Author Topic: G-Teched my 1.6TD - Part 2 (Read 146392 times)

935racer · « **Reply #105 on:** November 23, 2005, 05:11:15 pm »

Actually now there are 2 bolt on performance mods for the IDI's, downpipes and custom cams! Ther eis more stuff on the way, cheap electronic boost controllers, bov block off plates etc. all in good time. I am very open to suggestions so if anyone has some suggestions for performance parts they would like let me know!

malone · « **Reply #106 on:** November 24, 2005, 01:04:04 pm »

Thanks for the interesting posts, Joe. I understand the (lack of) IDI parts availability and it is true that the TDI prices are starting to go down. Semi-contrary to what I said earlier, I would have probably kept my TDI if I had room for an extra vehicle. The neat thing is that for over 300 wheel torque the ALH longblock does not need to be built. Just a few bolt-on mods, i.e. chip, injector nozzles, pump head, larger VNT turbo, etc. will yield 300 wtq very easily (see Smog's 365wtq example). And it still gets killer fuel mileage, perhaps retaining 40+mpg in a lightweight vehicle during normal driving with stock engine compression & internals.

For now we'll concentrate on finishing this 1.6 IDI eventually and perhaps a 1.9 TDI would be an ideal second car of mine. I won't mind the V8 style torque during low RPM and the long gears. 1.6 IDI vs. 1.9 TDI - two totally different animals!

I still have the nearly rust-free 1986 MK2 diesel Coupe that my TDI was intended for. I need to find a place to store the coupe though, starting very soon... if I'm forced to sell it then an alternative car I'd consider in the near future is a Mercedes Smart CDI (0.8L 3cyl), which can be chipped. The Smart weighs 760kg or 1741lbs, which is considerably less than even a partially stripped MK1 Rabbit :twisted: it makes about 56HP and 100lb-ft with chip only which is quite peppy especially with a six speed transmission. RWD too. Not to forget a potential turbo and/or injector upgrade :!: My significant other could use the Smart (with multiple chip programs, one being soft for street driving) while I'll use the 1.6 IDI on a daily basis (100km/60mi per day) unless it goes off the road for mod changes.

Happy Thanksgiving Joe! Maybe I should drive down to the US for a feast..

malone · « **Reply #107 on:** November 24, 2005, 01:12:45 pm »

Perhaps I should mention this because some people are looking forward to see my progress with high RPM and T3/T4 turbo upgrade. I've decided not to continue modding this car from now on because I have new financial priorities, including saving up for a new home (may move in the Spring) and I'm also saving for better equipment for my business. I was seriously itching for 200whp with this 1.6L, which I believe is easily do-able, but I need to be patient for now. It will pay off well in the end. I also would like compound turbo charging instead of a single large turbo. While we're doing that I could/should have the following done:

* Transmission upgrade. A good 02J with Peloquin LSD is approx $2,000 CAD (realistically).
* Main studs and a few other engine internal bits.
* Valves and pistons ceramic coated when 935racer gets a ceramic coater sometime this Winter!
* Two ball bearing turbos!
* Custom rods.. the stock rods may bend if we tune the compound turbo setup to its maximum potential.
* Major fuel pump upgrades.
* Engine mounts.
* Brakes.

... just to list a few. I decided that we should do it all at once for good results, so this IDI's progress will be put on hold for now. Gonna stick with the GT20 as I'm happy with the current power it makes. After all the engine only has 2,500km on it, and going from stock TD power to approx. 150whp is a pretty big jump already. Eventually I will get bored of 150whp and want to try 200whp :p when the time comes..

X@V · « **Reply #108 on:** November 24, 2005, 02:18:03 pm »

You can buy a complete 02A (CTN) transmission kit for 900$ CAD.

If I don't buy the kit, it will be for sale.

935racer · « **Reply #109 on:** November 24, 2005, 03:45:02 pm »

Erik might hit 200whp before you Mark! Today we started mapping out his twin setup and it looks like I have a 1.9 head lined up for him as well. So it looks like when you want to come back for some more mods we are gonna have to shoot for 250whp. Than Felix will want to try for more power, than Erik will be pist and come back for something even more ridiculous etc etc I cant wait!

dubCanuck1 · « **Reply #110 on:** November 24, 2005, 05:15:38 pm »

I like the twin turbo setup idea. I've had it for a while.....enough to think about badging of the two cars.....

1.6TT
1.9TT

That's on the 2 year plan right now.

malone · « **Reply #111 on:** November 24, 2005, 09:43:31 pm »

Quote from: "X@V"

You can buy a complete 02A (CTN) transmission kit for 900$ CAD.

If I don't buy the kit, it will be for sale.

Not bad.. if I look hard enough I may find one for less, 02J even. I have time now so it's doable. There's also the possibility of swapping O2J gear sets into a O2A casing, and retaining the MK2/MK3 shifter & cable clutch. Something to research on.

Thanks for the heads up though!

Quote from: "935racer"

Erik might hit 200whp before you Mark! Today we started mapping out his twin setup and it looks like I have a 1.9 head lined up for him as well. So it looks like when you want to come back for some more mods we are gonna have to shoot for 250whp. Than Felix will want to try for more power, than Erik will be pist and come back for something even more ridiculous etc etc I cant wait!

Erik might hit that before me? Damn. Looks like we'll have some competition :twisted:

Quote from: "dubCanuck1"

I like the twin turbo setup idea. I've had it for a while.....enough to think about badging of the two cars.....

1.6TT
1.9TT

That's on the 2 year plan right now.

I haven't even thought of the TT badging, pretty neat. It's nice seeing fellow TDs taking an interest in compound turbocharging. andy2 you should post a picture of yours!

3beejay3 · « **Reply #112 on:** November 25, 2005, 04:11:27 am »

[/quote]Not bad.. if I look hard enough I may find one for less, 02J even. I have time now so it's doable. There's also the possibility of swapping O2J gear sets into a O2A casing, and retaining the MK2/MK3 shifter & cable clutch. Something to research on[/quote]

Malone -

I have a source that has several 02J tranny's here in Ontario.

I believe he wants around $700.00 for them.

BJ

RabbitGTDguy · « **Reply #113 on:** November 25, 2005, 01:04:32 pm »

Malone, feel free to come down any time you like

Lots of diesel in my basement...well, only the TDI motor and the GTD but the orginal 79 1.5 bunny is outside as well.
I hope you find a place for that MK2 Jetta coupe...they are very hard to find around here and I thought about that for the base of the TDI instead of the rabbit (i have a 91 i'm parting right now, 4dr though). That'd make for an awesome canidate for the TDI swap...say... ALH...ok...but what about a PD 130 or 150!!!! Even more fun!
I know what you mean though when it comes to $$$ and doing the motors, upgrading, etc. Currently I kinda have to sell stuff I have, barter and trade to get this motor where I want it. I was able to source my pistons though (not using 1z's); got mikeyworks' pistons he had from the ALH block in his add and then sourced three more good ones in trade for my 4 good 1z's. Seems fair to me. Then...its hoping that parts, etc. will fund the remaining things I still need to get. I'll be doing ARP's in the bottom and racewares up top...unless I find that raceware is able to supply ARP rod bolts and mains for the motor...that'd be nice and the pistons will be sent out to swaintech here next week for coatings along with the mains and rod bearings. Also, props to Bildon Motorsports as they have IMO the best prices around for the racewares and ARP fasteners.
Man...200whp with sequentials...that'd be sweet

from the IDI!!! I hope you pursue that path in the future. That Mercedes sounds interesting though too!
Anyways...off to finish T-day festivities! This will prove to be an interesting project...

For the above post...where I mentioned the corrado. Here is a pic i found...old...right after I got it. Hadn't done much to it at this point...but the GTD just looks so much more fun!!!

Maybe in the future i'll do a PD150 rado like the one i've seen around here somewhere on the net!

Happy holiday!

Joe

malone · « **Reply #114 on:** November 25, 2005, 03:28:20 pm »

From this morning on my way to work:

First accident ever.. never even a winter fender bender before. We were in a narrow (& wet) tunnel so I was unable to evade otherwise I'd hit the wall, or head-on with incoming traffic. I didn't feel too bad about my car, the other people were OK. I was informed that my insurance rates won't go up because this is my first accident, so I'm relieved.

I've always bought collision for insurance since I first got my drivers license... however 2 weeks into this 3-month insurance (plates) I got into an accident without collision coverage. Talk about luck :? Regardless, I don't want to pay a $300-500 deductible and have the insurance / shop take 3-4 weeks repairing my car. Gonna take care of it myself.

The original radiator is cracked and leaks, so I'm replacing it with a VR6 version. I was pleased to see that there's a second radiator attached to the VR6 radiator (I didn't know until I took a large plastic cover off). It is large and I will use it for the air/water intercooler.

Joe, your TDI project sounds interesting

I can tell that Corrado is neglected by the Rabbit's fresh tire marks in the grass :lol:

3beejay3, thanks for the heads up. When I'm ready to buy I'll let you know. Do they have 02M transmissions as well? If so what's the ballpark on them?

Sorry for the short replies, got some errands.

Cheers,

dubCanuck1 · « **Reply #115 on:** November 25, 2005, 05:18:32 pm »

Couldn't help but get confused. What are you trying to achieve with the tranny? Putting an 02J gearset into your current tranny? Why not just get the 02J tranny and put it in? Seems easiest to me.....

malone · « **Reply #116 on:** November 25, 2005, 05:20:39 pm »

Quote from: "dubCanuck1"

Couldn't help but get confused. What are you trying to achieve with the tranny? Putting an 02J gearset into your current tranny? Why not just get the 02J tranny and put it in? Seems easiest to me.....

With a full O2J tranny I may have to install the O2J shifter (cutting & welding?) and convert to hydraulic clutch.

Putting 02J gearsets in a O2A case will allow me to keep my shifter and it's possible to keep the cable clutch as well. The tranny will need to be opened up for LSD install anyways.

vwmike · « **Reply #117 on:** November 25, 2005, 05:26:06 pm »

Quote from: "dubCanuck1"

Couldn't help but get confused. What are you trying to achieve with the tranny? Putting an 02J gearset into your current tranny? Why not just get the 02J tranny and put it in? Seems easiest to me.....

Well, it would be if he could get a TDI 02J or at least the TDI axle flanges. The 02A shift tower actually fits the 02J box and offers protection against overthrowing the gears. In 2001, the 1.8t 02J underwent some 2nd gear syncro revisions. I'm not entirely sure if the TDI trans was also revised. He would need the pedal cluster from a 4cyl 02A car, as well as the clutch master and slave. He would also need an O2A shifter (MK3 is preferred in a MK2 as it is taller) if he wants to use the 02A tower. I haven't heard of anyone adapting the 02J shifter as of yet. A G60 flywheel with a VR6 clutch would offer the best holding power as it is larger than the MK3 TDI clutch and any of the MK4 clutches at 228mm. Finding a TDI starter might also be fun

dubCanuck1 · « **Reply #118 on:** November 25, 2005, 08:10:02 pm »

Well, I had a big ol blab prepared, but I guess I should ask which car you're talking about? I've been working under the assumption that you were wanting to get 02J gears into your current tranny.

If you were going to mate an 02J to the IDI engine, it would bolt right up. The flanges are 100 mm. The Diesel MKII's came with 90mm as you've probably already noticed. However, the GT, GTI, GLI, GLX, and most gassers after 85 or so had 100mm CV's, so get some driveaxles from a gasser and voila.

Thanks to MrDave for the following (again.....Royalty cheque is in the mail

). The 02J is the cousin of the 02C (Rallye, anyone?), which is an offshoot of the 02A. The bracket from the the 02C should allow you to mount the 02J to the stock 02A mount location, avoiding the crazy MKIV mount on the frame rail). I've ordered this for my project and can give you the definitive answer in a couple weeks.

Oh yeah, and some of the Rallye's came with cable shift and......you guessed it, hydraulic clutches. I'm currently doing some homework to see if the hydraulic clutch and pedal cluster will work with the 02J.

Lastly, on the cable shift, no welding is/should be required. Look at the FutrellAutowerka VR6 swap for ideas on mounting it. You can also fab up some straps to hold it into place if you want.http://futrellautowerks.com/projects/89clvr62.htm

vwmike · « **Reply #119 on:** November 26, 2005, 12:52:36 am »

Quote from: "malone"

Quote from: "dubCanuck1"
Couldn't help but get confused. What are you trying to achieve with the tranny? Putting an 02J gearset into your current tranny? Why not just get the 02J tranny and put it in? Seems easiest to me.....

With a full O2J tranny I may have to install the O2J shifter (cutting & welding?) and convert to hydraulic clutch.

Putting 02J gearsets in a O2A case will allow me to keep my shifter and it's possible to keep the cable clutch as well. The tranny will need to be opened up for LSD install anyways.

I was under the assumption you had an 020 trans? How do you plan to retain your stock linkage shifter?