hello...in search of lots of answers

[dr.dub]

Hi I'm new to the site. and pretty mucht he diesel communitty. I recently got a job that requires lots of highway driving and I've owned tons of vw's in the past and even worked at a vw shop. though I never touched the diesel stuff.

I picked up a 82 diesel rabbit and don't know much about the diesel stuff and interchange on them. I've spent the whole day researching and reading but still would like some more confirmation on some things.

I wanna beef this thing up and make it a turbo diesel for sure. I got my hands on some of the turbo stuff already from previous projects and friends.

what else would I need to make this thing a beast. remember highway driving and I like to pass people.

turbo- seen alot of different people talk about different turbo's the only thing I can understand is get the t3 one.

injection pump- 1.6td and send it off to giles. or is a 1.9 better?

headgasket-use the 1.9 one? how do I determine what hole count I need?

from my understanding so far it's better for me to get a hydro motor out of a mk2 and start there?

thanks

[Mark(The Miser)UK]

I suggest you get the Caddy running with the turbo first.  Turning up the 'volume' on few screws gets surprising results. Get an EGT gauge and create something with a 'little beef' Then do your bigger mods.
 Make sure you have oil squirters under pistons.
Get to know how your engine sounds when running right at standard settings then add more mods, else if you have a problem, it'll be harder to solve it.

[dr.dub]

ok that's fine but I still need to know the other stuff for the motor I wanna put together then.

[dillenger1]

get a vnt from a tdi if you really want performance.Use the 1.9 metal layer head gasket.You measure piston protrusion from the deck to determine thickness.definetly send pump to giles.get yourself some bosio nozzles for you injectors.Oh yah definetly get a egt guage as you gonna be running hot.You can counter this with a huge down pipe 2 1/2"....an intercooler(there are alot of small effecient coolers on ebay perfect for our engines(i used a saab)You can also read up on water/methanol injection(poormans nitrous)

[Smokey Eddy]

I personaly like the hydro mk2's. Good Garett T3 on there, 1.6TD pump giles'd up and proper injectors. Big straight exhaust (2.5 or 3 inch) and you'll be makin power. Oh yeah, do the boost mods to. I'm building mine around 25 psi of boost intercooled.
Intercooling makes a huge diff too if you can do it. i read somewhere 65 stock hp increases to 80 something with just an intercooler
so...
look forward to seeing your build,
Ed.

[dr.dub]

thanks guys where do I find bosio nozzles? and what are the boost mods?

and what year am I needing the vnt off of? isn't there more parts needed to run one of those turbo's on a 1.6?

[subsonic]

Looks like you are trying to build a solid base.  I would suggest spending some time in the FAQ section.  There are topics regarding turning up the fuel pump for power.  
It sounds like you want a reliable car that runs well and goes good at highway speeds.  Are you planning on building up your current longblock setup, or are you going to strip it down for boring / honing, new bearings, etc...  Does your TD pump leak in it's current form?

As I can tell you, it is VERY easy to have a rebuild project get very expensive very quicly.  I think I had about 700 just into pistons ands rods.  1000 for the pump, and so on, etc, etc...It adds up quick.  You can have a pretty quick car just with making sure it is properly running and tuning the parts you have.  A 82 rabbit is light.  70-90hp will make it fly on the highway with the proper gearing.

[79rabbit4dr]

Are you looking to hop up the motor you have or transplant bigger/better right away?

What i'm planning to do is maintain the stock motor that's in there now, maybe try the free/cheap power tweaks, then once the motor's worn/done (or maybe when I just have the $$$) maybe do a transplant to one of the hydro motors ppl talk about.

[subsonic]

Assuming you have a solid longblock with good oil pressure, good compression, tight head that does not need valve guides or a valve job.  I would start with rebuilding injectors.  New nozzels and pop test.  Get the correct tools to set the timing.  Make sure it is correct.  New glow plugs. Ensure you have a healthy turbo, make sure the wastegate functions correctly.   Get a free flowing exhaust system, 2.5" should be fine.  Free flowing turbo muffler.  Straight pipe is nice but not for long highway drives.  You can upgrade to a bigger downpipe, 2.5" as funds are available.  Lighten your flywheel, heck, upgrade your flywheel to a 200 or 210 and then lighten it. A 10-12 pound flywheel will make a big difference.  While you are doing the flywheel,  get a transmission  that is geared for highway running.  That will make a huge difference.  After that, you should be almost ready to start turning things up.  Install a EGT probe and guage.  Install a oil pressure guage.  Install a boost gauge.  T in a boost pressure regulator.  Turn the boost up to 12-15psi.  Read the make your 1.6td faster thread.  Attack the spaceship and turn up the fuel in small doses.  Intercool if you want to start running more fuel and boost.

[dillenger1]

thanks guys where do I find bosio nozzles? and what are the boost mods?

and what year am I needing the vnt off of? isn't there more parts needed to run one of those turbo's on a 1.6?

you will have to search for the bosio nozzles im not sure who sells them now,you could also use the (gtd)type or mercedes.With a vnt you wont need boost mods if you set it up right.theres no wastegate on a vnt .Its controlled by vanes that concentrate the energy on the exhaust wheel.If you get a traditional turbo you can het a boost controler(air bleed valve)or you can just block it off completely and use your foot.

[dr.dub]

vnt might be a little pricey so I'm probally gonna go with the t3 and I have a boostcontroller already.

fired up the rabbit and it's pretty noisy. lots of topend noise so I think I'll just get my hands on a 1.6 hydro block and start with a fresh build. the rabbit keeps starting then dies a few times before it will stay running. doesn't look like any air in the line when it was running. so I guess I'll just pull it out and get rid of it. and start the build on a new badboy.

could only find bosio stuff listed for marcede's?

[Mark(The Miser)UK]

vnt might be a little pricey so I'm probally gonna go with the t3 and I have a boostcontroller already.

fired up the rabbit and it's pretty noisy. lots of topend noise so I think I'll just get my hands on a 1.6 hydro block and start with a fresh build. the rabbit keeps starting then dies a few times before it will stay running. doesn't look like any air in the line when it was running. so I guess I'll just pull it out and get rid of it. and start the build on a new badboy.

could only find bosio stuff listed for marcede's?

Rumour has it that mech setup is stronger than hydro.  Mercedes nozzles fit vw [not the injector bodies] Still not sure if you need ultimate power for highway/commute, unless your trips include empty roads with a few idiots you want to pass in a hurry. Try tweeking up a TD pump and see how different it is to an n/a.