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    Thread: Project Build: sc2020

    1. Member sdezego's Avatar
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      '90 Corrado | '62 Harley Panhead
      09-03-2006 10:58 PM #1
      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
      Build: Project sc2020

      My G60 now on MS3 | 4Cyl Torque Plate Rental | 02M Mounts

    2. Member sdezego's Avatar
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      '90 Corrado | '62 Harley Panhead
      09-03-2006 11:12 PM #2




      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
      Build: Project sc2020

      My G60 now on MS3 | 4Cyl Torque Plate Rental | 02M Mounts

    3. Member sdezego's Avatar
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      '90 Corrado | '62 Harley Panhead
      09-03-2006 11:22 PM #3
      Click to Enlarge








      Checking the Rods with Plastigage








      Modified by sdezego at 6:14 PM 1-2-2007
      Build: Project sc2020

      My G60 now on MS3 | 4Cyl Torque Plate Rental | 02M Mounts

    4. Member RaraK69's Avatar
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      09-03-2006 11:30 PM #4
      Wow. thats intense.
      running dizzy in block i take it? or going coils?

    5. Member sdezego's Avatar
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      '90 Corrado | '62 Harley Panhead
      09-03-2006 11:33 PM #5
      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
      Build: Project sc2020

      My G60 now on MS3 | 4Cyl Torque Plate Rental | 02M Mounts

    6. Member sdezego's Avatar
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      '90 Corrado | '62 Harley Panhead
      09-03-2006 11:34 PM #6
      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.
      Build: Project sc2020

      My G60 now on MS3 | 4Cyl Torque Plate Rental | 02M Mounts

    7. Member Darrsh's Avatar
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      94 Rado, 04 R1
      09-03-2006 11:37 PM #7
      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 [IMG]http://**********************/smile/emthup.gif[/IMG]
      Corrado VS. Rice Burner

      "Corrado Wins"

      I get a buzz out of the combination of design and sport.
      Adrian Newey

    8. 09-04-2006 12:08 AM #8
      I've seen the work in person...
      Ehhh... it's okay... if you are into that sort of thing [IMG]http://**********************/smile/emthup.gif[/IMG]

    9. Member Pigsdofly's Avatar
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      09-04-2006 12:33 AM #9
      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.

    10. Member Lurch Legs's Avatar
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      1990 VW Corrado 1.8t
      09-04-2006 02:36 AM #10
      I want to cut your brain out and eat it for the knowledge. Keep it up.

    11. Banned pueblorrado's Avatar
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      09-04-2006 09:41 AM #11
      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

    12. Member sdezego's Avatar
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      '90 Corrado | '62 Harley Panhead
      09-04-2006 09:55 AM #12
      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.



      Build: Project sc2020

      My G60 now on MS3 | 4Cyl Torque Plate Rental | 02M Mounts

    13. 09-04-2006 10:43 AM #13
      That's some meticulous work you are doing here dude.. Excellent..
      Wish I had time and patience and TOOLS to do all that.
      d

    14. 09-04-2006 10:59 AM #14
      Well wait a second, if you bored out a 2.0 block... isn't it a sc2120 or 2021 or 21.xxx

    15. Member sdezego's Avatar
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      09-04-2006 11:41 AM #15
      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
      Build: Project sc2020

      My G60 now on MS3 | 4Cyl Torque Plate Rental | 02M Mounts

    16. Member UTdaneVW's Avatar
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      09-04-2006 11:50 AM #16
      Thats going to be such a sick motor. [IMG]http://**********************/smile/emthup.gif[/IMG]
      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.

    17. Member sdezego's Avatar
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      09-04-2006 05:48 PM #17
      Quote, originally posted by UTdaneVW »
      Thats going to be such a sick motor. [IMG]http://**********************/smile/emthup.gif[/IMG]
      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
      Build: Project sc2020

      My G60 now on MS3 | 4Cyl Torque Plate Rental | 02M Mounts

    18. 09-04-2006 06:07 PM #18
      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

    19. 09-04-2006 08:50 PM #19
      I need to stop by and check this shizz out. Looks good man. [IMG]http://**********************/smile/emthup.gif[/IMG]

    20. Member VRT's Avatar
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      09-04-2006 09:06 PM #20
      goodluck and welcome to the 2020 club

    21. 09-04-2006 09:26 PM #21
      Glad I only live 10 min away!
      "When Jens gets a bottle from the team car, he gives the car a push."

    22. Member Salsa GTI's Avatar
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      09-05-2006 02:48 PM #22
      Looking Good

    23. Member sdezego's Avatar
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      09-05-2006 08:53 PM #23
      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.
      Build: Project sc2020

      My G60 now on MS3 | 4Cyl Torque Plate Rental | 02M Mounts

    24. Member
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      09-05-2006 11:25 PM #24
      sweeeeet technical posts are awesome. Screw this I got new tires crap, machine work and precision for the win

    25. Member d-bot's Avatar
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      09-06-2006 11:23 AM #25
      Awesome project. I want to see more of this stuff

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