After 600 miles, I got 2 cracked main caps. What the heck.

[theman53]

Line boring the crank? I hope they mean the main caps. By not guaranteeing the top of the piston what do they mean? They should be able to at least give a tolerance, if not they shouldn't be touching any of your stuff. It is sometimes hard to find a guy that will be as particular as you want/need to machine your stuff. Good deal on finding a TDI.

[Gizmoman]

Tony.
Thanks for the update. Your'e probably better off going with the TDI anyhow - that DOKA is certainly worth it.
I found this locally http://losangeles.craigslist.org/sfv/ptd/3931092090.html but shipping could be spendy.

Sad you can't find a good shop though. What sort of guarantee were you asking for?

[TonyTDTruck]

Thanks theman53. Yes the block and caps. I think what they are trying to say is, they can't guarantee that the top of piston will be within spec.
I'm not a machinist so I can't disagree with them. One shop just didn't seem to be interested because he felt it would cost too much. The other guy went on about having to mill the connecting rod and rod cap to compensate for any offset that might put the top of piston out of spec.
As you can see, frustration has set in. There is one more shop here called Bearing Services that I will try in a few days. I got some input telling me these guys know what can or can't be done.
Thanks for the link Gizmoman. This looks like a good deal. If he can't stat the engine though that's something to worry about. He would have to pull the wiring harness and ECU to make it happen. That can cost a bit as well. The best thing to do in a case like this, is to buy the whole car.
The TDI I got a hold of came from Canada. I also got a hold of the wiring harness.
Another thing to consider when buying a TDI is the year of the engine. The AHU block will fit my DoKa project better than a ALH for example. I believe the ALH started in 2000.

[libbydiesel]

ALH started in 99.5.

[burn_your_money]

ALH started in 98 in the NB didn't it?

[libbydiesel]

Yes, I believe so.  The new beetle never had the AHU or 1Z.  I tend to block the NB out of my memory, tho.

[RabbitJockey]

Yes, I believe so.  The new beetle never had the AHU or 1Z.  I tend to block the NB out of my memory, tho.

dont we all!

i once went to look at a nb tdi that had a bad turbo and was for sale cheap.  i took a look at how much of a pita it would be to change the turbo, and do maintenance on it down the road, then considered the condition of the rest of the car and how gay i would look in it and passed on it haha.

[TonyTDTruck]

Update:
I finally decided to part out the AAZ engine. After calculating the cost to line bore and adding various other parts I will need, it doesn't look like I'm rebuilding this engine.
These are the items I'll be selling.
This engine had 600 miles on it.

Giles pump $670 plus shipping and paypal fees. $16.85 to ship to US.
New cylinder head. German. $500 with pulley. Injectors at an extra cost.
Fuel injectors. Make offer.
New Fuel lines from pump to injectors. $75
TDI crank. $75
AAZ crank  $50

Engine block with pistons and used crank caps is sale pending.
Pistons and rods were checked and new piston rings.

Components that I will use on the TDI.
Intake and exhaust manifold.
K14 turbo.

Also:
From my 1998 TDI purchase I have:
Down pipe with CAT for a 1998 TDI and varoius other parts.
I will post up pictures soon.

Thanks
Tony