VWDiesel.net The IDI, TDI, and mTDI source.

Engine Specific Info and Questions => IDI Engine => Topic started by: giulianot on October 04, 2007, 11:20:49 am

Title: aaz into a mk1 cabrio build
Post by: giulianot on October 04, 2007, 11:20:49 am

So I've changed my mind. I'm going to use a serpentine belt setup on the aaz , but my cabby has p/s as well. Will the p/s pulleys fit on top off the serpentine belt pulley without touching the frame of the car? Is the enough room to run serpentine setup and p/s in a mk1 cabrio?

giuls

Title: aaz into a mk1 cabrio build
Post by: Quantum TD on October 09, 2007, 11:33:21 pm

Never done it myself, but I'd imagine that if the P/S pump is on the BACK of the motor, you should have no problem. If'n you're using the stock mounting brackets for the Cabriolet, then the only clearance issue you should really have is on the AC pump (and perhaps the hood given the extra height of the AAZ motor).

 The AC pump finishes quite close to the radiator support, and there is little extra room on the front of the car. But, if the PS pump is on the lower rear of the motor on the AAZ (as I think it is), it should be in the same locatation as on the 1.8 gassser motor that came in your Cabrio.

Title: aaz into a mk1 cabrio build
Post by: BlackTieTD on October 10, 2007, 06:49:54 am

you'll be damn close to the passenger side frame rail. if i had to guess if it would go or not like your describe, i'd guess that it would hit.

Title: aaz into a mk1 cabrio build
Post by: burn_your_money on October 10, 2007, 08:41:38 am

I don't know for sure but I know I ditched the serp setup because I was worried about clearance issues.

Title: aaz into a mk1 cabrio build
Post by: bert on October 10, 2007, 10:27:35 am

aaz in mk1 golf no p/s though

(http://i78.photobucket.com/albums/j95/citigolf_2006/ebay05022.jpg)

(http://i78.photobucket.com/albums/j95/citigolf_2006/ebayjune002.jpg)

Bert

Title: aaz into a mk1 cabrio build
Post by: giulianot on October 10, 2007, 11:19:48 am

Wow  :shock:  that alternator pulley is really close to the frame rail! I hope that my p/s pulley don't interfere with the frame rail. At least i dont have an a/c pump too. I'm waiting for my egt probe to come in so i can install  that before the motor and trany go in the shell.  My front mount intercooler is kinda thick (3") so i had to move the rad supports back an inch. Hopefully i'll have the motor in next week.

If the serpentine setup dose'nt fit I'll have to go back to v-belts. Do i need to run a 1.6td harmonic balancer , to dampen vibration, or can i run gasser pulleys straight on the crank pulley :?:

Title: aaz into a mk1 cabrio build
Post by: bert on October 10, 2007, 11:27:03 am

The photo lies,theres quite a gap to be honest,its in the shade so its hard to tell,ive gone garrett T3 as you,you will be impressed,mine flies,had to swap all the brakes as i burnt the pads out with solid discs,now gti setup with vented disc  :wink:
Bert

Title: aaz into a mk1 cabrio build
Post by: Black Smokin' Diesel on October 10, 2007, 12:56:59 pm

IIRC you have to hammer in the framerail to fit a 1.9TD in a MK2 because the crank pulley hits the side of the framerail if it has PS. IMO you should ditch the PS altogether, it's not like a MK1 is heavy  :wink:

Title: aaz into a mk1 cabrio build
Post by: bert on October 10, 2007, 12:59:20 pm

Ye dont need p/s to be honest,just put more air in the tyres  :wink:
Bert

Title: aaz into a mk1 cabrio build
Post by: BlackTieTD on October 10, 2007, 01:45:12 pm

i agree. no PS needed in mkIs.

Title: aaz into a mk1 cabrio build
Post by: giulianot on October 11, 2007, 05:30:41 am

I know that p/s is not a must, but there is a  power rack in the car and i don't have a manual rack. here are some pics of the build so far


(http://i124.photobucket.com/albums/p28/giulianot/cabby8.jpg)

(http://i124.photobucket.com/albums/p28/giulianot/cabby7.jpg)

(http://i124.photobucket.com/albums/p28/giulianot/cabby6.jpg)

(http://i124.photobucket.com/albums/p28/giulianot/cabby5.jpg)

(http://i124.photobucket.com/albums/p28/giulianot/cabby4.jpg)

(http://i124.photobucket.com/albums/p28/giulianot/cabby3.jpg)

(http://i124.photobucket.com/albums/p28/giulianot/cabby2.jpg)

(http://i124.photobucket.com/albums/p28/giulianot/cabby1.jpg)

Title: aaz into a mk1 cabrio build
Post by: giulianot on October 12, 2007, 10:00:00 am

I received my EGT gauge yesterday. Still got to drill and tap a 1/8 npt hole for egt probe. heres some pics of the gauge.

(http://i124.photobucket.com/albums/p28/giulianot/mjandcabby027.jpg)

(http://i124.photobucket.com/albums/p28/giulianot/mjandcabby030.jpg)

(http://i124.photobucket.com/albums/p28/giulianot/mjandcabby035.jpg)

and some more pics of me serpentine setup with p/s

(http://i124.photobucket.com/albums/p28/giulianot/mjandcabby039.jpg)

(http://i124.photobucket.com/albums/p28/giulianot/mjandcabby037.jpg)

Title: aaz into a mk1 cabrio build
Post by: giulianot on October 15, 2007, 08:55:28 am

IT RUNS :D

so i dropped the motor in the cabby, had to bang in the frame rail so that the serpentine tensioner pulley would clear.  Then i primed the oil pump and filled the ip with diesel and she fired up right away :D  some more pics

(http://i124.photobucket.com/albums/p28/giulianot/100_0353.jpg)
(http://i124.photobucket.com/albums/p28/giulianot/100_0355.jpg)

Title: aaz into a mk1 cabrio build
Post by: burn_your_money on October 15, 2007, 09:56:14 am

Looking good.
How much did the frame rail need to be bent?

Title: aaz into a mk1 cabrio build
Post by: giulianot on October 15, 2007, 10:12:46 am

Honestly it cleared with no banging with .005 in clearance but i was not comfortable with that so i lower the motor down and gave it a couple love taps with a 20lb sledge and that gave me  1/4 in clearance.

Title: aaz into a mk1 cabrio build
Post by: blkboostedtruck on October 15, 2007, 11:04:16 am

where did you find the EGT gage? I like that one! how much is that one?
thanks Duane

Title: aaz into a mk1 cabrio build
Post by: giulianot on October 15, 2007, 11:43:54 am

The  EGT gauge is a glow shift and it was $115 cn  and it was on ebay. It reacts to heat very quickly and looks cool, so i went with it.

Title: aaz into a mk1 cabrio build
Post by: giulianot on October 17, 2007, 06:54:26 am

Does anyone know where i can by a new rad fan shroud for the mk1's? mine is so rotted that its beyond sandblasting and paint

Title: aaz into a mk1 cabrio build
Post by: giulianot on October 22, 2007, 07:30:21 am

I made some progress on the cabby biuld. I painted the rad fan shroud, put a new rad in , new overflow bottle, new coolant hoses, and installed the battery.  heres some pics

(http://i124.photobucket.com/albums/p28/giulianot/bmw010.jpg)

(http://i124.photobucket.com/albums/p28/giulianot/bmw006.jpg)

Title: aaz into a mk1 cabrio build
Post by: blkboostedtruck on October 22, 2007, 05:04:41 pm

Quote from: "giulianot"

Does anyone know where i can by a new rad fan shroud for the mk1's? mine is so rotted that its beyond sandblasting and paint

 I have some good fan shrouds! where exactly are you located?
thanks Duane

Title: aaz into a mk1 cabrio build
Post by: giulianot on October 24, 2007, 05:09:35 am

Thanks anyways but i got one in for now

Title: aaz into a mk1 cabrio build
Post by: tSoG-84bit on October 25, 2007, 05:36:58 pm

Does the AAZ mate up to a mk1 clutch and tranny? I need a new engine, figured I might as well go all out, but plan on staying all mechanical (no tdi)

I've tried searching, and your swap is definitely the closest I can find to what I am looking for.

Any Info you are willing to share on this swap is greatly appreciated.

Thanks,
tSoG.

Title: aaz into a mk1 cabrio build
Post by: spencebm on October 25, 2007, 08:50:09 pm

my older bro is putting a 1.8 16v in his cabby... :(  i wish i had a real bro...

Title: aaz into a mk1 cabrio build
Post by: giulianot on October 26, 2007, 06:22:03 am

Quote from: "tSoG-84bit"

Does the AAZ mate up to a mk1 clutch and tranny? I need a new engine, figured I might as well go all out, but plan on staying all mechanical (no tdi)

I've tried searching, and your swap is definitely the closest I can find to what I am looking for.

Any Info you are willing to share on this swap is greatly appreciated.

Thanks,
tSoG.

Yes the aaz engine will mate to many different clutch combinations it all depend on what trany you will be running, is it an 020, does it have a big spine or a small spline, do you have a 210mm flywheel? my setup is an old 020 trany small spline so i went with a 87 rocco 16v gasser clutch and flywheel and that seems to be holding for now .well see what happens when the motor get broken in and i start to push high levels of boost.

Title: aaz into a mk1 cabrio build
Post by: giulianot on October 26, 2007, 06:23:44 am

Quote from: "spencebm"

my older bro is putting a 1.8 16v in his cabby... :(  i wish i had a real bro...

Convince him that hes making a big mistake going with a garbage gasser, or wait till hes done the swap, then smoke him in your diesel! :D

Title: aaz into a mk1 cabrio build
Post by: giulianot on October 26, 2007, 06:28:40 am

My new intake runner make to accept 2.5" piping :D

(http://i124.photobucket.com/albums/p28/giulianot/canoeingjuly14-15015.jpg)

(http://i124.photobucket.com/albums/p28/giulianot/canoeingjuly14-15014.jpg)

Title: aaz into a mk1 cabrio build
Post by: spencebm on October 26, 2007, 08:52:26 am

haha, yeah it will happen, this thing is going to be a monster!  what kind of tranny are you running?  make sure and get a tall 5th gear and go really fast!

Title: aaz into a mk1 cabrio build
Post by: giulianot on October 26, 2007, 08:58:05 am

Thanks, i cant wait to see how fast this car is really going to be.  The trany is an ACN with a very tall .69  fifth gear in it, im guesing 240kph @ 4500rpm :D  :

Title: aaz into a mk1 cabrio build
Post by: 935racer on October 29, 2007, 01:08:21 pm

Just finished welding up this custom unit for you this morning:
(http://i94.photobucket.com/albums/l83/935racer/PICT2090.jpg)
(http://i94.photobucket.com/albums/l83/935racer/PICT2091.jpg)

Title: aaz into a mk1 cabrio build
Post by: zukgod1 on October 29, 2007, 02:25:42 pm

Quote from: "935racer"

Just finished welding up this custom unit for you this morning:
(http://i94.photobucket.com/albums/l83/935racer/PICT2090.jpg)
(http://i94.photobucket.com/albums/l83/935racer/PICT2091.jpg)

SHAAWING!!!!!!!!   :D

Title: aaz into a mk1 cabrio build
Post by: spencebm on October 29, 2007, 08:50:53 pm

my goodness...

Title: aaz into a mk1 cabrio build
Post by: giulianot on October 30, 2007, 08:03:07 am

Quote from: "935racer"

Just finished welding up this custom unit for you this morning:
(http://i94.photobucket.com/albums/l83/935racer/PICT2090.jpg)
(http://i94.photobucket.com/albums/l83/935racer/PICT2091.jpg)

 
Thanks dave, the downpipe looks beautifull, and its worth every penny! 8) Now all thats left is ic pipe and exhaust then i can drive it! :P

Title: aaz into a mk1 cabrio build
Post by: giulianot on November 05, 2007, 05:20:59 am

PROGRESS UPDATE

So this weekend I concentrated on moving the battery to the trunk of the cabby. I did this to make some room up front for the intercooler piping and it make the car handle better. Heres some pics :P

(http://i124.photobucket.com/albums/p28/giulianot/cabby005.jpg)

(http://i124.photobucket.com/albums/p28/giulianot/cabby004.jpg)

(http://i124.photobucket.com/albums/p28/giulianot/cabby002.jpg)

I also wanted to put the rear disc brakes in and the big sway bar for the rear trailing axle so I striped it from the Donner cabby painted it and installed the rear disc conversion =)

(http://i124.photobucket.com/albums/p28/giulianot/cabby012.jpg)

(http://i124.photobucket.com/albums/p28/giulianot/cabby013.jpg)

(http://i124.photobucket.com/albums/p28/giulianot/cabby009.jpg)

Title: aaz into a mk1 cabrio build
Post by: Mk2Fanatic on November 05, 2007, 06:50:18 am

(http://i124.photobucket.com/albums/p28/giulianot/cabby009.jpg)

Title: aaz into a mk1 cabrio build
Post by: giulianot on November 07, 2007, 05:21:41 am

I decided to go with a plastic battery box for the rear, so i can contain any acid spills and I don't want it rotting out the trunk :wink:

(http://i124.photobucket.com/albums/p28/giulianot/cabby019.jpg)

and some pics of the donor car :cry:

(http://i124.photobucket.com/albums/p28/giulianot/cabby017.jpg)

and a pic of the FK lowering springs that are going in after winter :wink:

(http://i124.photobucket.com/albums/p28/giulianot/cabby018.jpg)

Title: aaz into a mk1 cabrio build
Post by: giulianot on November 08, 2007, 09:10:37 am

So I took  toplessbunnys' advice and installed a brand new plastic battery box. Not only did it clean up the trunk, it also protects from corrosion! =)

(http://i124.photobucket.com/albums/p28/giulianot/bat004.jpg)

I installed the downpipe  too and what a difference! :D  :eek:  :D  Right away i noticed that my egt's dropped 200 f under hard acceleration. the garret t3 now produces full boost at 2000 rpms :eek:  :D  this thing pulls like mad and the low end torque is just unbelievable . The car spins tires under rolling starts in second gear! :P  i can wait to race some Japanese gasser garbage. :P

(http://i124.photobucket.com/albums/p28/giulianot/bat001.jpg)

(http://i124.photobucket.com/albums/p28/giulianot/bat002.jpg)

Title: aaz into a mk1 cabrio build
Post by: 935racer on November 08, 2007, 01:14:16 pm

Glad you like it man, these 3" pipes really get the turbo spooling, few people believe you can make boost that fast but you can :twisted:

Title: aaz into a mk1 cabrio build
Post by: giulianot on November 13, 2007, 06:36:18 pm

UPDATE

So I finally received my intercooler piping and installed it. What a huge difference intercolling makes :eek:  :eek:  :D My stock wastegate is set at 9 psi. next i have to install a remote boost controller so I can turn up the boost in the car, any suggestions on a good remote boost controller?  Here are some pics of the intercooler routing.

(http://i124.photobucket.com/albums/p28/giulianot/enginebay025.jpg)

(http://i124.photobucket.com/albums/p28/giulianot/enginebay028.jpg)

(http://i124.photobucket.com/albums/p28/giulianot/enginebay027.jpg)

(http://i124.photobucket.com/albums/p28/giulianot/enginebay026.jpg)

Title: aaz into a mk1 cabrio build
Post by: cowboybootlegger on November 13, 2007, 10:56:41 pm

I've had good luck with the Perrin   Boost Controller (http://cgi.ebay.com/ebaymotors/Perrin-Manual-Boost-Controller-Universal-EVO-WRX_W0QQitemZ290180056268QQihZ019QQcategoryZ33742QQssPageNameZWDVWQQrdZ1QQcmdZViewItem) i have mounted inline between the compressor and the wastegate actuator.  It's nice, because if you mount it accessibly, you can do adjustments to it fairly easily, and it's very simple to plumb. And from what i can tell, it's reliability and durability ratings are high.

(http://i154.photobucket.com/albums/s256/sale12345/TurboBunnyBuild3065.jpg)

(http://i154.photobucket.com/albums/s256/sale12345/TurboBunnyBuild3066.jpg)

Perrin   Boost Controller (http://cgi.ebay.com/ebaymotors/Perrin-Manual-Boost-Controller-Universal-EVO-WRX_W0QQitemZ290180056268QQihZ019QQcategoryZ33742QQssPageNameZWDVWQQrdZ1QQcmdZViewItem)

Title: aaz into a mk1 cabrio build
Post by: stewardc on November 14, 2007, 03:13:27 am

I'm gonna use a Turbo XS 2-stage controller. More boost at the flick of a switch.
http://agpturbo.com/product.php?productid=16157&cat=255&page=1

Title: aaz into a mk1 cabrio build
Post by: giulianot on November 25, 2007, 10:39:01 am

I'm currently in the process of buttoning up the interior bits. The old carpet was all torn up from the previous owner butchering in a set of bmw e 46 seats.  I ordered a new carpet @  Onlinecarpets.com for $150 .So I ripped out the hack worked brackets and seats and filled and holes in the floor, vacuumed and painted the floor.  I started to fit the carpet in but  it requires more trimming, and a warm garage to work in! Is their a special glue used to paste the carpet to the floor or should it just sit there? Here are some pics of my new seats, I used 2X4 square tubing painted black for seat risers and they worked well for  raising the seat above the floor cross member.

(http://i124.photobucket.com/albums/p28/giulianot/carseats002.jpg)

(http://i124.photobucket.com/albums/p28/giulianot/carseats003.jpg)

(http://i124.photobucket.com/albums/p28/giulianot/carseats004.jpg)

(http://i124.photobucket.com/albums/p28/giulianot/carseats008.jpg)

(http://i124.photobucket.com/albums/p28/giulianot/carseats009.jpg)

Title: aaz into a mk1 cabrio build
Post by: Eli on November 25, 2007, 07:16:49 pm

First of all I must say your build looks awesome. It's inspiring. Very nice work.

I'll be using a Hallman ES boost controller. Seems very well made, and a friend of mine has had one installed for quite awhile now with no problems he seems to like it. (I have yet to install mine) They go for 75$ here http://www.hallmanboostcontroller.com/applic.html , but I think I got mine cheaper on eBay.

Hallman ES:
(http://www.boostcontroller.com/products/BC-10.jpg)


Keep up the good work.

-E

Title: aaz into a mk1 cabrio build
Post by: giulianot on November 26, 2007, 12:59:47 pm

Thanks , there is still many things to be done but today I made a big step, I got the certification on the car now i have to finish the exhaust and get emission test done which is a big joke in ontario for diesel cause it just a visual inspection. "So let me get this straight Im paying you $40 to rev me motor and look for black smoke?" ...... Yup , you passed now pay me! :mad:  :screwy:

Title: aaz into a mk1 cabrio build
Post by: giulianot on November 28, 2007, 04:51:52 am

Progress Report
The exhaust system is complete !! 2.5" ss from the down pipe back no cat and ss universal muffler. Sounds amazing not too loud but a s**** load of turbo spool sound :laugh:  :laugh:  :laugh:  and I got plates for it too. here are some pics of my exhaust.

(http://i124.photobucket.com/albums/p28/giulianot/mixed2253.jpg)

(http://i124.photobucket.com/albums/p28/giulianot/mixed2252.jpg)

Title: aaz into a mk1 cabrio build
Post by: giulianot on November 28, 2007, 05:13:01 am

Oh and what do you guys think of these 15x7 Pannosports ? will they suit the cabby? The owner wants $800 for the set but they a race alloys only :confused:  can they still be used on the road?

(http://i124.photobucket.com/albums/p28/giulianot/mixed2254.jpg)

Title: aaz into a mk1 cabrio build
Post by: con on November 28, 2007, 05:32:29 am

Wow thats amazing, what kind of 0-60 you getting?

Title: aaz into a mk1 cabrio build
Post by: giulianot on November 28, 2007, 05:55:24 am

i still dont know yet, for the mean time im running 10 psi boost until the motor is broken in, then i will turn  up the boost and well see what she can do :twisted:

Title: aaz into a mk1 cabrio build
Post by: giulianot on December 03, 2007, 04:56:45 pm

Well i got good news and bad news. We will start with the good news.... i got the panasports  :D  :gift: im guna rock them in the spring time with a sick set of summer tires. for now im goin to run the 14" snowflakes with gislavad snowtires (very aggressive tread pattern...great for Canadian winters eh) okay...now for the bad news,,,,i think im into a head gasket recplacement alreay  :banghead:  if i run the car easyand stay off the boost its fine but as soon as i get on the boost above 10psi i have compresion leaking into the coolant which causes the temperatures to rise real quick and over heats my motor blowing coolant everywhere  :banghead:  :confused:

suggestions on what could be causing it??? i have arp headstuds in torqued to 75flbs should i maybe retorque to 100?

please advise

Title: aaz into a mk1 cabrio build
Post by: burn_your_money on December 03, 2007, 05:20:17 pm

This is completely unrelated to your current questions but what gauge of wire are you using for your battery? It doesn't seem very think

Title: aaz into a mk1 cabrio build
Post by: giulianot on December 03, 2007, 05:41:36 pm

currently its a number four gage wire and its turns over the motor quickly even on cold starts but i am going to do twin runs of number four gage wire eventually.

Title: aaz into a mk1 cabrio build
Post by: burn_your_money on December 03, 2007, 06:23:14 pm

Oh Right on. I really like the way this is shaping up and because of your post I decided to buy a DP from Dave. I just need to get a damn car on the road first

Title: aaz into a mk1 cabrio build
Post by: giulianot on December 04, 2007, 05:58:54 am

Does anyone on here know of a better manufacturer of head gaskets for the aaz engine ? I talked to the people at arp and they did not recommend that i torque past 75flbs. They seem to think that the head is not perfectly straight and thats what is causing compression leakage into the coolant.  I don't see how the head could be warped as it just came from a machine shop that assured me it was straight.  I guess ill have to remove the head and check it with a straight edge myself :roll:

Title: aaz into a mk1 cabrio build
Post by: giulianot on December 05, 2007, 03:01:40 pm

:(  here are some pics of the head gasket failure :(


(http://i124.photobucket.com/albums/p28/giulianot/gasket001.jpg)

(http://i124.photobucket.com/albums/p28/giulianot/gasket003.jpg)

(http://i124.photobucket.com/albums/p28/giulianot/gasket002.jpg)

(http://i124.photobucket.com/albums/p28/giulianot/gasket004.jpg)

(http://i124.photobucket.com/albums/p28/giulianot/gasket005.jpg)

i sent the head out for pressure test and check for warpage  i hope the head isn't cracked :mad:

Title: aaz into a mk1 cabrio build
Post by: giulianot on December 12, 2007, 08:43:41 am

UPDATE

SO i heard back from my engine rebuilder and he said that the head gasket failure happened because the steel pre cups were falling out of my aluminum head. This is not normal. The pre cup were nerled then pressed in then pinned. Anyways is under warranty, im getting a new head then i got to switch over my valves, springs, cam, injectors, glowplugs, over to the new head and have to match port and polished. It looks like i wont have my car back till after Christmas. :rolleyes:

Title: aaz into a mk1 cabrio build
Post by: giulianot on January 09, 2008, 06:21:49 am

Finally I will be getting the head back on friday. Brand new oem aaz head with match port and polish on intake and exhaust. I'm gonna use a 2 hole victor reinz gasket this time and torque the arp head studs to 100 f/lbs. The cabby should be back on the road by Monday, hopefully :roll:

Title: aaz into a mk1 cabrio build
Post by: cal on January 09, 2008, 11:41:42 am

good to hear it :) what parts of the gasser loom did you use to wire in your aaz? i'm doing a mk1 gasser conversion myself and starting to get a headache working out the wiring :(


i just want to drive her :(

Title: aaz into a mk1 cabrio build
Post by: giulianot on January 09, 2008, 12:01:33 pm

Quote from: "cal"

good to hear it :) what parts of the gasser loom did you use to wire in your aaz? i'm doing a mk1 gasser conversion myself and starting to get a headache working out the wiring :(


i just want to drive her :(

I know how you feel! :(  as for the wiring loom I stripped everything to do with the gas engine management, computer , coil, and harness.  the power wire that went to the coil now goes to the i.p. solenoid. the tach wire that went to the coil now goes to the w of the alternator. I added a push button in the cabin and a relay under the hood for the glow plugs. Oil pres and temp gauges are the same!  :wink:  if you have any more questions don't hesitate to ask and good luck with your swap :D

Title: Re: aaz into a mk1 cabrio build
Post by: haybayian on January 09, 2008, 02:02:29 pm

Quote from: "giulianot"

So I've changed my mind. I'm going to use a serpentine belt setup on the aaz , but my cabby has p/s as well. Will the p/s pulleys fit on top off the serpentine belt pulley without touching the frame of the car? Is the enough room to run serpentine setup and p/s in a mk1 cabrio?

giuls

Thank you for this remarquable thread, interesting well illustrated. I have learned quite a bit and looking forward to read more about your rig.

Haybayian
AAZ  Crosstown engines, Giles moded pump,  T3 Garrett, Homebuilt Lotus Seven inspired sportscar.

Title: aaz into a mk1 cabrio build
Post by: cal on January 09, 2008, 04:38:26 pm

Quote from: "giulianot"

I know how you feel! :(  as for the wiring loom I stripped everything to do with the gas engine management, computer , coil, and harness.  the power wire that went to the coil now goes to the i.p. solenoid. the tach wire that went to the coil now goes to the w of the alternator. I added a push button in the cabin and a relay under the hood for the glow plugs. Oil pres and temp gauges are the same!  :wink:  if you have any more questions don't hesitate to ask and good luck with your swap :D

sorry i may seem like an idiot here but what do you mean by an i.p. solenoid? did you just connect the origional tach wire straight to the altenator without modifying the tach then?

Title: aaz into a mk1 cabrio build
Post by: foxracer1 on January 09, 2008, 05:53:32 pm

Quote from: "spencebm"

my older bro is putting a 1.8 16v in his cabby... :(  i wish i had a real bro...

Ben your just jealous.  

My uncle has been wanting to do this but he figures the TD engine is better off on the engine stand.

Title: aaz into a mk1 cabrio build
Post by: giulianot on January 10, 2008, 05:09:17 am

Quote from: "cal"

Quote from: "giulianot"

I know how you feel! :(  as for the wiring loom I stripped everything to do with the gas engine management, computer , coil, and harness.  the power wire that went to the coil now goes to the i.p. solenoid. the tach wire that went to the coil now goes to the w of the alternator. I added a push button in the cabin and a relay under the hood for the glow plugs. Oil pres and temp gauges are the same!  :wink:  if you have any more questions don't hesitate to ask and good luck with your swap :D

sorry i may seem like an idiot here but what do you mean by an i.p. solenoid? did you just connect the origional tach wire straight to the altenator without modifying the tach then?

I.P. = injector pump  sorry for being such a lazy typer :D  I had to remove the cluster and mod my gasser tach to work on the alternator's w signal.  The  FAQ section has a realy good wright up on how to.

Title: aaz into a mk1 cabrio build
Post by: cal on January 10, 2008, 11:22:51 am

lo sorry for asking so many questions but how did you calibrate the tach to read properly?

Title: aaz into a mk1 cabrio build
Post by: giulianot on January 10, 2008, 03:28:24 pm

fine tune calibration requires a function generator and a Osciliscope, but if you dont have all that you can turn the thim potentometer on the circuit board, while the cluster is pluged into the car at what you KNOW is idle. + or -  a 100 rpm is better than no tach

Title: aaz into a mk1 cabrio build
Post by: cal on January 10, 2008, 03:51:55 pm

i've got a friend who's got an osciliscope so i guess i could work it out from that reading alone?

Title: aaz into a mk1 cabrio build
Post by: giulianot on January 15, 2008, 04:28:13 pm

Success ! =)  the cabby runs again! The head was installed this morning and torqued down to 75ft-lbs. The car runs really well now, it has no overheating issues at the preset time. I do notice that the temps start to creep up under long hard pulls. here are some pics

rockin the 14" bbs

(http://i124.photobucket.com/albums/p28/giulianot/new179.jpg)

(http://i124.photobucket.com/albums/p28/giulianot/new180.jpg)

lower a arm brace installed

(http://i124.photobucket.com/albums/p28/giulianot/new181.jpg)

Rockin the 14" snowflakes with gislavad snow tires

(http://i124.photobucket.com/albums/p28/giulianot/new183.jpg)

3 vdubs in 1 shot, 2 cabbys

(http://i124.photobucket.com/albums/p28/giulianot/new184.jpg)

(http://i124.photobucket.com/albums/p28/giulianot/new186.jpg)

Title: aaz into a mk1 cabrio build
Post by: foxracer1 on January 15, 2008, 05:44:38 pm

Damn who roosted the bug?

Title: aaz into a mk1 cabrio build
Post by: giulianot on January 15, 2008, 07:15:03 pm

Thats the wife's 01 beetle tdi  w/ technine chip, 215 injectors, no cat.  It goes like snot!. Today i wanted to see how my cabby aaz/t3 would fair against the beetle, so i challenged the wifey to  a friendly race and........ no  challenge what so ever, the cabby pulled on the beetle in every gear  :twisted:  I never had to use WOT and never boosted past 16 psi 8)  I love this car

Title: aaz into a mk1 cabrio build
Post by: giulianot on January 21, 2008, 10:26:44 am

I just completed my fist tank of fuel today, so 50L of diesel bought me 625 km which equal 8L/100kms. Not too bad considering i was not driving conservatively and the motor isnt broken in yet. Power is good through the rpm band and the turbo is at full boost (23 psi ) at 1800 rpms  I also noticed that on long hard pulls the motor tends over heat slightly. I think im going to have to install a front mount  oil cooler and get rid of the oil to water heat exchanger or run a larger rad  :twisted:

Title: aaz into a mk1 cabrio build
Post by: giulianot on January 23, 2008, 12:54:29 pm

Well the motor is dead ! the #2 crank cap came unscrewed,  fell of spun round and put a hole the size of my fist through the block on piston #1 just above the oil pan :(    Now  can i put the blame squarely on the engine builder? More updates to come soon.

Title: aaz into a mk1 cabrio build
Post by: burn_your_money on January 23, 2008, 12:56:39 pm

Wow that really sucks man, this was a beautiful build, I hope you keep going with it

Title: aaz into a mk1 cabrio build
Post by: giulianot on January 23, 2008, 01:02:01 pm

what such even more is that it still runs fine, dosent sound like anythings wrong, other than the fact that there is a gaping hole in the side of the block

Title: aaz into a mk1 cabrio build
Post by: burn_your_money on January 23, 2008, 01:28:21 pm

So you have a 1.4 TD?

Title: aaz into a mk1 cabrio build
Post by: giulianot on January 23, 2008, 05:20:45 pm

All the connecting rods are fine it  performs like a 1.9l td with a hole in it  :cry: I suspect the crank cap bolts were not replaced during the over haul of the short block and the old stretch bolts were reused causing the #2 cap to come loose get caught on counterbalance of the crank and spit it out the side of my block  :x  :cry:

Title: aaz into a mk1 cabrio build
Post by: giulianot on January 24, 2008, 07:08:23 am

here are some pics of the damage caused by not installing new crank cap bolts :cry:

(http://i124.photobucket.com/albums/p28/giulianot/motor094.jpg)

(http://i124.photobucket.com/albums/p28/giulianot/motor090.jpg)

(http://i124.photobucket.com/albums/p28/giulianot/motor086.jpg)

(http://i124.photobucket.com/albums/p28/giulianot/motor085.jpg)

(http://i124.photobucket.com/albums/p28/giulianot/motor081.jpg)

(http://i124.photobucket.com/albums/p28/giulianot/motor078.jpg)

Title: aaz into a mk1 cabrio build
Post by: burn_your_money on January 24, 2008, 12:42:49 pm

ouch :shock:

JB weld it up

Title: aaz into a mk1 cabrio build
Post by: giulianot on January 26, 2008, 03:23:27 pm

So brought the short block to the engine builder today and we took of the pan and we saw this,

(http://i124.photobucket.com/albums/p28/giulianot/motor2005.jpg)

(http://i124.photobucket.com/albums/p28/giulianot/motor2009.jpg)

(http://i124.photobucket.com/albums/p28/giulianot/motor2007.jpg)

as you can tell there is alot of damage and the main cap bolts were not stretch bolts and were torqued to 48 ft-lbs . I really dont know what caused this failure. the engine builder is giving me a full warranty and is purchasing a new short block to rebuild for me. i should have the new short block back in a month or so.

Title: aaz into a mk1 cabrio build
Post by: giulianot on January 28, 2008, 11:57:29 am

The engine builder is buying a used short block from the junkers and boring it out. He also needs to replace two pistons since they are cracked and .5mm over (+.035). I am also going to machine a flat on the used aaz crank to fit a tdi crank sprocket. AAZ crank noses were inherently weak and were changed to a stronger design for the TDI's. As for the cap bolts i just came to a new discovery, there is an engine serial number specific cap bolt to use, prior to AAZ 560 000 you use N 102 638 01 which is a m10x65 bolt, and after AAZ 560 001 you use N 901 300 01 which is a AM10x80 bolt. I wish my engine builder new this before he did my motor

Title: aaz into a mk1 cabrio build
Post by: 935racer on January 28, 2008, 02:34:27 pm

Geez man you have had quite the troubles. At least your engine builder is manning up and fixing his screw up.

Title: aaz into a mk1 cabrio build
Post by: giulianot on February 04, 2008, 10:56:35 am

YA, this motor has brought me more pain then joy! Since the damage internally was so extensive the engine builder opted to replace everything. He also has a lead on a vw factory rebuild AAZ, which I personally would prefer. In my opinion nobody can rebuild them as well as VW. My question is,did i sheer are the factory cap bolts good enough for 23.5 : 1 compression ratio and an extra 30 psi boost? Are ARP cap bolts necessary in my application?

Title: aaz into a mk1 cabrio build
Post by: 935racer on February 04, 2008, 11:24:00 am

Quote from: "giulianot"

YA, this motor has brought me more pain then joy! Since the damage internally was so extensive the engine builder opted to replace everything. He also has a lead on a vw factory rebuild AAZ, which I personally would prefer. In my opinion nobody can rebuild them as well as VW. My question is,did i sheer are the factory cap bolts good enough for 23.5 : 1 compression ratio and an extra 30 psi boost? Are ARP cap bolts necessary in my application?

I would put ARP's in, I have them on my 1.6, the only mod to my bottom end  and I am just shy of 200WHP.

Title: aaz into a mk1 cabrio build
Post by: stewardc on February 04, 2008, 11:54:50 am

ARP all round is a necessity. I put them in my AAZ.

Title: aaz into a mk1 cabrio build
Post by: giulianot on February 12, 2008, 11:25:15 am

Not much progress lately. My engine builder has found a good used short block and is starting the rebuilding process all over again. This time I will be using ARP cap bolts, as they are much stronger. I also have to machine the crank nose to fit a tdi crank pulley. AAZ crank nose were inherently weak and were know to spin on the pulley. While the engine is being built im sourcing a better method of cooling the oil, like a thermostatically controlled front mount oil cooler, rather than the stock oil-to-water heat exchanger.  I wanna dissipate that heat into the atmosphere not the coolant.  Im ready to upgrade my stock t3 turbo now, its ok but it only makes boost to 23-24 psi reliably so....... im looking into a custom t3/t4 hybrid that can make 30 psi reliably!

Title: aaz into a mk1 cabrio build
Post by: stewardc on February 12, 2008, 11:55:20 am

http://www.glowshiftdirect.com/index.asp?PageAction=VIEWPROD&ProdID=274

Title: aaz into a mk1 cabrio build
Post by: burn_your_money on February 12, 2008, 12:52:23 pm

Hopefully you get a block soon. Look at the volvo 740 turbo cars for an oil cooler. It's bolt on. (I think I got that right)

The heat exchanger also heats the oil to reduce engine wear when the car is cold.

Title: aaz into a mk1 cabrio build
Post by: giulianot on April 22, 2008, 08:45:04 pm

So I've made some progress. My engine builder had the crank magna-fluxed and polished and looked great all except the crank nose. :mad:

(http://i124.photobucket.com/albums/p28/giulianot/DSCN9850-1.jpg)

(http://i124.photobucket.com/albums/p28/giulianot/DSCN9851-1.jpg)

(http://i124.photobucket.com/albums/p28/giulianot/DSCN9856.jpg)

the previous wrench flinging monkey mechanic decided to fix the wobbly crank by drilling a hole though the crank sprocket and into the crank nose and inserting a dowel !  what were they thinkin!

so to fix it right i had my little bro "the machinist" weld the old key hole up and machine a flat on the crank to accept the stronger tdi style crank sprocket


(http://i124.photobucket.com/albums/p28/giulianot/DSCN9872.jpg)

(http://i124.photobucket.com/albums/p28/giulianot/DSCN9871.jpg)

(http://i124.photobucket.com/albums/p28/giulianot/DSCN9870.jpg)


heres a vid of indicating a crank

(http://i124.photobucket.com/albums/p28/giulianot/th_DSCN9869.jpg) (http://s124.photobucket.com/albums/p28/giulianot/?action=view&current=DSCN9869.flv)

and my new crank sprocket
(http://i124.photobucket.com/albums/p28/giulianot/5945_lrg.gif)

and it all off the the engine builder for final assembly of the 2nd short block

 ;)

Title: aaz into a mk1 cabrio build
Post by: burn_your_money on April 22, 2008, 08:55:56 pm

Progress :D

Looking good man. I'll have to come over for a spin once you get it going (again)

Title: engine assembly
Post by: giulianot on July 01, 2008, 07:37:46 pm

I finally got the shot block back from the engine builder, this time with arp main cap studs ;)  First off I cleaned all the head studs and the re-lubricated all the threads with moly lube, and installed them in my new block.

(http://i124.photobucket.com/albums/p28/giulianot/cabbymotor005.jpg)

(http://i124.photobucket.com/albums/p28/giulianot/cabbymotor004.jpg)

I installed the new custom pressure plate that I bought from eurodrive cluthes. They lighted the flywheel and made me a kevlar disk

(http://i124.photobucket.com/albums/p28/giulianot/cabbymotor008.jpg)

(http://i124.photobucket.com/albums/p28/giulianot/cabbymotor006.jpg)

(http://i124.photobucket.com/albums/p28/giulianot/cabbymotor007.jpg)

(http://i124.photobucket.com/albums/p28/giulianot/cabbymotor009.jpg)

Then I decided to move on to the top end. Although the piston protrusion past deck is .029, which calls for a one hole head gasket , I went with a 3 hole head gasket to lower th cr slightly . I torqued the head bolts to 100 ft-lbs

(http://i124.photobucket.com/albums/p28/giulianot/cabbymotor001.jpg)

(http://i124.photobucket.com/albums/p28/giulianot/cabbymotor012.jpg)

(http://i124.photobucket.com/albums/p28/giulianot/cabbymotor013.jpg)

Then the trany went on so i can find my timing marks and injector pump was timed to .96mm

(http://i124.photobucket.com/albums/p28/giulianot/cabbymotor015.jpg)

(http://i124.photobucket.com/albums/p28/giulianot/cabbymotor016.jpg)

(http://i124.photobucket.com/albums/p28/giulianot/cabbymotor017.jpg)

(http://i124.photobucket.com/albums/p28/giulianot/cabbymotor019.jpg)


and now I'm  waiting for the lower cover to come from the vw dealer

(http://i124.photobucket.com/albums/p28/giulianot/cabbymotor018.jpg)

 I'm dropin the motor in the shell Thursday, it should be running in a week :D

Title: aaz into a mk1 cabrio build
Post by: Dr. Diesel on July 03, 2008, 04:15:33 am

and then we'll go autocrossing!.... in your car... because mine isn't done.  :evil:

Title: aaz into a mk1 cabrio build
Post by: giulianot on July 03, 2008, 08:10:07 am

I cant wait to autocross this car! soon enough!
I got the oil cooler today in the mail and it looks like it will work well. Only one problem, the oil cooler sandwich plate is thinner than my stock oil cooler. So I have to run the shorter style oil filter nipple off a vw without a oil cooler.

(http://i124.photobucket.com/albums/p28/giulianot/cabbymotor022.jpg)

and I got my new lower timing belt cover

(http://i124.photobucket.com/albums/p28/giulianot/cabbymotor021.jpg)

(http://i124.photobucket.com/albums/p28/giulianot/cabbymotor020.jpg)

Title: aaz into a mk1 cabrio build
Post by: Dr. Diesel on July 03, 2008, 09:49:11 am

if your cooler is anything like the volvo sandwich plates, you'll find the no cooler threaded pipe is way too short. You'll probably end up having to remove a half an inch of length from the current cooler-equipped pipe.

Title: aaz into a mk1 cabrio build
Post by: rabbid79 on July 03, 2008, 07:20:43 pm

Can you tell me specifically which main cap studs you went with (length too), and what influenced your decision?  I have a set of Raceware main cap studs that are 85mm long.  But with with the washers and nuts installed, only about 75 mm of that length goes down into the cap and the block.  This is about 5mm shorter than the stock bolts.  I'm debating getting some ARP studs that are longer than the Racewares, or going with bolts from the European PD-150 engine.  Any suggestions?

Title: aaz into a mk1 cabrio build
Post by: giulianot on July 04, 2008, 07:07:01 am

I personally don't know the arp p/n for the main cap bolts since my engine builder got them. The reason I went with arp main cap bolt is because my last motor spat the #2 main cap out the back of the block after it sheared the stock reused main cap bolt ( they were not the fully threaded stetch bolt type)

(http://i124.photobucket.com/albums/p28/giulianot/motor2001.jpg)

but that was my last block this new one has ARP main studs in it.

I went to the local vw shop in my area and the gave me a threaded nipple from a 1.6l na and proceded to bolt on the cooler.

(http://i124.photobucket.com/albums/p28/giulianot/cabbymotor025.jpg)

(http://i124.photobucket.com/albums/p28/giulianot/cabbymotor023.jpg)

(http://i124.photobucket.com/albums/p28/giulianot/cabbymotor028.jpg)

(http://i124.photobucket.com/albums/p28/giulianot/cabbymotor032.jpg)

(http://i124.photobucket.com/albums/p28/giulianot/cabbymotor029.jpg)

(http://i124.photobucket.com/albums/p28/giulianot/cabbymotor031.jpg)[/quote]

Title: aaz into a mk1 cabrio build
Post by: rabbid79 on July 08, 2008, 10:38:49 pm

Hi, where did you get your lower timing belt cover?  I gave my dealer part number 028109127AB and they said it wasn't available anymore.  I can get it through World Impex imported from Europe, but would like to know how you were able to get one "locally".  Thanks.

Title: aaz into a mk1 cabrio build
Post by: giulianot on July 09, 2008, 02:48:26 pm

I bought the lower cover from the dealer for $90, mine was p/n was 028 109 127 J. Try that p/n if your engine is a 1.9 aaz

Title: aaz into a mk1 cabrio build
Post by: rabbid79 on July 09, 2008, 05:47:33 pm

Great, thanks for the help!

Title: aaz into a mk1 cabrio build
Post by: giulianot on October 05, 2008, 07:01:48 pm

Real Progress Report  ;)

My friend Colin came over today and gave me a hand installing the engine. Heres how that went;

(http://i124.photobucket.com/albums/p28/giulianot/SANY0029.jpg)

(http://i124.photobucket.com/albums/p28/giulianot/SANY0031.jpg)

(http://i124.photobucket.com/albums/p28/giulianot/SANY0032.jpg)

(http://i124.photobucket.com/albums/p28/giulianot/SANY0033.jpg)

(http://i124.photobucket.com/albums/p28/giulianot/SANY0034.jpg)

(http://i124.photobucket.com/albums/p28/giulianot/SANY0035.jpg)

(http://i124.photobucket.com/albums/p28/giulianot/SANY0039.jpg)

(http://i124.photobucket.com/albums/p28/giulianot/SANY0040.jpg)

(http://i124.photobucket.com/albums/p28/giulianot/SANY0036.jpg)

Still need to install the rad and intercooler, should be ready for a test drive very soon :mad:

Title: aaz into a mk1 cabrio build
Post by: spencebm on October 06, 2008, 06:50:44 am

oh hell yeah, back in action :twisted:

Title: aaz into a mk1 cabrio build
Post by: burn_your_money on October 06, 2008, 07:28:54 am

Way to go man. :D

Title: aaz into a mk1 cabrio build
Post by: spencebm on October 06, 2008, 09:37:01 am

let's try to not put a hole in the block this time... :wink:

Title: IT'S ALIVE AGAIN
Post by: giulianot on October 07, 2008, 02:47:47 pm

So I put the rad and intercooler in today. Then I pulled out the vacume pump and primed the oil pump with a 3/8" pipe with a slot cut into it, and my cordless drill. I reinstalled the vacume pump, put coolant in the reservoir and decided to try starting it up. Great success   =)  =)

heres a vid of me starting it up for the first time

(http://i124.photobucket.com/albums/p28/giulianot/th_SANY0043.jpg) (http://s124.photobucket.com/albums/p28/giulianot/?action=view&current=SANY0043.flv)

Title: aaz into a mk1 cabrio build
Post by: Dr. Diesel on October 10, 2008, 07:58:31 pm

Giuliano brought the old honey down to my place for show and go.
The Giles pump really shines! Instant throttle response, lotsa power.
The T3 is... well-- a T3, and 20 psi is all it could muster... most of the time, anyway. It pulled really hard in 3rd and 4th. All in all, one quick little cabby! A k24 or better yet, a T2 would make it phenominal.
Nice ride, G!

Title: aaz into a mk1 cabrio build
Post by: giulianot on October 14, 2008, 08:30:52 am

Thanks , This has been a long awaited and now that its here I wanna do more. :twisted: I agree the t3 is a little to big, a t2 would be better suited for my needs. But i think I wanna try to make a vnt 17 work on the  AAZ with a stand alone vnt controller.

Title: aaz into a mk1 cabrio build
Post by: burn_your_money on October 25, 2008, 02:12:35 pm

Giulianot came by the shop and gave me a ride in the car.

Hearing the turbo scream is almost enough to convince me to go TD on my next motor. It's nice :twisted:

Title: aaz into a mk1 cabrio build
Post by: Vincent Waldon on October 25, 2008, 09:38:56 pm

Allergies have been known to go away as one matures...    :wink:

Title: aaz into a mk1 cabrio build
Post by: giulianot on October 27, 2008, 07:28:39 pm

Quote from: "Vincent Waldon"

Allergies have been known to go away as one matures...    :wink:

I think the sweat sound of the t3 cleared his allergies :D  I went to the local meet dubbed as Octoberfest and some friends snapped some pics of  the cabby diesel  doing a 3rd gear wot@22 psi,  pass!!
 :twisted:


(http://i124.photobucket.com/albums/p28/giulianot/cabbysmoke1.jpg)

(http://i124.photobucket.com/albums/p28/giulianot/cabbysmoke.jpg)

Title: aaz into a mk1 cabrio build
Post by: Dr. Diesel on October 28, 2008, 06:06:57 pm

That exhaust turn down works perfectly!  :D

Title: aaz into a mk1 cabrio build
Post by: giulianot on March 29, 2009, 11:22:41 am

Heya All, Today I finally got a chance to  dyno my 1.9 TD cabby! In its stock form the aaz motor make 75 hp and 90lb/tq, this is what my cabby put down :D  :D

(http://i124.photobucket.com/albums/p28/giulianot/cabbydyno.jpg)

The pulls were done in 4th gear and my boost would peak at 21psi@ 3200rpm and then taper to 15psi after that :rolleyes:  not bad for a tired garret t3. The engine definitely has more potential in my opinion and would produce much more with a healthier , smaller turbo.  :P Judging By how I totally fumigated the shop, the fueling is definitely there now i just got to get a good turbo in!
I out torqued a stock vr6 it made 150 hp and 146tq

A special thanks to Giles for building me the best pump in the world!, and To Brison thanks for the constant motivation!

Title: aaz into a mk1 cabrio build
Post by: 13ad13oy on April 06, 2009, 07:57:04 am

Thats Sweet!

Which turbo do you have in mind? K14?

Title: aaz into a mk1 cabrio build
Post by: Baixo on April 07, 2009, 05:21:01 am

dont go T2, there are many in Europe that have successfully ran a k24 on the AAZ.

you just have a lazy turbo.....and your IC piping is a big diameter so that will affect the laggyness

I think you should show everybody how its done and get a gt28rs or a vnt22



it would be a shame to have such a nice set-up and run alittle wimpy T2

Title: aaz into a mk1 cabrio build
Post by: burn_your_money on April 07, 2009, 09:41:39 am

I think a T2 or a K14 pushing 20psi would be ideal.

Title: aaz into a mk1 cabrio build
Post by: giulianot on April 07, 2009, 02:03:35 pm

I was initially content with the base line dyno #'s, but now Im just craving move. :evil:  A very good friend of mine has generously offered to let me try his k24/k26 hybrid with only 500 kms use. So upward and onwards  I have to space the exhaust manifold off the head for the turbo housing to clear. Need to get some 1/4x3"x12" precision machined flat stock to make some exhaust manifold spacers. Not even 1000kms on the motor and I'm all ready swaping the turbo :lol:

Title: aaz into a mk1 cabrio build
Post by: Baixo on April 07, 2009, 03:43:29 pm

i dont think a k14 or t2 will will be efficient at 20+psi

Title: aaz into a mk1 cabrio build
Post by: giulianot on April 25, 2009, 08:11:39 am

So I bought some M8 1.25  threaded rod in Stainless Steel from fastenall for $14 and cut it up in 2.5" sections .5" longer than the stock exhaust studs. I had my little brother "The Machinist" make me four  1/4" exhaust manifold spacers and the turned out really well. Now i have everything ready to make that monster k24/26 housing clear my intake manifold.

(http://i124.photobucket.com/albums/p28/giulianot/100_0423.jpg)

(http://i124.photobucket.com/albums/p28/giulianot/100_0424.jpg)
 
and finally some pics our future 24 hours of lemons  car??:twisted:  :P

(http://i124.photobucket.com/albums/p28/giulianot/100_0426.jpg)

Title: aaz into a mk1 cabrio build
Post by: giulianot on May 08, 2009, 05:51:46 am

So I finally got my turbo upgrade from Bryson and it is beautiful.  :)  A little history on this turbo, It was born a k24 and was bored out to fit a k26 impellers and shaft, within a k24 housing. Hence a hybrid turbo. This was all done at a professional turbo re builder  before I owned it. Without further delay some pics.

 (http://i124.photobucket.com/albums/p28/giulianot/100_0436.jpg)

(http://i124.photobucket.com/albums/p28/giulianot/100_0438.jpg)

(http://i124.photobucket.com/albums/p28/giulianot/100_0437.jpg)

(http://i124.photobucket.com/albums/p28/giulianot/100_0440.jpg)

(http://i124.photobucket.com/albums/p28/giulianot/100_0441.jpg)

the swap begins !! the car with the old t3 in

(http://i124.photobucket.com/albums/p28/giulianot/100_0442.jpg)

3" SS downpipe removed

(http://i124.photobucket.com/albums/p28/giulianot/100_0444.jpg)

next I removed the 4 12point 12mm bolts that hold the turbo on

(http://i124.photobucket.com/albums/p28/giulianot/100_0445.jpg)

and the old t3 on the floor  :P

(http://i124.photobucket.com/albums/p28/giulianot/100_0447.jpg)

now to remove the exhaust manifold

(http://i124.photobucket.com/albums/p28/giulianot/100_0447.jpg)

and now remove exhaust studs cause there gonna be to short now

(http://i124.photobucket.com/albums/p28/giulianot/100_0455.jpg)

and now the new longer SS studs installed

(http://i124.photobucket.com/albums/p28/giulianot/100_0456.jpg)

next i installed the double gasket and the manifold spacers

(http://i124.photobucket.com/albums/p28/giulianot/100_0460.jpg)

now to prep the turbo , Im putting a plug where the wastegate takes its pressure from the turbo, and going right to the intake manifold for wastegate  reference.

(http://i124.photobucket.com/albums/p28/giulianot/100_0449.jpg)

(http://i124.photobucket.com/albums/p28/giulianot/100_0451.jpg)

then i mounted the oil return line and installed the manifold and turbo

(http://i124.photobucket.com/albums/p28/giulianot/100_0461.jpg)

(http://i124.photobucket.com/albums/p28/giulianot/100_0464.jpg)

(http://i124.photobucket.com/albums/p28/giulianot/100_0465.jpg)

(http://i124.photobucket.com/albums/p28/giulianot/100_0466.jpg)


The new turbo spools quicker than the old t3 and will sustain 25 psi of boost.
the car is alot more powerful now and i cant wait till may 30th when i will hit the dyno again and see what kind of numbers this setup will put down.

Title: aaz into a mk1 cabrio build
Post by: Dr. Diesel on May 08, 2009, 06:41:03 am

And then, we start feeding some REAL boost to it!  :twisted:

Title: aaz into a mk1 cabrio build
Post by: stewardc on May 08, 2009, 06:54:55 am

I'm interested to see how fast it will spool up. My Garrett T3 is great, but I'd like the higher boost to come in at lower RPMs.

Title: aaz into a mk1 cabrio build
Post by: TurboJ on May 08, 2009, 09:21:37 am

Interesting stuff.
I'm looking forward to the new dyno numbers!
That's a nice turbo BTW! I always thought the KKKs work better than the Garretts, for some reason.

Title: Re: aaz into a mk1 cabrio build
Post by: RabbitJockey on May 21, 2009, 08:48:07 pm

aaz's are sweet.

Title: Re: aaz into a mk1 cabrio build
Post by: Jay on May 23, 2009, 12:36:48 pm

Very nice project here 8)

Can't wait to see what it's running now on the dyno.

Title: Re: aaz into a mk1 cabrio build
Post by: giulianot on May 27, 2009, 07:26:41 pm

SO I needed a new plate sticker for the cabby, and that meant another "Joke" ontario emissions test. I decided to bring it to the vw dealer in orangeville since it a flat rate anywhere $36. I book an appointment with the service dept and let them know its a diesel. (Diesel emissions test in ontario is a VISUAL inspection so long as the exhaust is intact and there is no visible smoke @ idle, it's a pass)  I arrive to the dealer with the cabby and the guy at the service desk ask me for Make and model of vehicle. I tell him it's a 1990 vw cabriolet 1.9td. He says "Impossible".  He walks out to the lot and looks under the hood then says "OH we'll have to test this under hotrod/ swap class " . Ok whatever  I tell him my ownership say Power/D so it is registered as a diesel at the ministry of transportation. FINALLY he agrees to send a mechanic to preform the diesel emissions test. The VW mechanic (nice guy)  started my car in the lot and popped the hood, poked around, looked at the tailpipe @ idle, then turned to me and said "you pass". COOOl :)   So then he asks "off the record, how much fuel is this Injector pump really pushing" and I said "It's a Giles pump". "AHHH  enough said".  ;D  Now all is great I have a valid emisions and valid stickers and I'm all set to lay down some new #'s this  Saturday  at the Diesel Doctor Dyno day.  ONLY  2 more days :)

Title: Re: aaz into a mk1 cabrio build
Post by: giulianot on May 30, 2009, 02:30:46 pm

Today was a great day! I made it down to diesel doctors dyno day and put my cabby with its new setup on the rollers. I was the only IDI to dyno today, alot of nice tdi's and even a 09 2.0 tdi ! so here is a video of one run and my dyno sheet.

(http://i124.photobucket.com/albums/p28/giulianot/th_cabbyk24-26dyno004.jpg) (http://s124.photobucket.com/albums/p28/giulianot/?action=view&current=cabbyk24-26dyno004.flv)

(http://i124.photobucket.com/albums/p28/giulianot/cabbyk24-26dyno.jpg)


I put down 133 hp and over 200 flbs of torque :P  Im pretty happy with that for now . ::)

Title: Re: aaz into a mk1 cabrio build
Post by: hamradio on May 30, 2009, 04:11:39 pm

Very impressive!  I'm envious.  ;D 


That thing must pull like crazy..bust up any 020's yet?

Title: Re: aaz into a mk1 cabrio build
Post by: giulianot on March 16, 2010, 02:02:36 pm

 time for some updates. Last fall before putting the car away for the season I did a compression test and leakdown test. I found that cylinder 1&2 had low compression and were leaking at the intake valves, so i tore the head off again and sent it out for new valves and seals.

and the head comes off again 

(http://i124.photobucket.com/albums/p28/giulianot/head%20instal/100_2227.jpg)

I start to assemble refurbished head

(http://i124.photobucket.com/albums/p28/giulianot/head%20instal/100_2199.jpg)

I installed all new valve lifters , I used lucas as assemble lube

(http://i124.photobucket.com/albums/p28/giulianot/head%20instal/100_2205.jpg)

A shot of the bottom of the cam and the  head with the new valves and new precups pressed in

(http://i124.photobucket.com/albums/p28/giulianot/head%20instal/100_2202.jpg)

 a look at how bad my old precups were burned out from over fueling and high egts

(http://i124.photobucket.com/albums/p28/giulianot/head%20instal/100_2203.jpg)

Next I installed the cam and torqued down the caps

(http://i124.photobucket.com/albums/p28/giulianot/head%20instal/100_2207.jpg)

 glowplugs were next

(http://i124.photobucket.com/albums/p28/giulianot/head%20instal/100_2210.jpg)

then injector heat shields and injectors torqued to 51 ft/lbs

(http://i124.photobucket.com/albums/p28/giulianot/head%20instal/100_2212.jpg)

(http://i124.photobucket.com/albums/p28/giulianot/head%20instal/100_2218.jpg)

(http://i124.photobucket.com/albums/p28/giulianot/head%20instal/100_2213.jpg)

Exhaust manifold studs installed

(http://i124.photobucket.com/albums/p28/giulianot/head%20instal/100_2221.jpg)

Intake manifold torqued to 15 ft/lbs

(http://i124.photobucket.com/albums/p28/giulianot/head%20instal/100_2222.jpg)

Exhaust manifold spacers installed

(http://i124.photobucket.com/albums/p28/giulianot/head%20instal/100_2224.jpg)

Finally the exhaust manifold gets torqued to 15 ftlbs

(http://i124.photobucket.com/albums/p28/giulianot/head%20instal/100_2225.jpg)

the kkk 24/26 gets bolted to the exhaust manifold and torqued to 50 ft/lbs

(http://i124.photobucket.com/albums/p28/giulianot/head%20instal/100_2226.jpg)

Now the head the ready for install so I cleaned the block and put in a new 2 hole head gasket and placed the head on the block. I reinstalled the arp head studs and applied the arp approved lube and torqued the head to 75 ft/lbs.
I connected all the hoses and put some coolant in it started write up!

(http://i124.photobucket.com/albums/p28/giulianot/head%20instal/100_2228.jpg)

Title: Re: aaz into a mk1 cabrio build
Post by: burn_your_money on March 16, 2010, 08:02:43 pm

Looking good buddy. Hopefully we get some more go out of it on Friday :)

Title: Re: aaz into a mk1 cabrio build
Post by: rabbitman on March 16, 2010, 11:28:37 pm

I bet a better intake manifold would get you more power/lower EGT's.

Title: Re: aaz into a mk1 cabrio build
Post by: NintendoKD on March 17, 2010, 05:49:40 am

That is the PD mani isn't it, wasn't aware that there was one better than that.  Nice build. 8)

Title: Re: aaz into a mk1 cabrio build
Post by: theman53 on March 17, 2010, 06:05:30 am

No it is the regular one with no blow off valve.
PD is better.
Performance had one even better.
I got the "best"...I just need to fit it.
(http://c3.ac-images.myspacecdn.com/images02/71/l_3137b0d632e44f39bae01944282d5ea2.jpg)
(http://c4.ac-images.myspacecdn.com/images02/96/l_1199ecf40c014558b37ae0cd46d9aceb.jpg)

Title: Re: aaz into a mk1 cabrio build
Post by: rabbitman on March 17, 2010, 12:06:05 pm

Where'd you find the new precups?

Title: Re: aaz into a mk1 cabrio build
Post by: NintendoKD on March 17, 2010, 07:30:14 pm

 :oYEAH! what he said!!!  where did you get thems cups???

Title: Re: aaz into a mk1 cabrio build
Post by: giulianot on March 18, 2010, 08:03:01 am

I really dont know were my head rebuilder got the new precups from, maybe a dealer item only :-\

Title: Re: aaz into a mk1 cabrio build
Post by: NintendoKD on March 18, 2010, 07:28:21 pm

just who is your rebuilder, or will you tell?

Title: Re: aaz into a mk1 cabrio build
Post by: giulianot on March 19, 2010, 01:55:23 pm

His name is Jim . He was recommended by a friend of mine, and I was happy with his work. he is located in hamilton, ontario, canada and his phone number is (905) 544-8514

Title: Re: aaz into a mk1 cabrio build
Post by: Dr. Diesel on March 21, 2010, 09:09:44 am

I just posted a vid of this car in the General section.

Title: Re: aaz into a mk1 cabrio build
Post by: giulianot on March 29, 2010, 02:54:06 pm

I dynoed the cabby on sunday and here are the results

with a dr. diesel high lift cam and a giles pump and k26@24psi egts 1600-1800

(http://i124.photobucket.com/albums/p28/giulianot/cabbydynomarch2010001-1.jpg)

Title: Re: aaz into a mk1 cabrio build
Post by: Dr. Diesel on March 29, 2010, 03:20:50 pm

Your car did really well, G! Far more entertaining to watch than any other vehicle that rode the roller.
Copies of this camshaft will be available soon.

And, here's a quick vid of Giuliano's cabby on the dyno.

http://smg.photobucket.com/albums/v225/vwpics/?action=view&current=MOV00274.flv (http://smg.photobucket.com/albums/v225/vwpics/?action=view&current=MOV00274.flv)

Title: Re: aaz into a mk1 cabrio build
Post by: theman53 on March 29, 2010, 04:24:07 pm

Quote

I dynoed the cabby on sunday and here are the results

with a dr. diesel high lift cam and a giles pump and k26@24psi egts 1600-1800

EGT's were WHAT?
How much for the cam??? You sir are killing me, I need to put A/C in my build car...heck I just need to get it done.

Title: Re: aaz into a mk1 cabrio build
Post by: NintendoKD on March 29, 2010, 08:21:19 pm

this is a mech cam we are talking about here to be certain, correct?  if so I highly awiat the numbers so that I can use this in my build looks great, keep on truckin.

Thanks,

Kevin

Title: Re: aaz into a mk1 cabrio build
Post by: Dr. Diesel on March 29, 2010, 09:00:56 pm

Actually, it's a hydraulic cam. It's likely that it could be used on a solid lifter engine, using lash caps between the valve and the lifter. Perhaps we'll get around to figuring that out in the future, but for now we're deeming them for use in hydraulic engines exclusively.
We're rapidly closing in on the official release date for these cams. We'll disclose all the info and specs on them then. We believe you'll find the pricing quite agreeable.  :)
I'll tell you this now:
On Giles' B3 modded AAZ Passat, installation of this cam with no other changes resulted in almost an entire second shaved from the quarter mile time.
Giuliano's results below speak for themselves.
Even on my stock-everything AAZ Passat, it made an improvement in the mid to upper-mid range, but was clearly truncated by the govenor.
More soon.
To speed the process, see Burn_Your_Money's post requesting AAZ valve face depth measurements.

Title: Re: aaz into a mk1 cabrio build
Post by: NintendoKD on March 29, 2010, 09:27:09 pm

COOLNESS! I readily await the results, especially on the mech cam details.
 :D
take care, and God Bless,

Kevin

Title: Re: aaz into a mk1 cabrio build
Post by: 53 willys on March 29, 2010, 10:02:57 pm

great numbers!!  8)wow those EGT's were NASTY high :o :o.....I would be scared to take mine up that high....how long did you run at that temp?

Title: Re: aaz into a mk1 cabrio build
Post by: NintendoKD on March 29, 2010, 10:27:28 pm

 well... the good news is that now you have a forged/cast aluminum head :P  I don't know, certainly possible, as the exhaust gasses are passing relatively quickly and exiting the exhaust at a very high rate of speed and low back pressures, due to the way the engine is setup.

Title: Re: aaz into a mk1 cabrio build
Post by: Dr. Diesel on March 30, 2010, 06:15:13 am

There's also the nagging question in the back of my mind, "just how accurate is this gauge?" I've done some pretty mean things to diesel engines, and haven't EVER suffered a failure that could be attributed to over-temping the exhaust.

Title: Re: aaz into a mk1 cabrio build
Post by: 53 willys on March 30, 2010, 08:20:51 am

with those kinda EGT's I would be thinking REAL hard about spraying water! ;)

Title: Re: aaz into a mk1 cabrio build
Post by: burn_your_money on March 30, 2010, 09:46:35 am

I think they would come down substantially if the exhaust leak pre turbo was fixed.

This isn't a stock cam btw, it's a custom grind.

Title: Re: aaz into a mk1 cabrio build
Post by: NintendoKD on March 30, 2010, 08:43:25 pm

Quote from: 53 willys on March 30, 2010, 08:20:51 am

with those kinda EGT's I would be thinking REAL hard about spraying water! ;)

Now I wonder, with those kind of egt's would meth injection be too cold and cause cracking, or worse, KABOOM! :o  kinda like dry ice on a hot water filled glass.  How cold is too cold with something like this?  cryo cool "spray liquid co2" the intercooler and use meth injection maybe?  Sorry to be off topic.

Title: Re: aaz into a mk1 cabrio build
Post by: theman53 on March 30, 2010, 08:46:55 pm

On this cam is there no time when the intake and exhaust are open at the same time? I figure that would be best for a turbo app. Also, I knew it was a custom grind and I am going to be in need of a Mech one though...but like I said I just need to get it done.

Title: Re: aaz into a mk1 cabrio build
Post by: 53 willys on March 31, 2010, 08:21:41 am

Quote from: NintendoKD on March 30, 2010, 08:43:25 pm

Quote from: 53 willys on March 30, 2010, 08:20:51 am

with those kinda EGT's I would be thinking REAL hard about spraying water! ;)

Now I wonder, with those kind of egt's would meth injection be too cold and cause cracking, or worse, KABOOM! :o  kinda like dry ice on a hot water filled glass.  How cold is too cold with something like this?  cryo cool "spray liquid co2" the intercooler and use meth injection maybe?  Sorry to be off topic.

I would only spray water...no meth...plus if you set your system up to start spraying before the high temps then you got nothing to worry about....spraying water is a good thing IMHO
I know my set-up will need water Injection...soon if I wanna run it at the track at full pulling power.

Title: Re: aaz into a mk1 cabrio build
Post by: vanbcguy on March 31, 2010, 09:23:38 am

Quote from: theman53 on March 30, 2010, 08:46:55 pm

On this cam is there no time when the intake and exhaust are open at the same time? I figure that would be best for a turbo app. Also, I knew it was a custom grind and I am going to be in need of a Mech one though...but like I said I just need to get it done.

Nope, there's no room to have any overlap - the piston is essentially flat against the head at TDC, so you can't possibly have the intake and exhaust valves open at the same time like you would on a gasser.

Title: Re: aaz into a mk1 cabrio build
Post by: Dr. Diesel on March 31, 2010, 09:56:56 am

Actually, there's a suprising amount of room for overlap.  ;D
Not that we're gunning for a lot of overlap, but if a little extra comes from a LOT more lift and duration, small price to pay!  ;)

Title: Re: aaz into a mk1 cabrio build
Post by: Smokey Eddy on March 31, 2010, 11:19:46 am

Very nice work. My egt's are never ever that high. I'm now my self extremely curious what my car will dyno when i have a clutch that will handle my foot on the floor.
I did my own pump mods - for the most part it's still stock. I have a 1.6 bottom end and a smaller downpipe (yours is HUUUGEEE).

that thing is laying down some mean torque numbers and i LOVE a table top dyno sheet (the read out looks like a table). None of this ... gasser staircase dyno crap. Why would you ever want to make peak power at the tail end of your RPM range? peak torque at 2,750 sounds good to me =)

HP numbers may be low but HP means nothing... i'd much rather have big torque and low RPM (HP is just torque * rpm [with a constant number in the middle i dont remember what it is])

I can't wait to dyno mine now. I'm hoping for 90hp at an unknown amount of torque.

My ONLY ... bother with your build is that you put that stinking bus bar on the glowplugs when you had them out! dude you gotta pimp your glow plugs ;)

Title: Re: aaz into a mk1 cabrio build
Post by: theman53 on March 31, 2010, 02:35:40 pm

Quote from: vanbcguy on March 31, 2010, 09:23:38 am

Quote from: theman53 on March 30, 2010, 08:46:55 pm

On this cam is there no time when the intake and exhaust are open at the same time? I figure that would be best for a turbo app. Also, I knew it was a custom grind and I am going to be in need of a Mech one though...but like I said I just need to get it done.

Nope, there's no room to have any overlap - the piston is essentially flat against the head at TDC, so you can't possibly have the intake and exhaust valves open at the same time like you would on a gasser.

Not overlap in the piston and cam, but the intake and exhaust lobes. Burn has a cam spec table and it shows overlap with every cam he has done stock. For highest boost without loss you would want close to zero if I am recalling correctly.

Title: Re: aaz into a mk1 cabrio build
Post by: Smokey Eddy on April 01, 2010, 12:08:19 am

Quote from: theman53 on March 31, 2010, 02:35:40 pm

Not overlap in the piston and cam, but the intake and exhaust lobes. Burn has a cam spec table and it shows overlap with every cam he has done stock. For highest boost without loss you would want close to zero if I am recalling correctly.

If you had valve overlap you would bleed boost on the exhaust stroke. You don't really have to recall anything. just think about it - 4-stroke engine.

intake, compression, power, exhaust...

on intake stroke if you had some exhaust valve over lap it might rid the cylinder a little better of the exhaust gases with that rush of air from the turbo - but there is a fine line here between wasting boost and getting lots of clean 02 into the cylinder...

on compression ... well that doesn't need ANY thought hahahahh

power, same as compression...

exhaust, having a marginal amount [how much i have NO idea] of valve over lap here would be slightly beneficial but again its the same issue as the intake stroke - lost/wasted boost pressure unless you had such a big turbo and were fueling it enough such that you could "afford" to spend boost on such things... after all it would just go through the turbine on the other side anyways.

I know you all were already thinking what i just said, i just like to illustrate it - i find it easier to visualize.
In my completely inexperienced opinion; a tiny tiny amount of valve over lap might be advantageous to ensure the exhaust is totally getting out of there - just like how having a couple degrees of over lap helps a big/small block make bigger power.

Title: Re: aaz into a mk1 cabrio build
Post by: truckinwagen on April 01, 2010, 12:12:45 am

I have a hard time believing that the diesel cam has much(if any ) overlap.

the piston to valve relationship would make it really difficult, and most of the stock gasser cams have negative overlap(that is rotation where both valves are closed)

what I would love to see is a diesel cam with stock duration and timing, but more lift.

Title: Re: aaz into a mk1 cabrio build
Post by: Smokey Eddy on April 01, 2010, 12:17:12 am

I too would love to see Maximum lift on a cam. To the point where the valves are chasing the piston as it goes down. Also add 2 more valves per cylinder...
I agree that a stock cam would have zero over lap.

Title: Re: aaz into a mk1 cabrio build
Post by: theman53 on April 01, 2010, 06:16:00 am

(http://img.photobucket.com/albums/v603/burnyourmoney/IntakeAndExhaust-1.jpg)

This is from tylers post and if I read this correctly there is the overlap of intake and exhaust being open at the same time. On small and big blocks that get turbos the usually get a custom grind cam that has the intake closed and right after then the exhaust opens. That way the intake charge doesn't leave out the exhaust. For naturally aspirated the cams are built opposite and you can run tuned headers to actually pull more into the combustion chamber.

Disclaimer: I am not a professional engine builder, but I have stayed at a motel 8. This is just the way my head machinist and I have talked about it and he even said under 20lbs boost it really doesn't matter.

Title: Re: aaz into a mk1 cabrio build
Post by: burn_your_money on April 01, 2010, 09:44:41 am

Yes there certainly is overlap. For the record, those are cam degrees,not crank.

Title: Re: aaz into a mk1 cabrio build
Post by: Darkness_is_spreading on June 26, 2010, 10:14:29 pm

Hey when you installed this motor into the Cabrio, did you have to change the passenger side engine mount...  (Ie removing the IP and replacing the brackets to to match up)?
To me it looks like this must be done in order to support the motor properly in the first gen frame....

Title: Re: aaz into a mk1 cabrio build
Post by: burn_your_money on June 27, 2010, 05:37:06 pm

Yes the pass motor mount needs to be replaced with the MK1 diesel version.

Title: Re: aaz into a mk1 cabrio build
Post by: rabbitman on June 28, 2010, 09:55:49 am

I did a leakdown test on my rabbit and found that at TDC on the exhaust stroke it wouldn't hold any pressure, when I turned it a little either way it sealed up. Definitely overlap.

Title: Re: aaz into a mk1 cabrio build
Post by: ktownboostn on February 21, 2011, 05:34:28 am

Damn ! This car has come along way since i saw it at Jitterbug 09 !
Really interested in the info on the cam. IS it still possible to have them re-ground ? has the guy left the country ? Anyone else know the details ?

Title: Re: aaz into a mk1 cabrio build
Post by: stewardc on February 21, 2011, 06:51:41 am

Isn't Giles (erformance Diesel Injection) the dealer for them now ?

Title: Re: aaz into a mk1 cabrio build
Post by: Giles@PerformanceDiesel on February 21, 2011, 06:26:14 pm

yes Dr D. has passed on the duty to me now.
i have two freshed gound cams in stock if anyone wants one.

Giles

Title: Re: aaz into a mk1 cabrio build
Post by: 8v-of-fury on February 21, 2011, 06:27:03 pm

Amazazazing. :)

this looks great, how is it now!!

Title: Re: aaz into a mk1 cabrio build
Post by: Digital K on March 07, 2011, 12:25:38 am

great thread :)