A build thread: VNT15+Gasser intake mani on a 1.6 NA

[hamradio]

So, gasser intake manifolds seem to be a popular topic right now.  I'll post up my stuff.


The car is a 1982 rabbit, originally an NA.  Approximately 225k miles, and the engine is very worn...I can move the pistons back and forth in the bores and hear them make noise as they rock.  The pistons are also slightly melted from bad injectors.   Exhaust is a 2" straight pipe from the turbo back, with one small straight-through resonator.








Boost+egt gauge (egt is the digital one...it was cheap, but if I did it again, I'd go with analog...vdo or something)




ARP studs+aaz gasket.  I used a piece of oil cap gasket to plug the hole.




The vnt and gasser manifold together.




How much I had to grind off of the nut/stud...




If one rips out the stock vacuum nipple things with a vise grip, the hole is about perfect size for a 1/4" NPT tap.  





A blockoff plate and throttle body adapter in the making...





I'm going to try using copper tubing for an oil drain...I'll tig weld that fitting tomorrow. (it's just tacked together...it's not as clean or simple of a fitting solution as I would like, but I had the parts laying around, and I seriously doubt this engine is going to last another year, so it doesn't need to be super awesome)




A mockup of sorts of my charge piping, from stock saab parts.  Whenever I get around to it, I'll get a neon SRT4 intercooler, relocate my battery, and run that.  For now, no intercooler, and maybe 20 psi or so.






And, here's a vid of it before I blew the fiber HG and was running the stock TD manifold.

http://www.youtube.com/watch?v=Ah9fYf5Jnp8




I'll update this thread as I do stuff/get new parts and install them.  I found a very reputable shop locally that will rebuild my injectors for $31/ea with chevy nozzles ($11/nozzle vs $33/nozzle for vw ones), and am pretty excited about that...apparently they well get media blasted and sprayed with high temp clearcoat, too.

[rabbitman]

Nice rabbit, looks like the body's in excellent condition.

How many hours ya think you have into the project?

That's the same intake I'll be using, I had to wack off some of the ex mani to make mine fit though.

Here's my thread if you feel like seein' it.

http://vwdiesel.net/phpBB/viewtopic.php?t=19458

[Rabbit on Roids]

crap... i think its time to go take some pictures. my engine bay is ready. im not embarrassed by it anymore. im actually kinda pretty happy with how my stuff looks compared to some of what ive seen on here..

[hamradio]

Here's my terrible looking engine bay.  I need to clean that manifold up and paint it.





Also, I'm not overly concerned about the copper cracking...I can't see the copper actually taking much vibration to begin with (I don't think the stretch will be long enough to do any resonating of sorts), and I'm only running it for a year or two.  


Also, I have an issue.  I can't get the tbelt to run straight over the IP pully for the life of me.  The bracket is straight from my checking.  The belt runs about 1/8" off of the pulley.  I tried bending the bracket to make it run straighter...it helped very slightly.  Any ideas?  It is wearing out the side of the belt, as it comes back around to the crank pully and is straightened.


So far, things left are:

Put new VC gasket in (switched to g60 style)
Make oil drain pipe and bolt up turbo
Figure out adapter to go from the turbo-2" charge piping
Make throttle body adapter
Make 5th injector blockoff plate for gasser manifold
Get injectors rebuilt
Redo some exhaust hangers so the exhaust stops rattling

[rabbitman]

I had that same problem and got it mostly fixed by doing like what Andrew said only I didn't loosen the bracket that holds the engine mount. I loosened the one that bolts to the front of the block and messed with it, what I found is the tranny end of the pump needs to go up, the problem is the bracket when tightened tends to tweek the main pump bracket the wrong way. I ended up drilling the bolt holes in the bracket a little bigger so I could have more to wiggle.

BTW I had my pump off and on at least 20 times one day, my back still hurts from it :roll: .

[hamradio]

Thank you very very much, Andrew.  The timing belt thing has been driving me bonkers...I'll mess with the bracket tonight.  


5th injector blockoff has been made, and I started on the throttle body adapter.  I just need to cut the hole for the fitting to go to the charge piping, and weld that fitting on.  I dropped off injectors to be rebuilt, gaskets are in the mail...it's coming together!


I'm banking on next wednesday or so to drive it...I can't wait to see how it does with new injectors (old ones had abotu 220k on them).

[Rabbit on Roids]

now someone needs to use the 5th injector for some meth injection.

[rabbitman]

Got any pics of the completed intake adapter?

Did you use any sort of flex pipe in the exhaust?

Nice work

[hamradio]

Thanks!


Yes, there's a flex joint...I'll grab some pics of how the downpipe is set up, tomorrow.


Here's the throttle body adapter.  It looks kinda janky, but, I'm over it.  The angle is so it works nicely with intercooler piping, whenever I put an intercooler in the car.






Here it is with the charge piping:




My 5th injector blockoff, as well.