~My 91 GLI to 1.6TD conversion build up~

[arb]

I like your wiring harnesses. Did you make them or did the come with the insturments ?

[zukgod1]

Isspros's are just sweet gauges that come with all that nice wiring.

Good stuff right there.


Mark, what are you doing with the A Pillar gauges? Changing them over to the BLK face ones?

[53 willys]

Isspros's are just sweet gauges that come with all that nice wiring.

Good stuff right there.


Mark, what are you doing with the A Pillar gauges? Changing them over to the BLK face ones?

yeah  I wanna change them to black with white needles to match....I will probably post them on the comp D...white faces go like hot cakes over there.

[53 willys]

thanks gents!!
the wiring is STOCK isspro..they come with separate amplifier boxes..so they have built in harnesses.


the lighting still needs to be wired..the wiring in the pics is just the power and signal for the amplifier boxes.

so water temp and oil psi are electric...the drive pressure gauge is mechanical.

[88jetta350]

Those gauges are great. I may end up using them as well. What color do they light up?

Also, could you please explain exactly what "peening" is?

I've heard of "shot peening" before, but I've never had explained to me. I assume it's used to repair cracks in metal?  :?:

[53 willys]

Those gauges are great. I may end up using them as well. What color do they light up?

Also, could you please explain exactly what "peening" is?

I've heard of "shot peening" before, but I've never had explained to me. I assume it's used to repair cracks in metal?  :?:

the isspros I have light up green.....like stock..

since I had the head off I decided to peen the chambers some more...I only penned them in 2 spots the first time..but I was still kinda scared they might drop so I gave them some more peens...

it's kinda hard to see with my bad phone pic...but the small round "dents" around the prechambers are the "peening"
basically you are just using a pointed punch to smash the prechambers into the head...
clear as mud???

[vwjunkie53]

Hey Mark,
I noticed your screen name on here and recognized it from the DTR forum...  I used to post on there pretty often in the 3rd gen section when I had my '05.  Who would have guessed you were a vw diesel freak too!  

I read through a few pages of this, and man you really did a nice job on the conversion! Nice find on that GLI too!  I should have picked up a GLI or something nice and done that instead of the '85 jetta I did.  Every diesel Jetta I see for sale is always a worn out pile!  There are some nice gas ones that are real survivors though.  

 I'm back around on here again as I scored volvo with a D24T... I should be sounding like my cummins here shortly!  I was almost thinking of sticking some "C" badges on the front fenders just to mess with the local truck guys...

Just wanted to drop in and say good work.

Jason

[53 willys]

Hey Mark,
I noticed your screen name on here and recognized it from the DTR forum...  I used to post on there pretty often in the 3rd gen section when I had my '05.  Who would have guessed you were a vw diesel freak too!  

I read through a few pages of this, and man you really did a nice job on the conversion! Nice find on that GLI too!  I should have picked up a GLI or something nice and done that instead of the '85 jetta I did.  Every diesel Jetta I see for sale is always a worn out pile!  There are some nice gas ones that are real survivors though.  

 I'm back around on here again as I scored volvo with a D24T... I should be sounding like my cummins here shortly!  I was almost thinking of sticking some "C" badges on the front fenders just to mess with the local truck guys...

Just wanted to drop in and say good work.

Jason

thanks Jason!! yeah I'm on DTR, compD...pretty much all of them..lol
i am a hard core diesel freak...I love them!








WOOT WOOT
the postman left a note saying they tried to drop some thing off from "gaskets to go"!!!!
I will have my gaskets tomorrow MORNING!!!!!! :twisted:

[vwjunkie53]

Well we are all interested to see how these work for you...  I'm sure you'll be posting a couple pics of this new HG's???

Jason

[53 willys]

Well we are all interested to see how these work for you...  I'm sure you'll be posting a couple pics of this new HG's???

Jason

forsure....

[88jetta350]

I'm sure you'll be happy to have her back on the road again.

I can't wait to start my diesel swap. This thread just makes me even more eager to do it.

[53 willys]

got some more stuff done this week..
daisy chained my lighting for the gauges


also built my drive pressure gauge tubing..

 
I drilled out and through the old turbo support bolt hole...tapped it with some 1/8NPT and screwed in my compression fitting and my Custom coiled brake line tubing(by custom I mean I coiled it around my Mag light :lol: ) to cool the gases before they hit the poly tubing....I also made a soot filter(filled with brilo pad)

[53 willys]

I also got this little bundle of joy!:twisted:  :twisted:  :twisted:  :twisted:  :twisted:



opened it up... and found both theses little beauties...
2 notch


3 notch


out of the package...
it looks great!!! I am pretty impressed with the quality..
it did have some slightly rough edges around the #1 and #2 bore hole...but nothing to be worried about..


hurried and took it outside to check it against the head...

PERFECT MATCH!!!!!!!(it looks a little off in the pic..but that cause I'm trying to hold it with one and and take a pic with my SLR camera)
 


note the steam pocket holes!!


Put the new MLS on the block..marked the holes with a sharpy
laid out some painters tape and drilled the steam pocket holes.
the holes end up being pretty darn deep...at least 1/2"+



Done..

[53 willys]

on the block it looks just as pretty!..lol


you can kinda see the rough edge in this pic.




I slapped the head on TQ'ed it in steps and proper sequence to 80ftlbs..I will start and run it WITH NO COOLANT CAP to get it up to operating temp.then I will let it cool and do a re TQ@90ftlbs..



Drive pressure gauge installed...











I have ran it tonight...I'm waiting for it to fully cool and I will re torque it in the morning and then it's GO TIME....
 :twisted:
finally!!!
I'm gonna be nice to it this time....no 20 psi rally runs:lol: ...least not till I get some time in the drivers seat...

[Vincent Waldon]

Very nice work... nothing like that first fire-up, is there??!!


Guess which part I like the most






Yup, the glow plug wiring !!