VWDiesel.net The IDI, TDI, and mTDI source.
Engine Specific Info and Questions => IDI Engine => Topic started by: fuslit on November 04, 2006, 07:48:28 pm
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First off, sorry for the long post :) As promised, this will be a buildup thread
This will be a long background story...
The first car I had was an 82 NA rabbit diesel LX. I hit a cow with it coming home from work @ three am in the morning. :(
(http://fuslit.org/photo_gallery/picKLE-cache/misc/car/crashed_rabbit/IMG_4657_640.JPG)
Believe it or not, I escaped that crash with only cut knuckles! Scared the heck out of me, but did not make love for driving vw's any less!
The next car I had was an 85 8 valve gli, and I loved that car! I've been through a few since (only vw thank you very much.) All Gas though, I missed my diesel rabbit (how reliable it was, easy to work on, and the cheapness of parts... Vr6's are fun to drive, just expensive to maintain...) I bought a cheap(ish) yellow diesel rabbit which was in questionable shape (The intake was held on by zip-ties and 1 bolt!!!) The rest of the bolts had sheared off.... I was able to back most out of the block and got it up and running with 5 of the 7 bolts holding the intake on, the body unfortunately had quite a bit of the rust syndrome... But the engine started every time last winter!!! I drove it every day and did not put it on a block warmer once. (pretty impressive compared to my 1st car which needed the block heater to start in the 32 and below weather.) but with my first car I was young and inexperienced so I probably missed a simple thing I could have fixed it. Anyway here's a picture for the sake of the background story....
(http://fuslit.org/photo_gallery/picKLE-cache/misc/car/rabbit/IMG_5115_640.JPG)
Through my lurking on Vortex I found some posts by Joe (RabbitGTDguy) about his GTD and I fell in love with his car. I was (am?) excited about the untapped prospect of power AND great gas milege! so I started to pull together some parts to build up a turbo diesel. But I started having second thoughts about dropping the $$$ on a motor to put into something who's body was 'questionable' at best.
Found a caddy which from the pictures I saw had quite a bit of potential, it didn't run but originally was diesel and had a clean title! so I traded the yellow Bomb and a cabrio that I had picked up for the caddy sitting in my garage
(http://fuslit.org/photo_gallery/picKLE-cache/misc/car/caddy/06-27-06/IMG_7459_640.JPG)
At the time it seemed like a good idea... from what I could tell in the pictures the body was in good shape.... Ahh not being able to see under the truck with 1 foot of snow hid the rust on it that... Anyway, I still was going to proceed with my TD project. In the meantime, I figured I may as well get it running and on the road. While I'm in the process of tearing down and rebuilding the 1.6td block.
The parts I bought, I bought 2 motors who's TB's had broken/slipped. One still had the head on and I had hopes that it only had 'slight' contact unfortunately it turned out to be the worse of the two. the other engine had major valve impressions on the cylenders. I traded a 1.6TD Injection pump to Joe for some 1.6 pistons which are in great shape. (compared to the others I got) and started tearing down the motor that was the better of the two.
(http://fuslit.org/photo_gallery/picKLE-cache/misc/car/1.6_turbo_diesel_engine_tear-down_09-08-06/IMG_7713_640.JPG)
(http://fuslit.org/photo_gallery/picKLE-cache/misc/car/1.6_turbo_diesel_engine_tear-down_09-08-06/IMG_7712_640.JPG)
(http://fuslit.org/photo_gallery/picKLE-cache/misc/car/1.6_turbo_diesel_engine_tear-down_09-08-06/IMG_7707_640.JPG)
(http://fuslit.org/photo_gallery/picKLE-cache/misc/car/1.6_turbo_diesel_engine_tear-down_09-08-06/IMG_7726_640.JPG)
(http://fuslit.org/photo_gallery/picKLE-cache/misc/car/1.6_turbo_diesel_engine_tear-down_09-08-06/IMG_7740_640.JPG)
(http://fuslit.org/photo_gallery/picKLE-cache/misc/car/1.6_turbo_diesel_engine_tear-down_09-08-06/IMG_7742_640.JPG)
(http://fuslit.org/photo_gallery/picKLE-cache/misc/car/1.6_turbo_diesel_engine_tear-down_09-08-06/IMG_7744_640.JPG)
(http://fuslit.org/photo_gallery/picKLE-cache/misc/car/turbo_diesel_buildup/09-11-06_parts_cleaning/IMG_7784_640.JPG)
(http://fuslit.org/photo_gallery/picKLE-cache/misc/car/turbo_diesel_buildup/09-11-06_parts_cleaning/IMG_7785_640.JPG)
The block appears to be in ok shape, there is a part that is broke off that apparently the power steering attaches to according to a friend of mine. I think I'm going to build it up anyway and run it. I have a few turbo's in various stages of disrepair, the one that is in the best shape is an eco turbo. It will be the 1st one to go on.
Here's a couple shots of the shell, in Joe's Garage it's got a couple rust spots that need to be taken care of. I will need to get a suspension for it, basically this is the blank slate to work from building the car from the ground (almost) up.
(http://fuslit.org/photo_gallery/picKLE-cache/misc/car/turbo_diesel_buildup/rabbit_shell_09-09-06/IMG_7747_640.JPG)
(http://fuslit.org/photo_gallery/picKLE-cache/misc/car/turbo_diesel_buildup/rabbit_shell_09-09-06/IMG_7751_640.JPG)
(http://fuslit.org/photo_gallery/picKLE-cache/misc/car/turbo_diesel_buildup/rabbit_shell_09-09-06/IMG_7768_640.JPG)
(http://fuslit.org/photo_gallery/picKLE-cache/misc/car/turbo_diesel_buildup/rabbit_shell_09-09-06/IMG_7752_640.JPG)
Found a sweet set of rims that I plan on running for a decent price (the pic is a little dirty but it's all I have at the moment)
(http://fuslit.org/photo_gallery/picKLE-cache/misc/car/ATS_rims/SP_A0051_640.jpg)
That's pretty much it for now, I will post more when I get the shell here and the block back from being hot tanked and honed. I have a massive intercooler and new fender flares to go on. I haven't decided what else I want to do to the car, I've been kicking around the idea of a mk3 dash (and have a full swap) but I may go w/the old school style dash as well...
More to come as this project develops develops.
-Todd
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nice pics! that engine stand is from princess auto isnt it!!!! I bought one just like it when it was on sale for around 70 bucks! can't go wrong with that!
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Hi,ive just built a GTD in the u.k. believe me they are great fun :wink:
http://www.vwdiesel.net/phpBB/viewtopic.php?t=5082
bert
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We don't have Princess auto here... Could be from autozone (a similar store) I'm not sure where it's from though, I bought it off a kid for $50 bucks which I thought was a pretty good deal. It's a pain to get in the center my engine hoist of with the two outer 'legs' But for $50 it's a deal :)
Found a pic of the intercooler and new flares
(http://static.flickr.com/113/266014062_f25f57d0f5.jpg)
The intercooler was on a friends 300hp rabbit, :shock: he had it custom built to his specs (of which I don't know off the top of my head.) I think it should be able to keep things pretty cool on the GTD. I'm going to look into a non-overflow radiator to clean the engine bay up and give me some more room to run stuff.
Got a spot in the garage cleaned up yesterday in preparation for the rabbit's arrival. A friend of mine has the car casters (I think that's what their called.) they let you move the car around w/out having back it up, steer move forward, backup steer, move forward, repeat. I'm going to look into how much they cost, they save quite a bit of work and when I need to work on the rabbit I can just push it into a spot that would be convenient.
-Todd
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Looks good. I really need to get a garage so I can work on my cars.
If you need any rabbit parts let me know, I have piles of them and I just want them gone to make a bit of walking room
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do a burn out
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Princess Auto = Harbor Frieght in the USA. :wink:
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Good to see your ready for her Todd...will be glad to work with you and see it back on the road sooner than I could at the current moment!
Joe
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That's pretty much it for now, I will post more when I get the shell here and the block back from being hot tanked and honed. I have a massive intercooler and new fender flares to go on. I haven't decided what else I want to do to the car, I've been kicking around the idea of a mk3 dash (and have a full swap) but I may go w/the old school style dash as well...
I'll ask a total newbie question here, but searches haven't answered it so I don't feel bad asking: What's "hot tanking"?
I'm serious; never been into the engine rebuilding scene beyond a few ACVWs, and did pretty much all the work on those myself since it was all stock stuff.
Looks like it'll be one sweet ride when you're done.
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Hot taning is droping theblock in a tank of hot water/chemicals to get it really clean.
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http://fuslit.org/photo_gallery/index.php?album=misc/car/turbo_diesel_buildup/12-02-06_moving_the_rabbit/
I was absolutily beat last night after this trip, I drove 200+ miles down and back then down and back again to drop my brother's truck and the tow dolly off. It was the first time I'd driven a tow dolly, but I think it went fairly well, a couple snags but nothing that caused the day to be anything less then a success!
A big Thanks to Joe (RabbitGTDGuy) for riding shotgun, it helped more then you know...
and now the pics (crappy cell phone pics sorry) you've all been waiting for :)
Dont' go to the light Joe!!!
(http://fuslit.org/photo_gallery/picKLE-cache/misc/car/turbo_diesel_buildup/12-02-06_moving_the_rabbit/SP_A0210_640.jpg)
Got it on the dolly
(http://fuslit.org/photo_gallery/picKLE-cache/misc/car/turbo_diesel_buildup/12-02-06_moving_the_rabbit/SP_A0211_640.jpg)
(http://fuslit.org/photo_gallery/picKLE-cache/misc/car/turbo_diesel_buildup/12-02-06_moving_the_rabbit/SP_A0213_640.jpg)
(http://fuslit.org/photo_gallery/picKLE-cache/misc/car/turbo_diesel_buildup/12-02-06_moving_the_rabbit/SP_A0214_640.jpg)
Joe's Sweet sweet rides
(http://fuslit.org/photo_gallery/picKLE-cache/misc/car/turbo_diesel_buildup/12-02-06_moving_the_rabbit/SP_A0215_640.jpg)
his M-TDI build was fantastic (we were on such a tight time frame weather wise I didn't get to go for a spin with it, but I guess it got power that is 'neck snapping') After hearing it run, I belive it! I can't describe the sound but it's pretty agressive to say the least!
(http://fuslit.org/photo_gallery/picKLE-cache/misc/car/turbo_diesel_buildup/12-02-06_moving_the_rabbit/SP_A0217_640.jpg)
(http://fuslit.org/photo_gallery/picKLE-cache/misc/car/turbo_diesel_buildup/12-02-06_moving_the_rabbit/SP_A0222_640.jpg)
I thought this sticker is hilarious
(http://fuslit.org/photo_gallery/picKLE-cache/misc/car/turbo_diesel_buildup/12-02-06_moving_the_rabbit/SP_A0221_640.jpg)
Safe at home
(http://fuslit.org/photo_gallery/picKLE-cache/misc/car/turbo_diesel_buildup/12-02-06_moving_the_rabbit/SP_A0223_640.jpg)
Tucked away in Bed
(http://fuslit.org/photo_gallery/picKLE-cache/misc/car/turbo_diesel_buildup/12-02-06_moving_the_rabbit/SP_A0225_640.jpg)
Thanks Joe, for the oppertunity to give the shell with a lot of history a new leaf in its book (and a new lease on life!) So much to do on this shell... Rust repair, re-run brake lines, etc. BUT The engine build is next and I hope to have that coming along between now and spring. I was checking out the heads that I have and they all have a few things that are shot, so I'm contemplating a 1.9td head on a 1.6 block. I know the jury's still out on this. What are your thoughts?
-Todd
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Again, sorry for the crappy cell phone pics.
Got my head studs today on my trip up to Canada to visit my sister in Niagra falls, had a bit of a traffic problem on the way home and we were stuck on the thruway for 1/2hour to 45 minutes longer then usual. People are idiots and it was snowing so you do the math but this was the end result...
(http://fuslit.org/photo_gallery/picKLE-cache/family/Blakemore/12-03-06_megan/SP_A0240_640.jpg)
<rant>
Also as a side note I would like to add, Fog lights are for fog, not the thruway when it's clear with no fog/rain/snow. if you have fog lights and you drive with them on in the middle of traffic on the thruway your an idiot. When your behind someone, Their bright as hell and when traffic flows at 0-5 miles an hour annoying as hell to the person in front.
</rant>
Moving on :)
The head studs are bigger then I pictured they would be but I'm psyched, they look awesome! Thanks again Dr Diesel!
(http://fuslit.org/photo_gallery/picKLE-cache/misc/car/turbo_diesel_buildup/12-03-06_head-studs/SP_A0242_640.jpg)
(http://fuslit.org/photo_gallery/picKLE-cache/misc/car/turbo_diesel_buildup/12-03-06_head-studs/SP_A0243_640.jpg)
Took a pic of the engine bay...
(http://fuslit.org/photo_gallery/picKLE-cache/misc/car/turbo_diesel_buildup/12-03-06_head-studs/SP_A0241_640.jpg)
-Todd
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Also as a side note I would like to add, Fog lights are for fog
You should have made yourself a nice smoke screen to block them out :lol:
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(http://fuslit.org/photo_gallery/picKLE-cache/misc/car/turbo_diesel_buildup/12-03-06_head-studs/SP_A0243_640.jpg)
Is this a M12 x 1,25mm wire?
how long is the bolt without the head?
(http://img245.imageshack.us/img245/3517/pict0009rj9.th.jpg)
Greetz, Benjamin
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I measured the one of the bolts w/out the nut on it, the whole length is about 133mm? (guessing here, all I have is a plastic gauge from boltdepot.com)
(http://fuslit.org/photo_gallery/picKLE-cache/misc/car/turbo_diesel_buildup/12-04-06_bolt_length/IMG_7880_640.JPG)
one end looks to be M10x1.25 (this side is what tightens against the head with the nut on it) the other end M12x1.75 this is the end that goes in the block?
I need to get a copy of the directions a friend of mine has, the originals these had ran into a unfortunate accident when the PO dropped the directions into some used motor oil...
-Todd
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fuslit tnx :wink:
Greetz, Benjamin
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you've got your measurements right there... the M12 threads to the block, the other is over course the end that ties the head down. Can't go wrong with Raceware's Todd :) good stuff...
glad to see pics of the shell up as well, it'll be interesting to see how the build was and my mTDI thanks you for relieving the GTD from outside status and possibly a worse storage condition and making a nice warm place in the garage for the mTDI :) As a matter of fact...it wanted to say hi...
Inside, awaiting new ebrake cables so I can get it inspected and put it away for winter to begin installation of more upgrades and new goodies...maybe even paint this year if its in the budget...
(http://i18.photobucket.com/albums/b109/joeallison_99/79%20Rabbit%20DD/100_2750.jpg)
Either way, the GTD has a great new home and a great potential. Glad you could use her !
Joe
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Just a little update, I've been working my side business quite a bit so I haven't gotten much done on the build and with Christmas coming I've been spending my side time working on making some nice cutting boards up for people on my list
I Almost have enough money to get the block hot tanked so things are slowly moving along.
On the build side of things, I just scored a nice deal on some NOS GTD nozzles on Ebay. For $64.95 shipped not to shabby!
(http://fuslit.org/photo_gallery/picKLE-cache/misc/car/turbo_diesel_buildup/12-10-06_GTD_injectors/idi1_640.jpg)
(http://fuslit.org/photo_gallery/picKLE-cache/misc/car/turbo_diesel_buildup/12-10-06_GTD_injectors/idi2_640.jpg)
Hope everyone's holidays are going well :)
-Todd
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Also as a side note I would like to add, Fog lights are for fog, not the thruway when it's clear with no fog/rain/snow. if you have fog lights and you drive with them on in the middle of traffic on the thruway your an idiot. When your behind someone, Their bright as hell and when traffic flows at 0-5 miles an hour annoying as hell to the person in front.
Same problem here, but there was bit of a campaign a couple of years ago to stop idiots using them unless the fog is REALLY bad, and it has to be. In fact i think most rear lights, and these new blue HIDS are obsceene today, esepcially those LED strip brake light repeaters, stop you seeing aything ahead anymore - overkill IMHO
BTW Seasons' Greetings VWGTD folks, have learnt a lot this year from you all..
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I just thought I'd post to say hi and nice work.
I'm practically your neighbor, other side of the lake in Lansing. I hope to pull the engine out of my '92 ECO soon. It needs some TLC.
I'd love to check out your work if you ever have the time and are in the area. If you ever need a hand give me a shout.
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Sparkman: Excellent, nice to know that I'm not the only one out here working on vw's :D But you give me to much credit, this is my first build, so I'm learning as I go :shock:
I picked up a valve spring compressor set last night on ebay for a pretty decent price. I'm hoping that it will allow me to disassemble the heads I currently own so I can clean them and figure out if any of them are good. I am planning on going with a 1.9td head for the project and have seen prices on a couple, but I don't have the cash at the moment to swing one. So I figured start with ones you have and see how shot they are. (plus I'll get some experience ripping them apart AND get to buy a new tool!)
Assenmacher Specialty Tools PN# VW 541 (crappy ebay pic)
(http://fuslit.org/photo_gallery/picKLE-cache/misc/car/turbo_diesel_buildup/12-28-06_valve_spring_compressor_set/7615_1_640.JPG)
That's pretty much it for this year, on a side note: I managed to find a gastank from my Caddy on ebay as well. I got a pretty good steal I think $65 shipped for one that didn't leak.
It's in pretty decent shape I plan on doing a por15 treatment to it and you can check out the GTD in the background. (kinda)
(http://fuslit.org/photo_gallery/picKLE-cache/misc/car/caddy/12-22-06_caddy_gas_tank/IMG_7931_640.JPG)
Speaking of the Caddy *grin* I pulled it inside before the holidays to work on it if I got the urge and time ... (mostly time)
(http://fuslit.org/photo_gallery/picKLE-cache/misc/car/caddy/12-22-06_caddy_gas_tank/IMG_7944_640.JPG)
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So I needed to get some suspension for this beast, since the stuff that's on it isn't mine. I found a pretty decent (I think) deal on some
bilstien sport struts w/some kind of coil sleeves big drop 3.5" $225
($245 shipped, not to shabby)
(http://fuslit.org/photo_gallery/picKLE-cache/misc/car/turbo_diesel_buildup/01-19-07_suspension/bilstien_and_coilsleeves_640.jpg)
The shocks are used, and the coilsleeves are new. They guy said that they dropped the car 3.5" which may be a tad more then I want to drop it. But I've read a bit on the coil sleeve setups and I think this could fit the bill for me at least to get it driving and the bugs worked out. RabbitGTDGuy (aka Joe) has some experience with a coilsleeve setup that he was pretty happy with and is gonna help me get them set up. I figure I should have a semi-decent ride from them (after some tweaking)
Whelp that's the update kids
-Todd