to the CE2 style fuse box, and then splice in the ECM harness, etc. to that system. Your way will work as well. you will have some faults, etc. in the ECM when reading with VAG COM, but they can be overcome without issue.
My shift box is the b3 passat cable box. The difference in length is not significant between the two...i can't even remember if there is a big difference. I know I had an MK3 vr6 box by a b3 one and there was no difference in cable length. Either, or...any will work. Your MKIV box is a bit more unique to the MKIV and its tranny than the 02a style boxes...
You'll have to replace the entire cable vs. just the end. From what I know anyways, at least...thats the way it is with the 02a style boxes... its the reason why i have a corrado box here with one good cable...one bad.. I got it...and snapped one of the cable ends :( Its a "spares" box for me now as I have a good b3 02a one here as well.
The end couldn't be replaced on my 02a one...short of welding the end back on, etc. However, its cheaper to just buy the single new cable which can be done through the dealer...or go to you local pick a part and pick up a box w/ cables for 15.00!
Working on getting those graphics/drawings :)
Joe
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After digging through all of my collections of pictures from the various projects over the last 5-7 years or so...i did find this drawing of one of the needed o2a mounts for the MK1
(http://i18.photobucket.com/albums/b109/joeallison_99/02a-mount.jpg)
I can't seem to find the one for the lower tranny mount for the 02a conversion...i'm sure its out there somewhere.
Also...here is your cable acutated clutch setup from the 02a...
(http://i18.photobucket.com/albums/b109/joeallison_99/02a_clutch.jpg)
I have all of these parts physically, so let me know if you'd like to see them "in detail" just need to take pics...
Joe
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Thanks for the photos and tips on the tranny swap. I saw a cable clutch kit on Vortex for $160 that looked just like what your diagram shows, but you were saying it may not fit the TDI slave flange? That tranny mount looks very simple and straight forward though I would probably try to include some additional suppot on the arm between the mount and bracket.
I was picking apart and continuing to label the chassis harness on the Golf last night. I have the engine harness intact and that should be plug and play, the hybridizing of the chassis harness will be the real challange but with the dash swap it should make things simpler wiring wise as I will use the A4 fuse box, relays and switches and then just splice into the Rabbit accessories and lights. This is what I did on the Mini project which used and engine and running gear from a Rover Metro which fortunately used similar color coding and sensors with similar values. The only thing that didn't work out well was my hybrid spedo cable which is consistantly off by 15%.
The Rabbit itself is almost road ready with the exception of the reverse lights, chipped windshield, horn and the last 20 inches of exhaust none of which is too intimidating other than the glass which will cost a few $$.
I am trying to decide whether to put this car on the road and drive it for the winter which would mean finding another shell for the TDI build or find another daily driver and start digging into the TDI swap which would mean a decent 4-speed 1.6 with fresh clutch, seals and 1,9 turbo swap will be up for grabs.
It may be easier to find another daily driver than to find another decent 2-door Rabbit shell. Speaking of shells is anyone looking for a stripped 2-door A4 golf Shell?
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I'm having a hard time reading the specs on that tranny mount sheet. Do you have a larger image or PDF you can email me? [email protected]
Are you going to want one of these If we make one? You think others will want them if we do a small batch? I already have one rubber mount that I was going to put in the Rabbit for the current tranny but turned out I didn't need it, those are cheap. I guess some people woulf want urathane or solid mounts for gasser applications.
Looks like you did something similar to MR Dave for your engine mount. Looks like the front (core support) mount will bolt up at the bell housing, what are pleople doing for the rear mount?
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I am returning to the board after a long absence with a new project. I gave away my original Rabbit GTD after it sat in an idle state of restoration in my garage for 2 years (stripped out for body work). Discouraged by the amount of work I had into the car and the amount of work needed to complete it and distracted by numerous other projects and running my business, I handed it off to my friend Jay who is working on building her up on his own.
Sorry to go off topic, but I'm the Jay who has Justin's old car. It's a great project for me, and I can't thank Justin enough for the opportunity to build up his old car. Here is a pic of it in it's current state, in my garage, being worked on whenever I get time.
(http://i199.photobucket.com/albums/aa179/JMOVT/9asitsitsnow.jpg)
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Justin,
I'll email you the actual graphic itself. Its compressed slightly for posting I imagine because I use Photobucket for hosting...
I would def. be interested in that mount in particular (and I'm sure others would be too). It could benefit with a little bit of reinforcement and/or gussetting on the arm I agree as well. I'm still trying to find the plans for the lower rear tranny mount...but haven't found it yet.
To give you and idea of what is out there. Here is what WRD USA is offering for the tranny conversion...
(http://wrdusa.com/Merchant2/graphics/00000001/010a180.jpg)
They can be bought here on their website...
http://wrdusa.com/Merchant2/merchant.mvc?Screen=PROD&Store_Code=WRD&Product_Code=010A180&Category_Code=mounts
Review's have been fairly decent on them. However, they are also one of the only "options" that we have at the moment on this side of the pond...short of making our own, etc. There were a few people offering them on the 'tex as well, needavr6 made them for a while, as well as patatron and then there is one other that illudes me. Someone here mentioned using his.
As for the front mount. Man...so many different variations. I've seen many ways. I've seen people that have welded in the complete MK2/MK3 style mounts for all engine points, I've seen Rabbit mounts with the MK2/3 style front mount (attached to modified core support and also attached to a core support reinforcement bar...basically square steel tubular stock run in between the front bumper supports with bolt plates welded to this bar and then attached/secured at the bumper mounting points and stock MK1 front engine mount location), and then also...the stock rabbit mount, or the stock style mount using one of these "core support reinforcment" pieces...
They can be bought on the market from a few places...and many people make theirs at home as well. Black Forest Industries is one place that sells them right now.
I planned on the stock engine mount up front utilizing one of the core support reinforcement bars.
I don't know if you were referring to my pass side engine mount as being similar to Mr. Dave's, but...its not really
Using the ALH block from the MKIV you have to use the style of mount that he made...it uses two points on the block where the stock mk1 mount would bolt...but the ALH block lacks the other two MKI block mounting points...so...you "wrap" the mount around the rear and use a couple of the other mounting points found on the back of the block.
On the earlier TDI's... the 1z/AHU motors found in Mk3's and the b4 TDI's...you can use the stock rabbit mount. Mine is a modified straight injection pump bracket from the MK1 with the IP portion cut off (as I wanted to use all the 1z/AHU timing belt goodies, backing plate, etc...) and then contoured to the front of the block. It is a STRONG mount...much more so than the gasser mk1 equal IMHO as its thicker steel (can' t remember the exact measurement right off...) and its also got "ribbing" that reinforces it as well.
The gasser mk1 mount can be used on these motors as well...but then you have to make spacers for it (has a "rise" at the front of the mount where the gasser accessory bracket wraps around), or use the stock accessory bracket, etc. My route ended up more direct and looks pretty stock.
As for the cable actuated clutch setup for the 02a, etc. the only reason I mentioned it is the location of the slave on the mkIV, true "02j" style tranny I believe is more towards the "back" of the bellhousings. Looking at an 02a TDI trans (CTN code with 02j style diff/bolt on cups) you'd find the slave is mounted at "12 o' clock" looking at the tranny from the bellhousing. If memory serves me correctly, I believe the MKIV 02j style mounting is located at 1 or 2 o'clock on the bellhousing. But again...don't quote me on that.
Mounting wise though...the MKIV 02j slave and the 02a b3/4/mk3 mountings are the same bolt pattern. The slaves are a particular common problem on both trannys and I've heard of people "interchanging" the MKIV one with the early one, etc. Taking the cable acutated clutch into consideration then, with your MKIV style 02j tranny...the dimensions of the cable and the orientation of mounting the cable acutator itself may....may present clearance problems, etc. However, it should bolt right up to the tranny.
Make sense?
:)
By the way...the "old car" looks nice! Glad to see that it has a good home!
Justin, if your on a quest for another 2dr. keep your eyes peeled. I seem to only find decent...decent 4dr's...ultimately, I wanted my mTDI mk1 project to be a 2dr. pre 80 german diesel rabbit. No luck there yet though.
Joe
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I have found a few worthy 2-door shells in the $1000-1500 range but they have all been mid '80s. Most of the decent German 2-doors are in the PNW and really cheap, probably worth the shipping cost but I hate buying stuff like that sight unseen.
Jay, looking good. I was waiting to see sommore shots of the progress. When is it going in for paint? You should definitely get a build thread going on the board then this spring we can have a face-off.
I finished getting the wiring harness, steering column and dash support bar out of the Golf last night with minimal damage aside from a few little harness mounting clips. There sure is a ton of wire in that thing. I plan on weeding out the airbag and brake pad sensors from the chassis harness and hope to re-wire the light circuits to the Rabbit bulb sockets so that I can just swap the whole fuse and relay cluster. The chassis harness was incinerated on the other side of the firewall but we have the ECM end of the Chassis harness left over from Ethan's 1.8T swap and hope to splice that into what we have left of the TDI harness. Most of the chassis accessories and color coding should be the same between the 1.8T and the TDI.
The geometry of the A4 column linkage seems very similar to that of the MK1 and I plan on attempting to splice them together. I need to get a shell so we can start mocking this all up and with the current budget it is looking like driving the maroon car and picking up another shell for the build may make more sense than buying another driver and stripping out the marooner.
Here are the shell options I am looking at. Right now I am leaning towards the first (silver one) because it has been garaged and I can probably scrap out some of the gasser stuff to defray the cost.
http://forums.vwvortex.com/zerothread?id=3422982
This one seems a bit sketchy
http://forums.vwvortex.com/zerothread?id=3398180
By the way here is the TDI Rabbit that Lagomorph is selling.
http://forums.vwvortex.com/zerothread?id=3417155
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Justin, your new rabbit looks pretty mint. I'd say using that as a DD and looking for another shell to build may be a good idea, but only because you're in need of a DD . A tdi swap in that car would be awesome, but since it's so close to being road worthy it may make more sense to find just a shell for the tdi because that will be project that will take some time.
Anyway, here is another link to a shell for sale up here, just for the heck of it:
http://www.dubsnorth.org/forum/viewtopic.php?t=6643
Progress on the '82 rabbit is slow lately, but still moving forward. Wedding stuff has taken up the majority of my time lately though. I have two options for paint, both can't happen until later in October...but hopefully that will work out. While waiting for paint the rest of my time on the rabbit is spent sorting through wiring and trying to modify the rain tray a little, and creating my new intake piping.
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Joe, you painted your old 4-door right? Green pearl if I remember correctly. Other than a bunch of wet sanding how did you feel it came out? I never saw it in person but it certainly looked pretty good in all the photos I've seen
http://i18.photobucket.com/albums/b109/joeallison_99/Pavilion2.jpg
I think Jay is on the fence as to whether he should paint his or spring for the $$ pro job.
I pulled the Heater, A/C, duct assembly out of the Golf today, it actually is not that big and only weighs about 10 lbs. Because the duct work all mates upt directly to the dash vents (w/o a bunch of tubes like the old rabbits) I figure I'll try to at least cut and paste it. These are the times when a stripped out Rabbit shell ready for mock-up would be nice. I may go and check out that silver shell Sunday, otherwise later this week. I agree that with the work put into the maroon turd to get it road ready it doesn't make much sense to take it apart. Plus I really want to see what that 1.6 will do, sounds mean.
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BTW the guy on the Vortex that makes the 02A/J mounts for Mk1 is Dan Bubb, or JDaniels on the Vortex. I've met him a few times and his mounts were featured in a european car mag once too. IIRC, his mounts are roughly the same price as the ABD ones. I personally will be going with his since I've met him and he's a Scirocco guy too. :P
Brendan
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yeah, i've talked to him as well. They are slightly more expensive than the WRD ones (not abd) but the only problem with his one mount that I saw was that it was a 2 pc. design and looked to be of a thinner gauge steel. He has said that they have handled 300hp or so...on a 1.8T setup in an MK1 out there.
Justin... check your PM's... I need your email addy to send you the larger resolution pic.
On the Classic Green Pearl I had on the GTD....yah, it was nice paint...really nice IMHO . Original color found on the Corrado "Storm"...loved it.
Remind me to tell you the "other" story behind it though...the reason why I don't like to talk about it too much.
Joe
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Doesn't look like too many folks are keeping an eye on this but I'll post an update anyway.
Finished fabricating my 2.25 exhaust and added a "Cherry Bomb". Sounds sweet, a lot mellower than the straight exhaust did.
I have some inter-cooler parts on their way and will be setting up my intake for boost gauge and wategate actuator tube. All that's left to get the car inspected and registered is a windshield replacement, and fixing the horn and reverse lights.
Here are a couple of shots from last night:
(http://i225.photobucket.com/albums/dd32/Greasecar/DSC00006-1.jpg)
(http://i225.photobucket.com/albums/dd32/Greasecar/DSC00005.jpg)
(http://i225.photobucket.com/albums/dd32/Greasecar/DSC00003.jpg)
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Wow, I didn't realize how crappy those photos were until I reviewed the post. I gotta figure out what's wrong with the shop camera.
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Looking good! Keep the updates coming...I'm interested in seeing how the 1.6 performs with the tdi manifolds/turbo.
Also, my spare TD pump may be on it's way to your shop soon so you can play with that...
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Wow, I didn't realize how crappy those photos were until I reviewed the post. I gotta figure out what's wrong with the shop camera.
Thank God! I thought my sight was failing!
GREAT POSTS, thanks for making the effort.
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Well, tomorrow the new windshield is going in so I took the opportunity to pop out the old chipped glass and clean and repaint the frame. Conor and Ethan dug into the wiring and got the horn working so now all that is really needed for inspection is a new reverse switch.
(http://i225.photobucket.com/albums/dd32/Greasecar/DSC00013.jpg)
Of course we couldn't resist taking a few runs around the building with the glass out, but safety first! Nice job Ethan.
(http://i225.photobucket.com/albums/dd32/Greasecar/DSC00014.jpg)
I'm heading to CT on Sat. to check out the silver rabbit previously mentioned. It has been garaged since 1992 and is currently owned by the original owner. Sounds like it was a pretty cool car 15 years ago but I'm not sure how well the Koni and neuspeed gear ages. We'll see.
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Well, we had the car almost ready to register but my intercooler kit arrived! It was a cheapo kit bought on Ebay (less than $200 shipped) but looks like it will do the job nicely.
(http://i225.photobucket.com/albums/dd32/Greasecar/DSC00020.jpg)
I'll need to make up a few adaptors to knock the 2.5in IC tubes down to mate up with my turbo but otherwise there are more than enough tubes, couplers and clamps to get the job done.
Look at that fit.
(http://i225.photobucket.com/albums/dd32/Greasecar/DSC00024.jpg)
I also picked up the fittings and tubing needed to complete the boost gauge and wastegate plumbing and drilled and tapped the intake manifold.
(http://i225.photobucket.com/albums/dd32/Greasecar/DSC00027.jpg)
(http://i225.photobucket.com/albums/dd32/Greasecar/DSC00026.jpg)
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hey Greasecar,
could you post a link to the seller of the I.C. supplyer? I got one coming from Tyler (burn your money) if that one don't fit to my liking .I would like to go with a kit like what you got to fit my caddy!
I would appreciate the info? and like to see more pics when you get more of it hooked up!
thanks Duane
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Well, we had the car almost ready to register but my intercooler kit arrived! It was a cheapo kit bought on Ebay (less than $200 shipped) but looks like it will do the job nicely.
I'll need to make up a few adaptors to knock the 2.5in IC tubes down to mate up with my turbo but otherwise there are more than enough tubes, couplers and clamps to get the job done.
Look at that fit.
Looks good! Glad to hear that the kit came in, and it looks like the car will be on the road soon! How thick is that IC?
Did you get my intake manifold and TD injection pump yet??
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The company is called CXRacing and they have an Ebay store. A friend of mine turned me onto them who also bought an intercooler from them. The quality and completeness is amazing for the price (the T-clamps alone from other suppliers would be the price of the whole kit ). Don't get me wrong though, this is a Chinese kit and will likely lack a bit in performance and longevity but for a budget project I don't see how you can do much better. The customer service was pretty good too and they even offer a $30 rebate if you send them installation photos that they can use.
If you go with them, I would recommend getting a full kit rather than just the cooler because it is all those incidentals that can really add up. Fortunately I have a nice tig and can weld up all the tubes but with the amount of tubes, couplers and clamps anyone should be able to cut and paste a fairly elaborate tube set.
I hope to get most of the equipment installed in the next coulpe of days so that I can get the car put back together and on the road, I'll post updates.
http://stores.ebay.com/CXRacing_intercooler-kit_W0QQcolZ4QQdirZ1QQfsubZ10881276QQftidZ1QQtZkm
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Okay, a little update
I picked up the new shell for the actual TDI build which is loaded with oldschool stuff to swap over to the IDI car. I bought it from the original owner who loaded it up with add-ons over the years including Neuspeed and Koni suspension, Hella lighting, short shifter Zender rear spoiler amongst others. Also a Techtonics motor which I hope to sell to defray the cost of the shell. They key for me is that this thing is rust free and should make a clean and solid platform for the build.
The interior is in good shape under the mildew (car has been sitting in a garage for the last 15 years) so I plan on swapping that into the maroon car to make way for the MK 4 stuff we are planning for the TDI.
(http://i225.photobucket.com/albums/dd32/Greasecar/DSC00038.jpg)
I have fabbed up all of my IC plumbing and swapped the TD pump that Jay gave me (condition unknown, cross your fingers). I should be getting my EGT and boost gauges tomorrow along with the narrower radiator I need to clear the IC pipes and should be ready to roll.
(http://i225.photobucket.com/albums/dd32/Greasecar/DSC00036.jpg)
(http://i225.photobucket.com/albums/dd32/Greasecar/DSC00045.jpg)
I also got the battery re-located and wired
(http://i225.photobucket.com/albums/dd32/Greasecar/DSC00041-1.jpg)
I guess the one thing I left out is the intake which I will probably just slap together for now but plan on making a cool air box when time allows. My imidiate need is to get the car out of the shop and clear some space for the longer term TDI project especially because we have cars scheduled to come in for conversion.
Hopefully I'll have it all together in the next week and will post photos. I want to be able to drive up to see Jay and his progress on the 4-door in the next month.
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very nice looking silver shell there Justin!!!
Progress is coming along nicely as well!
Joe
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Awesome!! Glad to hear you picked up that shell, it looks great! A perfect candidate for the TDI swap.
The idi car looks like it's coming along real well too! I'm excited to check that out. I really hope that pump works for you...it's been sitting for a long time, but was mint when I got it so I'll cross my fingers.
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Well the brakes are slammed on the maroon car. I got everything back together today and thought i was ready to run but it turns out the injection pump is junk, leaks like a siv from the output shaft and throttle shaft and doesn't give any pressure to the injector lines. I ordered a VE gasket set this weekend to have just in case but it will likely be a week or so until I get it. With the amount of time and hassle it has cost me I may just buy a reman. I can't imagine going through the trouble of pulling this thing, throwing gaskets into it, putting it back only to find that it has something else wrong with it.
I have a couple of leads on pump sources but if anyone has any suggestions let me know.
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Opened up the pump today to see what I'm dealing with and it turns out I would need more than seals. (here is one of the issues)
(http://i225.photobucket.com/albums/dd32/Greasecar/DSC00032.jpg)
Since this n IDI issue I am discussing it primarily on the IDI board but I am thinking about building a hybrid pump with one of my ALH cores so the TDI crown may have something to say.
http://vwdiesel.net/phpBB/viewtopic.php?t=10828
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first: Wow, nice build up bummer about the ip...
second: I hardly ever come on to the tdi side of the forum but saw the thread and thought I'd post because you have been asking about Joe's old car.
Joe passed the shell along to me which I took to keep it from hitting a junk yard which I thought would be a shame. there are a few rust issues that need to be taken care of and I had planned to rebuild a turbo diesel motor I have pulled parts together for and put it in.
(http://fuslit.org/photo_gallery/picKLE-cache/misc/car/turbo_diesel_buildup/12-02-06_moving_the_rabbit/SP_A0225_640.jpg)
some pics of the move, although it's dustier now
http://fuslit.org/photo_gallery/index.php?album=misc/car/turbo_diesel_buildup/12-02-06_moving_the_rabbit/
This is a long term project for me at the moment.
I've gotten quite a few parts (and projects) laying around.
Priority project at the moment is my daily driver (a vr6 jetta) needs its timing chains replaced before I can get into anything else. The car has been a source of frustration because to me it is not a 'fun' car to work on and it's precipitated me complaining to Joe about many things (sorry man)
To make a long story short, I've fluctuated with what I want to do with the Jetta, rabbit and I also have a caddy. Space is an issue in some sense, but GTD is taking a bay up in my garage.
I thought I'd sell the caddy as it had been sitting quite a while and needs some body work. I was thinking I would sell the caddy to get some space freed up The problem is I also have a wife who likes the practicality of the caddy and isn't so enthused about the gtd. note: while Cate (my wife) has some input as a happy wife = happy me, I do still like the gtd. But, when the Jetta timing chain issue propted up I became frustrated. (with cars in general as I have other projects that get put on hold while I come up with the money to fix an expensive in my view issue.) I got into vw's in a diesel rabbit, cheap to drive and bullet proof. The complete opposite of the GLX ...
Anyway, as the caddy is forbidden to sell, I have gone back and forth with what I want to do with the shell. (i.e. keep or pass along.)
Because it seems I have about 100 projects in the air at once so it makes it discouraging sometimes to see something an know you can't get to it right away.
So, I sat back and thought about everything where I was, what I needed to do and talked the glx parts issue over with my wife. The parts for the timing chains are cheaper than a car payment and in reality it has been fairly reliable. (almost 220k on it) It's fun to drive and I know the history behind it. Rational thought replaced the urge to sell all cars and ride my bike to work. (it's almost an hour drive one way)
Since I have managed so far the space issue in the garage and am working slowly to add better storage of stuff, at the moment I settled on fixing the rabbit up (yeah Joe, I'm worse than a yo-yo.) I see great potential in it and the final thought is, I really really enjoy working on the mk1's.
my mk3 jetta, well, that's a large source of frustration some times (mostly about how much parts cost for a vr6) but at least it's fun to drive. Since it's a daily drive I gotta keep it running.
I also have a longblock tdi (sans ip, and turbo) which needs to be bored over to fix one cylinder that got hosed but that's a possible motor for my long term project plan for the glx (mk3 coupe with cabrio side skirts, maybe syncro m-tdi)... it's a 95 so pre-obd2... *grin* anyway as I say, long term project and I can dream.
(not really making the story short am I?)
and I'm getting sidetracked. I guess what I am trying to say Joes' old GTD is still in play to be returned to it's former glory, but it's in a very long que at the moment.
I'll be following the car build, hybrid pump build and that intercooler set is a pretty great deal for sure! Thanks for the info and I'll try to do better about posting.
-Todd
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Good to hear Todd...with your talking last week, etc. I had actually had a few conversations with family and friends at home if indeed you were going to get rid of her (for storage sake, so I could revisit it down the road when I have more time...and another bay or two!)!
Glad to hear it. It'll be great!!!
Justin...how are things going?
Joe
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I think it's great that we have the past and present of both Joes and my Rabbits on this thread. That four door really did get stripped before you handed it off.
Todd, looks like you have a couple of nice chunks of hardwood there next to the Rabbit what sort of woodworking are you doing?
It's a bummer about rust on these old bunnies and the maroon rabbit is no acception. I spent weeks patching the old four-door that Jay is getting painted up this weekend and it really sucked the momentum out of me, that's why I went through the trouble of tracking down the rust-free silver shell for the TDI build. Speaking of rust here are a couple of shots of the floor patching I did on the maroon car.
(http://i225.photobucket.com/albums/dd32/Greasecar/DSC00063-1.jpg)
My shield gas tank is being held hostage at the Mini shop so I had to do the job with flux-core and was not too happy with the results, but since this is the slap together beater I just wanted to get it water tight. I'm waiting on some POR 15 to finish the job then the carpets and interior are goin in.
I'm still waiting for my nozzles and gasket kit that I foolishly ordered through a Canadian vendor (I forgot how long that can take) so I am still at a standstill mechanically. However, I used that spare time to get the air intake, oil seperator and washer tank together.
(http://i225.photobucket.com/albums/dd32/Greasecar/DSC00059-1.jpg)
(http://i225.photobucket.com/albums/dd32/Greasecar/DSC00065-1.jpg)
Conor did most of the final fab on the air box which just needs a bit of trim to finish up.
I also got a killer deal on a set of 15" Corrado steelies ($60 w/ tires)! The two in the photo haven't been cleaned but they are close to mint under the brake dust.
(http://i225.photobucket.com/albums/dd32/Greasecar/DSC00064-1.jpg)
Here's a little shot of the two cars crammed in the single bay. I can't wait to get the maroon car back on the floor to see how it sits on the new wheels.
(http://i225.photobucket.com/albums/dd32/Greasecar/DSC00046.jpg)
Here is the turbo pipe I made up goes from the outlet to the IC tubes (my Cummins in the backround)
(http://i225.photobucket.com/albums/dd32/Greasecar/DSC00030-1.jpg)
Here are a few shots of the "Franken-pump" workbench. I plan on cleaning up quite a bit before re-assembly operations. The plan is to build the NA pump into a TD pump with the extra LDA I have, hybridize the TD pump with the TDI head and then see what I need to order to piece the corroded pump back together (looks like almost everything). If anyone has core pumps let me know because I wouldn't mind recycling parts.
(http://i225.photobucket.com/albums/dd32/Greasecar/DSC00054.jpg)
(http://i225.photobucket.com/albums/dd32/Greasecar/DSC00055.jpg)
(http://i225.photobucket.com/albums/dd32/Greasecar/DSC00056.jpg)
The powder in that last shot is from the fire supressant (this stuff is ubiquitous and nearly impossible to get rid of)
If I get a few more parts in (which I should today) I hope to have the Maroon car runnin' and out of the shop then I should be able to get going on the "TDI" build that this thread was started for.
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I think it's great that we have the past and present of both Joes and my Rabbits on this thread. That four door really did get stripped before you handed it off.
Todd, looks like you have a couple of nice chunks of hardwood there next to the Rabbit what sort of woodworking are you doing?
It's a bummer about rust on these old bunnies and the maroon rabbit is no acception. I spent weeks patching the old four-door that Jay is getting painted up this weekend and it really sucked the momentum out of me, that's why I went through the trouble of tracking down the rust-free silver shell for the TDI build. Speaking of rust here are a couple of shots of the floor patching I did on the maroon car.
...
Ah, the woodworking, bringing up another longterm hobby...
the stuff on the bench is blackwalnut scraps which i've picked up for cutting boards, they have cracks throughout which would make it tough to use for anything else.
the green rabbit has rust issues which need to be addressed before I do anything else to it.
(http://fuslit.org/photo_gallery/picKLE-cache/misc/car/turbo_diesel_buildup/03-18-07_dash_removal/IMG_8529_640.JPG)
(http://fuslit.org/photo_gallery/picKLE-cache/misc/car/turbo_diesel_buildup/03-18-07_dash_removal/IMG_8530_640.JPG)
While, I've got some body work ahead of me. I'm waiting until I pickup a bottle for my welder before I tackle any of the sheetmetal work.
I have a couple 1.6 diesel pumps, I had planned on rebuilding.
BUT, I'm not sure what they're worth and I've no idea what condition they're in, perhaps we could work something out if you can't find one to use.
-Todd
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Well, after a few stumbles getting the throttle set up the rabbit is finally up and running! Here are a few photos, Hopefully I'll have time to type up an update tomorrow and get a video later this week.
(http://i225.photobucket.com/albums/dd32/Greasecar/rabbit006.jpg)
(http://i225.photobucket.com/albums/dd32/Greasecar/rabbit003.jpg)
(http://i225.photobucket.com/albums/dd32/Greasecar/rabbit002.jpg)
(http://i225.photobucket.com/albums/dd32/Greasecar/rabbit004.jpg)
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Looking good Justin! This particular car is going to have to be moved to the IDI forums as its looking like a very nice build on it alone.
Then...not to mention the TDI that'll eventually come here!
Joe
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Def looking good, glad to hear you got it running under it's own power :)
my vr6 project should be started (and hopefully finished) this weekend than it's onto the body work on the caddy and rabbit.
-Todd
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The car is officially registered and insured now. I've been driving it for the last few days and figuring out what needs to be dialed in. The first thing was the alignment which was toed way out explaining the funky touque steer feeling I was getting. I also need to straighten out the exhaust which buzzes like crazy at idle.
The most boost I have gotten out of the car was 20PSI on the highway. I am still running the 130bar injectors and it feels like I am hitting a ceiling. The pump has been modified with the common LDA, governor and timing mods and the fuel screw turned up but I am not getting much smoke to speak of, starts right up and gives some pretty serious performance.
I'm planning on runnning this way for the next couple of weeks to get a baseline on performance and economy, then bumping up to stock 155s then later to the GTD nozzles I got.
I do feel like I may be losing a bit of boost response due to the large IC pipes that I got. Jay is going to be using 2.25" which sound a bit more suitable.
Here are a couple of video links to check out, hope they work. These were shot in the driveway at the shop so we weren't able to really open her up.
http://s225.photobucket.com/albums/dd32/Greasecar/?action=view¤t=RabbitBurnouts001.flv
http://s225.photobucket.com/albums/dd32/Greasecar/?action=view¤t=RabbitBurnouts004.flv
I'm driving to Boston on Friday, hopefully I can take the Rabbit if the other half doesn't insist on the Passat.
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These were shot in the driveway at the shop so we weren't able to really open her up.
:shock: you mean there's more power? looks really fast! try tweaking the LDA. some people grind a more aggressive taper into the pin. :wink: that way you're getting tons of fuel on boost!
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Awesome! That thing seems to be running great! I'm definitely impressed with the power. I can't wait to bring my car down and take the rabbits for a cruise.
Yes, I'm going to be running a very similar intercooler pipe kit, although mine is 2"...just got it today (so I'll be replacing my exhaust pipe set up asap). I have a different intercooler though, a spearco I believe, but it's really similar in size.
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Just figured I'd give a little update. I haven't had time to dig into any major projects with the car but was able to do a few cosmetics and some winterizing.
I scored these cool NOS mudflaps to keep the slush at a minimum
(http://i225.photobucket.com/albums/dd32/Greasecar/DSC00014-1.jpg)
Also added this nice Italian steering wheel
(http://i225.photobucket.com/albums/dd32/Greasecar/DSC00015-1.jpg)
and found out where some of my power issues were coming from
(http://i225.photobucket.com/albums/dd32/Greasecar/DSC00001.jpg)
(http://i225.photobucket.com/albums/dd32/Greasecar/DSC00002.jpg)
and here is another burnout clip for those like that kind of thing.
http://s225.photobucket.com/albums/dd32/Greasecar/?action=view¤t=MVI_0024.flv
The major project I have in the works ight now is a mechanical actuator for the VNT since I currently have the vanes wired about in the middle and am loosing out on the bottom end. There have been a lot of topics covering this and I only hope I can put together a setup half as slick as the one TinTin made.
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Justin, that oil filter doesn't look like fun!
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Even worse, that's the fuel filter!
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thats a pretty disgusting fuel filter... fram makes fuel filters or is that an oil filter? looks like an oil filter.
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thats a pretty disgusting fuel filter... fram makes fuel filters or is that an oil filter? looks like an oil filter.
I see in the pic. it says secondary fuel filter on it! so it's a fuel filter!
looks just like an oil filter don't it?
Duane
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I love the Steering wheel. All you need is anice chrome downturn for the cherry bomb :) I love the sound of a cherry bomb on a diesel.
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guess i wasn't looking too well...still NaSTy!!!
Joe
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found out where some of my power issues were coming from
power issues?? I've seen the burn out videos, what power issues are you talking about heheh ;)
Nice mud flaps, I love the green stripe.
J