Author Topic: ~My 91 GLI to 1.6TD conversion build up~ (Read 152676 times)

53 willys · « **Reply #270 on:** January 17, 2009, 06:31:06 pm »

Quote from: "jtanguay"

Quote from: "arb"
OMG !!! 110 ft/lb !!! How close is that to shearing off the bolts / studs ?

my raceWEAR stretch i mean 'studs' gave out at approx 90 ft/lbs. :roll: ARP FTW!

so you had some bad issues with the beloved raceware???
I thought those are supposed to be "the best"

GIDDY_UP_GO · « **Reply #271 on:** January 18, 2009, 09:25:23 am »

Well, it has taken me the last 3 nights here and there to read through this thread, and I finally made it to page 20!!! Now I am setting here awaiting the news to see how it did on your trip to and fro work!!!

Keep up the great work and especially the posts with pics!

I have learned so much and cannot wait to tear down my 86 Golf Diesel and rebuild it with everything I learned here!

53 willys · « **Reply #272 on:** January 18, 2009, 11:00:15 am »

Quote from: "GIDDY_UP_GO"

Well, it has taken me the last 3 nights here and there to read through this thread, and I finally made it to page 20!!! Now I am setting here awaiting the news to see how it did on your trip to and fro work!!!

Keep up the great work and especially the posts with pics!

I have learned so much and cannot wait to tear down my 86 Golf Diesel and rebuild it with everything I learned here!

hey thanks alot man!! I still got LOTS of work to do...

I would say the MLS is a success!!!! I drove to and from my work last night with no engine issues at ALL..the worst part is my heater resistor pack is blown...and my blower motor is shot so it rattling and bouncing around!!
so hey I would say success if that all I can complain about!!

I took it up a nice big hill on my way home...18-19psi... holding strong..

:twisted:
I'm trying to keep the boost down under 20psi......

it's hard....boost=

Dirtrag2 · « **Reply #273 on:** January 18, 2009, 11:07:43 am »

Quote from: "53 willys"

I took it up a nice big hill on my way home...18-19psi... holding strong..

:twisted:
I'm trying to keep the boost down under 20psi...... it's hard....boost=

congrats on the trip to work and back!

soooooo hard to keep boost under 20 lol

53 willys · « **Reply #274 on:** January 18, 2009, 12:06:25 pm »

I forgot to add...my ride to work is a pretty big drive...68 miles round trip..
nothing like Zukgod1's commute! but still a pretty good test run..

just installed my lower temp fan switch into the radiator..the engine is not really running hot..operating temp is about 195-205*...but for the summer time and AC on..I think I will want to give the fan a head start on the cool down
:wink:

I also took the control arms back off today....these dang audi TT bushing are not the perfect upgrade...someone really need to make a sleeve for the MK2bolt/TTbushing..there is just to much slop in these things for me to feel good about them.
I'm gonna make some sleeves today..hopefully that tightens then up..

did I tell you guys how excited I am?!?!?!?!?!? :lol:
WOOT WOOT

Quantum TD · « **Reply #275 on:** January 18, 2009, 12:59:44 pm »

Originally, the MK2 had a sleeve in the bushings. Sometimes, they rust to the inside of the old bushing, and you can't see them.

Did you install a new MK2 sleeve on the bushing when you installed the TT bushings?

I'm asking because, I have a GLI, and am thinking of rebuilding the a-arms with the TT bushings. I may pass on that idea, if I have to make a custom sleeve for the bolt/bushing.

53 willys · « **Reply #276 on:** January 18, 2009, 01:04:46 pm »

Quote from: "Quantum TD"

Originally, the MK2 had a sleeve in the bushings. Sometimes, they rust to the inside of the old bushing, and you can't see them.

Did you install a new MK2 sleeve on the bushing when you installed the TT bushings?

I'm asking because, I have a GLI, and am thinking of rebuilding the a-arms with the TT bushings. I may pass on that idea, if I have to make a custom sleeve for the bolt/bushing.

well on vortex I found some threads and most of them are saying just torque it down tighter..or add a washer so the sub frame can pinch the bushing in place....
to me that is unacceptable..
if it loosened up later and moved you would lose your alignment.
the stock MK2 sleeve does not fit with the TT bushing. If you want the bushing and the bolt to be 100% straight and aligned (like the stock MK2 bushing and sleeve do) then you need to build a sleeve of some sort to take up the slack in the bushing hole..
clear as mud?
I'm gonna take some pics....

JetPo · « **Reply #277 on:** January 18, 2009, 02:03:28 pm »

Incredible project, hope i can put that much work into mine !!! Really nice diesel !!! Keep up the good work ! :twisted:

Alleslowbuged · « **Reply #278 on:** January 18, 2009, 02:23:33 pm »

Dear 53 Willys,

nice to see, that you engine runs. I was very scarry, when i read, that you gasket (i get my on the same day) was leaking on the first start up. As i understood you right, everthink is fine now.

You have a 1.9 AAZ head or? If yes the compression ratio should be less than stock, how is you engine starts, do you feel a differend at start up or even until it is warm?

Best Regards
Clemens

53 willys · « **Reply #279 on:** January 19, 2009, 07:59:12 pm »

Quote from: "Alleslowbuged"

Dear 53 Willys,

nice to see, that you engine runs. I was very scarry, when i read, that you gasket (i get my on the same day) was leaking on the first start up. As i understood you right, everthink is fine now.

You have a 1.9 AAZ head or? If yes the compression ratio should be less than stock, how is you engine starts, do you feel a differend at start up or even until it is warm?

Best Regards
Clemens

yes everything is holding great now!!
my engine is a early 1.6td CY code...it's FULL mechanical..head and block. :twisted:
I am running the correct size headgasket for my application...so it starts GREAT!! :wink:

53 willys · « **Reply #280 on:** January 19, 2009, 08:00:29 pm »

some more update....I was not happy with my R32/TT control arm bushings...so I did this to fix them....

well after reading all the great reviews about the R32/TT bushing on the MK2's I figured I would try it since my stock bushings were gone....
I ordered all my control arm bushings from GAP...fast shipping just like always...

I get my parts go to install them and I realized when I am test fitting everything that the STOCK bushing bolt is WAAAAY to small for the stock R32/TT bushing...I tried to find some info on vortex about it but all I could find was threads saying that they don't need a sleeve and that you just need to tighten down the bolt more....
this is just plain stupid IMHO...the bolts fit TIGHT from the factory...and they are FAR FAR from tight with a R32/TT bushing.
so I call GAP and they tell me I'm the first person to have this "issue" I really surprised that this is such a talked up upgrade when it is not a BOLT IN UPGRADE..yes the sub frame might hold the arms in place if you go super tight..but that's not how this stuff should be!!

Basically I decided to build my own sleeves to make the bolt fit squarely and snug...without over torquing the bolt and just "hoping" it will not move and mess your alignment out.

here is the problem...
lots and lots of slop!! :thumbdown:

so what I did was take a 5/8"X3.5" grade 8 bolt..I cut the smooth shoulder off...and drilled it out to fit my metric bushing mounting bolt(stock bolt)..after the hole is drilled in the 5/8" bolt...you need to drill out the R32/TT bushing to you can "press fit" the new sleeve into place.
I used a 39/64" drill bit for the press fit hole in the R32/TT bushing..
here is a shot of the 39/64" drill bit~NEW sleeve~ and a 5/8" bolt to show what the sleeve was made from..
you can also see that one sleeve is all ready installed..the other just needs to be pressed in.
My sleeves did not come out "perfectly straight and square"...but they are a nice tight fit and they will for sure hold better then with no sleeve.

Stock R32/TT hole next to my drilled out and sleeved R32/TT

new sleeves installed and no more sloppy bolt holes and clunking Arms... :thumbup: :cool:

i'm happy with the results...and cant belive all you guys run this set-up without a sleeve!! :screwy:

53 willys · « **Reply #281 on:** January 22, 2009, 12:41:33 pm »

Quote from: "53 willys"

Quote from: "88jetta350"
Those gauges are great. I may end up using them as well. What color do they light up?

the isspros I have light up green.....like stock..

need to clarify...I was under the impression my gauges light up green...but to my surprise they are just plain yellow lighting...I had some in my old doge and they were green...
I just wanted to correct this so people are not mad if the get this style isspro gauge and its not green.

what I will say is you can change the bulbs to a LED of your choice and they REALLY glow nice!!!
More on gauge lighting....next week.

word of the day...
coolant leak....but not from the headgasket...a hose or something..i'll find it.

53 willys · « **Reply #282 on:** January 22, 2009, 12:43:05 pm »

Quote from: "JetPo"

Incredible project, hope i can put that much work into mine !!! Really nice diesel !!! Keep up the good work ! :twisted:

thanks Jetpo!!

I still kinda wish I had a 1.9.....next time..

zukgod1 · « **Reply #283 on:** January 22, 2009, 12:51:13 pm »

I sure am glad this car is moving now.

Those control arm bushing you made look really nice Mark, I suspect I'll go with stock bushings should I ever change them. I don't want to mess with making bushings for the new "Bushing-less" TT ones. Seems stupid to me. That should tell you the general intelligence level other "there" if ya know what I mean.

I need to come by for a ride next week, I'll text ya at some point to see if we can meet up.

Time for intakes now? Maybe I should wait till the VC comes back before I give you a hard time :lol:

Alleslowbuged · « **Reply #284 on:** February 01, 2009, 01:21:07 pm »

Dear 53Willys,

something new here? Is the car still running fine. Are you shedule to make a dyno run? Are you running high boost now or still keep it smooth?

Best Regards
Clemens