Project Build: sc2020

[sdezego]

Assembly has finally begun.

Since my Interior Project is now complete -> http://forums.vwvortex.com/zerothread?id=2772227, I finally had some time to start assembly of my Hybrid 2L-20v G60.

Planning, parts gathering, prototyping and machine work has been going on for about the last 6 months, but Assembly finally started yesterday. And progress has been great with no snags thus far.

Here is the plan for those who don't frequent the G60 Forum:
- 2L ABA Bored to 83mm with Custom JE Forged Pistons (9.25:1)
- ABA OBDI block with Forged Internals, ARP hardware, Resized and Shot peened rods
- AEB 20v Head (Large Port)
- Custom Modified SuperSprint SS Mk2 16v Header re-Flanged for 20V
- Light PnP and gasket matching
- Stage IV G60 , Pulley size TBD to match higer revs
- MsnS-e
- FMIC Precision Core under Dietrich RS
- Euro AGU Intake
- some other stuff

1.) Before I begin, let's get some semantics out of the way. This project is not about "the biggest numbers on the tex" so please don't talk about Big Turbos "BTs" here.

2.) If you have any basic questions on 20v Hybrids, please visit this thread -> http://forums.vwvortex.com/zerothread?id=1674618. Al ot of details on my research and specifics are in there.

3.) Although I am not the first 2020 by far, my setup will definitely be unique and will be full trim with A/C.

3.) pic centric thread as usual.

DisAssembly of donors

Since no machine shop around here had a Torque plate to bore my block with, I decided to make my own

Painted Block

Pinning the Crank Pulley

ABA Intermediate Shaft Modification for distributer using AWP 52T Cam Gear (initially)

Modified by sdezego at 6:24 PM 1-2-2007

[sdezego]

After Checking the IM Shaft bearings, I realized that the machine shop honed them to big... I shoudl have just done them myself to begin with.

Checking the Crank Shaft Axial Play

Plastigage'ing the Mains. I always check..

Modified by sdezego at 6:28 PM 1-2-2007

[sdezego]

Click to Enlarge

Checking the Rods with Plastigage

Modified by sdezego at 6:14 PM 1-2-2007

[RaraK69]

Wow. thats intense.

running dizzy in block i take it? or going coils?

[sdezego]

Forgot to add my original Mock-up. Shown is the Euro Large Port Intake from the AGU Golf.

Click to Enlarge



Modified by sdezego at 6:43 PM 1-2-2007

[sdezego]

Quote, originally posted by RaraK69 »

Wow. thats intense. running dizzy in block i take it? or going coils?

I am going to Run Dizzy Initially, but will then go to either Coil pack using the ABA 60-2 took trigger or may even go COP.

[Darrsh]

Let me be the first to tell you that even though there r a good number of 2020's out there, your car is gonna stand out from the crowd, newer style w/hvac swap is awesome, so is the interior renewal.

but 20vG60, i cant wait to here a sound clip

keep it up man

[leebro61]

I've seen the work in person...

Ehhh... it's okay... if you are into that sort of thing

[Pigsdofly]

Quote, originally posted by sdezego »

I am going to Run Dizzy Initially, but will then go to either Coil pack using the ABA 60-2 took trigger or may even go COP.

Why go through the extra work to fit the dizzy if your using the MSnSe, it's a thing of simplcity to run a missing tooth setup from the get go.

[Lurch Legs]

I want to cut your brain out and eat it for the knowledge. Keep it up.

[pueblorrado]

I wish i had the money to dive in to a motor build like this. rebuilt a 3.0L infinity motor for a class, and all i want to do is rebuild my g60 to pure awesomeness

[sdezego]

Quote, originally posted by Pigsdofly »

Why go through the extra work to fit the dizzy if your using the MSnSe, it's a thing of simplcity to run a missing tooth setup from the get go.

An excellent question really. Especially, since you need to do a special board tweak for MSnS to accommodate VW's Dist Hall Sensor.

The orig plan was to Build MS, Config and install it on my existing G60 on Dist, get it tuned and run it for a while. Basically, get it all ready to throw on the new motor and then have to just tweak the maps rather than work out any bugs on the new motor. Still the plan actually, but since I finished the MS build a few months ago and the motor is well under way, the idea is making less sense.

Also, I already had all of the stuff for ABA Dist and the only thing I needed was the Cam gear and a 20 minute IM Shaft mod.

The past week or so, I have been seriously rethinking this though and may go 60-2 Coil pack right off. I may even setup a 60-2 on my current PG to get it all ready. I go back and forth.

[fastslc]

That's some meticulous work you are doing here dude.. Excellent..

Wish I had time and patience and TOOLS to do all that.

d

[leebro61]

Well wait a second, if you bored out a 2.0 block... isn't it a sc2120 or 2021 or 21.xxx

[sdezego]

Quote, originally posted by leebro61 »

Well wait a second, if you bored out a 2.0 block... isn't it a sc2120 or 2021 or 21.xxx

Not all that much gain on a 4 cyl only going .5mm. Stock ABA is 1984cc @ 82.5mm Bore. 83mm Bore brings it up to 2008cc

[UTdaneVW]

Thats going to be such a sick motor.

I want to see this car in person, all the work on the interior and now this. Def holding it down for the FL Rado scene.

[sdezego]

Quote, originally posted by UTdaneVW »

Thats going to be such a sick motor. I want to see this car in person, all the work on the interior and now this. Def holding it down for the FL Rado scene.

Thanks! You will definitely see it. Been driving it alot lately and enjoying it. Realistically, the motor will not go in for a few months as I am not rushing it. LOTS of stuff to work out between now and then.

Among other things, I am thinking about the gearbox as well. Peloquin at the bare min, but need to sell some more parts to pay for that. I have also been thinking about an 02M lately That is just a matter of money, not effort.

Shawn

[leebro61]

Quote, originally posted by sdezego »

Not all that much gain on a 4 cyl only going .5mm. Stock ABA is 1984cc @ 82.5mm Bore. 83mm Bore brings it up to 2008cc

Ahh gotcha. For some reason I assumed the ABA was an 81mm bore like a vr6/1.8t. I figured you were going +2mm

[DarkDragon]

I need to stop by and check this shizz out. Looks good man.

[VRT]

goodluck and welcome to the 2020 club

[32176G60]

Glad I only live 10 min away!

[Salsa GTI]

Looking Good

[sdezego]

Here is what I will be using to take care of the waste.

SuperSprint 16V mk2 header modified with a 20v Flange and some gentle persuasion to reorient the headers.

[Froto-gL]

sweeeeet technical posts are awesome. Screw this I got new tires crap, machine work and precision for the win

[d-bot]

Awesome project. I want to see more of this stuff

[eduardopepe]

hotness!

[IN-FLT]

Dude, can't wait to see this completed! Kick Ass

[98vr6t]

Dude, got me jealous, but glad to see we both had the same idea!

[hubbell]

must be something in the water down there, we're lazy as balls around here....wish i was down there....palm tree hugers....
oh the engine looks good in case you needed my approval to continue and not lose sleep at night....

[98vr6t]

Do all rocket scientists drive crazy Turbo cars or whatt!

Yeah I'm usually lazy, speaking for myself, but this guys got good drive, hope to see it at FixxFest!

[sdezego]

[Cyberfire]

So I take it you're a machinist...

Nice work man!

[SLC Guido]

More pics!! show me the car that all this is being done for too!
Great job.....

[sdezego]

Quote, originally posted by SLC Guido »

More pics!! show me the car that all this is being done for too! Great job.....

Check out the first link at the tippy top of the first thread

More progress pics will be forth coming. Stay Tuned...

[sdezego]

Been out of town and busy, so no major progress except for spending more money and more circular decisions regarding ignition.

I have some 16V IM Shaft parts coming Tues, so I will make a Final decision on Dist vs Coil Pack (or COP). If you want to know what I think was the final clincher, you may laugh. I will be running the Timing belt guards and the lower AEB guard will not fit on the 52T IM Shaft Gear for Distrubuter (obviously since the AEB uses a 43T gear like the 9a). It is just one of those things you don't think of until you go to do it. Also, the 43T gear will turn the Oil pump faster, which can't be a bad thing I just want to take the ABA and 9a oil pumps apart to compare and make sure this is nothing I am missing (other than the forked vs splined shaft). I am almost certain the gears are the same size, but want to verify reliefs and such.

I did get my Vr Lenses and Bezels installed on my ECodes though. All I can say is Flush! The G60 Ecode gaps and steps from Vr grill to fenders really annoyed me. I also have a set of Vr Fogs coming for the RS Front that will house the Precision FMIC.

Mock pic of the head and belt on (now all subject to change). I also, did not make the tensioner mod yet to affix it (since the stock 20v uses the hydro damper and relay roller).

Modified by sdezego at 5:37 PM 1-2-2007