~My 91 GLI to 1.6TD conversion build up~

[subsonic]

Perhaps a different exhaust manifold.  I Nnoticed you have yours sandiched inbetween.  This manifold will angle the turbo, and has a seperate port for the wastegate, also at a angle.

http://www.kineticmotorsport.com/products/KINETIC_MOTORSPORT_VW_2L_8V_TURBO_MANIFOLD-467-93.html

[53 willys]

Perhaps a different exhaust manifold.  I Nnoticed you have yours sandiched inbetween.  This manifold will angle the turbo, and has a seperate port for the wastegate, also at a angle.

http://www.kineticmotorsport.com/products/KINETIC_MOTORSPORT_VW_2L_8V_TURBO_MANIFOLD-467-93.html

I yeah I debated between that manifold and the one I got....it's only about $200 diffrence between the two..lol

I dont know I gotta take some measurments and see whats up...also not sure the 38mm wastegate manifold would/could work with my 40MM wastegate??

[Alleslowbuged]

Dear 53 willys,

looks impressive, again nice work.
If it will not fit into your car and you wand to get rid of it, you can just
send it to me  :shock: , because i have the car (MK1) were it will fit



Just for my understanding, i was thinking that your car is allready running. Do you work on two cars, or is that just the evolution 1 setup?
Just for your information, my gasket-to-go mls headgasket it still ok and i run the car (BMW 524 TD) very hard with approximate 26 psi.

Best Regards

[53 willys]

Dear 53 willys,

looks impressive, again nice work.
If it will not fit into your car and you wand to get rid of it, you can just
send it to me  :shock: , because i have the car (MK1) were it will fit



Just for my understanding, i was thinking that your car is allready running. Do you work on two cars, or is that just the evolution 1 setup?
Just for your information, my gasket-to-go mls headgasket it still ok and i run the car (BMW 524 TD) very hard with approximate 26 psi.

Best Regards

hey buddy...I dont have 2 cars...this is just more evolution of the same project.

thats great news about the gasket! they seem to be holding well so far.








Well my cast exhaust manifold is NOT going to fit with my external wastegate spacer...I'm gathering parts to build my own...



PM me if you want a good deal on a t3 exhaust manifold for all 8V VW's...

[53 willys]

well I been ordering parts and waiting...then ordering more parts because the first ones were wrong....so I order more...wrong again...so after 3 try's I finally got the stuff I want to build my Tube header...
this is not a equal length head for 2 reasons...
1. I don't have lots of room..and I don't want the turbo stuffed in there to where I cant access it.
2. this is my first time tig welding SS....so i did not want the headache of arranging equal runners.

so here is what I got so far...
1.5" SS tubing tig welded to a 1/2" steel flange
It takes 2x U-bends to make what I have here....













I also got my 11mm pump head!!!! I will have my stage 4 zukgod1 injection pump running soon as I get this header built...






let me know what you think...

[theman53]

Wow! How are you going to hook that up to the other 2 ports? How stinking hard is it to fab this? At least my mess is flat and something exists to mate it to, but you are going from nothing and have tubes. Making the patterns is what is taking me so long on mine I can't even imagine doing something like this it would take a little bit of forever to get it right...for me I guess.

[53 willys]

Wow! How are you going to hook that up to the other 2 ports? How stinking hard is it to fab this? At least my mess is flat and something exists to mate it to, but you are going from nothing and have tubes. Making the patterns is what is taking me so long on mine I can't even imagine doing something like this it would take a little bit of forever to get it right...for me I guess.

thanks! the other 2 runners will be rough cut and notched...then the VERY time consuming process of fitting them up starts...lots of fitting and grinding...until it's right...the outer runners and collector will stay tacked in place until I have the inner runners notched...
it's not easy to fab this stuff...you need to have a pretty good arsenal of metal working tools. and lots of patience, shoot this is already my second version of it...I had a different set-up all tacked up..only to realize it was not gonna pan out how I wanted...so I cut it all back off...there goes a few hours down the drain..lol
this current style is pretty sweet if I do say so myself.
should have great flow...not too big with giant runners=less lag.
I should be able to make the last two runners and finish the collector and weld a couple SS 1/8" bungs(pyro & drivepressure) on it this week....finally some progress!!

[Rabbit on Roids]

good job on that mani. that looks like a quality piece that i would build. you are a fine craftsman. crap, its not even done, but i can tell its going to be a professional quality piece.

[53 willys]

zukgod makin pumps now?

well...he lives real close to me and I'm lucky enough to have him help me with mine....so yes he makes pumps..but I dont know if he is making them for others?? I'm just giving Dan some props for making me a nice running pump the first time around...all the small stuff is done to my pump...now I just need this bigger pump head and I should be set!! sooo yeah my stage 4 zukgod1 pump!!

[Rabbit on Roids]

oh yea...
if you keep a stock TD manifold on there, with that work of art you call a turbo manifold...
i will slap you.
you can build cool stuff...
build a cool intake too, or at least use a gasser one.
or cut that one up like dave does and build a dual plenum one.
i love daves intakes. they are pretty.

[53 willys]

oh yea...
if you keep a stock TD manifold on there, with that work of art you call a turbo manifold...
i will slap you.
you can build cool stuff...
build a cool intake too, or at least use a gasser one.
or cut that one up like dave does and build a dual plenum one.
i love daves intakes. they are pretty.

haha...yeah I plan on making my own version of the PP intake....pretty much the same design but wont have as nice of welds since I'm not that great at tiging...
I just had the stock one on there for a height reference...I will be building the intake manifold soon...the header will fit with the stock intake or the dual plenum intake I will be making..

thanks for the compliments...I'm still learning so I know I can do better..hopefully it turns out ok...

[Rabbit on Roids]

tig welding isnt that hard. if my retarded ass can tig weld, anyone should be able to. but then again i learned how to tig when i was a freshmen, and it was in a senior welding class. honestly, if you can weld good with an oxy-acetylene torch, you will be good to go with a tig. same basic principal, just with an electric fire instead of a gas fire. although i would need lots of practice with a tig gun before i made anything pretty. its been so long since i welded alot. ***, i used to weld every day it seems like.

[foxracer1]

Any action? What are the specs on the charger? turbine A/R wheel trim comp A/R trim? comp map? We all wanna know. And i wanna know how she runs.

[jtanguay]

awesome job on the exhaust! did you make the plate yourself or can you buy it pre-made???  are you going to have it ceramic coated?

[jack's lack]

Just read this entire thread in 2 sittings.  WOW I am completely humbled by your build. This car is totally sick. You sir have inspired me to push my aaz swap a little further than I had planned. I can't wait to see where this goes.