different approaches to 1.6 n/a power upgrade

[bryanbryan89x]

Ah yes back to the original post....

So essentially you are just purchasing the pick up for the 1.6 NA engine??? Im sure you dont want to hear this, but I would try and find a 1.6 td.  It would be more economical I think...

Good news: there is a 1.6 td complete engine at michaels auto salvage in Howell, Michigan.  for 400 dollars

Bad news:  Im on my way to pick it up right now...

[kyledallas]

:shock: Bryan send that TD here...  That's really one of the key's here though... the availability of used/complete/builders... looking at the
for sale/wanted in this forum....  not near the parts/engines are being swapped/sold in the VW/td realm as in other performance forums.....
  it would be nice if someone had production figures on vw diesels year by year to give us and idea of used availability.
  I read an article on a 1.9 swap using 1.6 pump and accessories...
   an option
  While I've struggled finding TD's... I have found oodles of 9000 Saab's
 with intercoolers at a local boneyard....

   I've also got a line on Cooper "S" intercoolers....
  so I've considered building this motor to stock spec intercooled/1.6td

   my figures are showing that motor:

       1.6TD w/Intercooler       90 horsepower       125  ft/lbs tq @ 2400

    that's pretty close to the TDI    90 hp/149 ft-lbs motor without the price
this would be built counting on Ion Bonding/thermal barrier to help with
heat control ... rather than the squirters...
    the rest of the engine set to 90hp/intercooled stock spec..
  Happy for you on your junkyard score Bryan... good luck with the TD

[deepmud]

I'm shipping a mechanical-converted TDI (no electronics) from CZ for $3750 to my door. Should be right at 130 hp when left alone, and plenty for my friends Sammy on 31's.

Not 500, but it's "done", and complete.

How fast you wanna' go? The NA 1.6's do 60 ok in Zuks with 31's. Same weight, length, width.......ya, I think Suzuki copied flatfender specs. I'd do 8 pounds of boost with an EGT on there and not another dime on project. All that inside work will make you cry if you burn the motor anyway.

[kyledallas]

I won't build the motor unless I'm sure I won't burn it...
 want to run highway speed... 70mph and not worry about heat while doing it...
   My 240D Mercedes was a 4cyl n/a... slow sucker but it would run the speed.... just took 10 hours to get there... and forget hills..
    Tires will be 31's or less...more than likely less...like stock mil jeep
   I realize alot of guys throw things together... (engines) and hope for the
 best.... not here..
   Too many of my friends are Mech Engineers... I'm going to know..
  not guess..that things will work..
   The things this forum offers that my engineering buddies can't is practical experience...better product knowledge....
    With the science and practical experience I should be Ok... and the engine should have the power and reliability I need w/out grenading..
    ... I should be able to accomplish this on a budget...
     sure wish there were more VW diesels out there to pick from...
   this would be easier..

[kyledallas]

Unsinkable... like the Titanic???...  No, Andrew... I've had to many
 problems when there should have been none to believe that..
   I melted a piston once when a water pump failed on a Caterpillar 3406B
 ... about a $1500 mistake.. it happened on I-70 in Colorado (mountains)
 where there was no place to pull over... it only took 5 minutes at 30mph
  ... cooked!!!
     What I am saying is my science will be solid and I will not be setting
 boost/fuel at max...
     If I do take a hit... I sincerely hope it is because a part failed and not
 because I failed to be dilegent in my "build" homework...or got power
 greedy... or scimped on part selection...
      Don't you have an intercooled 1.6? maybe you could inform me on it's performance... is it the 90hp version?? I noticed it listed on your stable of vehicles...
      I found some brand new intercoolers yesterday for $200 to $270
  ... have a buddy at a muffler shop who can mandrel me pipes and I'll use the turbo hose where the pipes meet... maybe chrome or cermakote the pipes... should be slick looking set up..
      only real question at this point is whether thermal barrier coating will be sufficient to omit oil squirters... I haven't priced converting the block to
squirters... or found a source for simply a td block.. I don't know if there are bosses for squirter set up in the block already... I believe this is an
 81 or 82 vintage 1.6n/a .....  send a little knowledge this way "unsinkable" inquisitor...hehe
                                                        thanks,
                                                               Kyle

[kyledallas]

You really should help Andrew... after all, I'm going to trade you a beaten down, munched up, rusted out, and severly wrinkled pickup body
  for you to tow to the crusher... all for a competely fresh 90hp td...
    wasn't that what you said?