mk3 Jetta GT to GTD conversion (and pre-conv rebuild)

[akrallysport]

Hey guys... I was on the forums a while back but disappeared when I was fixing up my dad's old mk3 Jetta GT to use as daily driver  since mine was rusting out and broke the aluminum alternator bracket. Anyways, I stripped it and scrapped the chassis/doors etc. and kept all the functioning bits. In the meantime, I've been driving around with the ABA gas engine and it just chugs fuel. Instead of trying to diagnose a $$$ sensor problem, I've decided to swap in the 'ol AAZ because:

- economy (I've been used to 5L/100km, but now I'm getting 10L/100km with the gasser)
- I've spent a bit on the TD by rebuilding the turbo, new clutch, etc.

So, while the weather outside is cold I'll be freshening up the engine:
- new rings
- bearings (if needed)
- ARP head studs
- HG
- manual boost control (run it at 12-14psi)
- IP reseal, maybe some tweaks (considering going 10mm)
- 1.6TD pin (or machine the current one)
- GTD nozzles (maybe)

Just a couple of basic questions before I begin...
1 - What's the best way to clean the outside of the block? I really don't feel comfortable sandblasting it with all the critical faces exposed. Or should I just tape them off and hope for the best?
2 - Anything else I should do while I'm in there?

Pic of what I'm starting with...

[akrallysport]

Pulled off assorted bits and pieces to give myself a break while studying for finals. I discovered that one of the previous coolant leaks was indeed caused by a leaky injection pump.

Should I be going for a 10mm plunger if I plan on machining the boost pin, GTD injectors and upping the boost, or can I stick with the 9mm?

[TurboJ]

That'll depend on the power goal. You can go surprisingly far with the stock plunger head, so I would suggest you first try it that way (do the governor mod and see if that takes you where you want to go).

[akrallysport]

Yeah, I think I'm going to stick with what I have and see... I'm trying to keep it a daily driver with a reliable power boost (stock TDI levels are the minimum).