The gasket used was not a TDI part but one for a 1.9TD. The 1.9TD uses a steel shim gasket very similar to the TDI unit but has the proper outline for the prechambers. As I recall this gasket was used on a solid lifter 1.6 but required some plugging of the unused holes. With a hydraulic motor it would be a bolt on.

cool yes if someone has part #s that would be cool..are they available in all the thickness sizes / notches?...any one oring a head using the steel one?
thanks
deo

Blessed are those with information!

I just wanted to add that although the multi-layer steel 1.9lTD head gasket thicknesses are the same as an equivalent-number of notches 1.6l hydraulic lifter motor head gasket, the thickness can be different comparing a 1.6 liter solid lifter motor head gasket.

1981-1984 1.6 liter solid lifter head gasket thicknesses are (according to ETKA):

1-notch: 1.4mm
2-notch: 1.53mm (or 1.50mm according to Bentley)
3-notch: 1.61mm (or 1.60mm according to Bentley)

I have had good luck with the 1.9 metal headgaskets. I actually use 1.9 gaskets on allt he head jobs I do now, na, stock turbo diesels or high performance. Haven't blown one yet. I put one in dvst8rs jetta and he was running 35 psi with headbolts not studs for 3 months so far with no problems. I put one in Malones 1.6 with 1.9 head but he has head studs, when I add a gt30 to his gt 20 I hope to run 45 psi, and I think the gasket will hold. As far as o ringing and flame rings go I looked into it originally for malones motor but I couldn't find anyone who could do a  bore so small, I was plannign on making my own tool to o ring but I can't blow the headgaskets with the 1.9 metal ones so until then no need I guess. Oh and aren't the one hole 1.6 hydraulic gaskets 1.4mm? this is just off the top of my head and my etka is down, quicktd what is it?

According to ETKA, 1-notch hydraulic lifter 1.6 head gaskets are 1.53mm thick (and 2 notches 1.57mm, and 3 notches 1.61mm) ...same as the 1.9lTD gaskets.

The multi-layer steel head gasket worked great as well when I tried it on my 1.6 solid lifter probably a couple years ago.  The only problem was the design of the plug I made to fill up the extra oil return hole wasn't sufficient to completely hold back the coolant, so when the motor cooled down completely and sat with headgasket relaxed, a tiny amount of coolant would weep out the front of the block/head past the plug.  Although it never actually effected the coolant level, it was still annoying.  I'm going to try again with the plug this time using a different design that is more elastic.

You're right about the extra dead space as a result of the larger bore, but in some cases the better head gasket seal is just plain worth it.  On the old multi-layer steel gasket I removed from my 1.6, I noticed that the dead area around the bore was at least partially filled in with carbon.

The VNT turbo'ed Rabbit despite studs has sprung a head gasket leak.  I think it was simply a result of the boosting happening on cold motor, so it will be receiving one of the multi-layer steel HGs.  My Rabbit GTD autocrosser, now that it is desined for high boost pressure, will get the other one.

all good to here..i want to test my twins on my new engine before i do a tdi in it ...so these all some good..i would take to haisley machine here http://www.haisleymachine.com/
 they make fire ring kirts for cummins engines.  i spoke to them last summer an dthey could get their supplier to get a ring our bore size, i forgot the spec but they need to crush i think 15 thousands it is strongest if you do a block and a head receiver groove and figure out the extra depth to do the groove ..with a idi the harde rprechamber is there so a blokck groove only would work..i've hear dof people doing head only grooves also..i thing a blosk only groove with studs would be the easy...of course figuring out th proper groove depth forth ecrush would probably eat up afew  fire rings and i would like to have aextra set of 4 around to have if you had to tear the engine down..if we get enough people maybe we can get a group buy. the advantage to the fire ring is there is no gap its a 1 piece donut type ring. so they use em inthe tractor pullers  ie 200 psi and up...no leaks...you have to cut teh factory head gasket to clear them ..but i bet a mls head gasket could get its fire ring waterjetted to fit..
thanks
Deo
\x/ hillfolk!