Project Build: sc2020

[sdezego]

This weekend or so...

[sdezego]

A little update...

I finished the welding. The head was preheated and slow cooled in my oven. You should have seen my wife's face when she opened the oven to cook some pork chops I also did some rough machining and had it shaved for a finished HG surface. I went with the plan from the previous page (See Pic) and ended up creating the interconnecting oil drains to the corners. Welding this buildup was not fun due to the tight spaces and trying to get the TIG torch in there, but I managed.

One Key note is that I was so focused on the oil drains that I noticed that the crush zones on the head gasket between the back of the head and the Cylinders impeded into/near/too close to the cooling jackets for my satisfaction. So, I ended up bridge welding those as well. (see annotated pic below)

Pics after the machining will be up tomorrow. (click to enlarge)

Drilling the Oil Galleys

Plugging the Oil Drains machined from AL Rod to aid in Plug Welding

The HG Crush Zone I was referring to

One of the corner drains welded but not yet machined (very poor pic I know)

[sdezego]

Teaser Pic. Notice the build up areas on the Exhaust side for the new Oil Drain Galley(s) interconnecting the 3 center drains to the corners respectively. Also, notice the now bridged area between the Cyls and the rear (exhaust side) of the head.

Have not finished the machining here:
- Corner Block Drains have not been redrilled
- Rear Coolant passages, not opened up yet to match Headgasket.
- Large offset front drain not remachined
- Head has not been PnP'ed yet

Click to enlarge
Before and after:

Modified by sdezego at 2:12 PM 2-7-2007

[leebro61]

Meticulous attention to detail

[brilliantyellowg60]

Quote, originally posted by leebro61 »

Meticulous attention to detail

It is good to see people do things right for a change

[Urieal]

how much did you machine off after the welding?
sure your pistons aren't gonna hit the valves?

why so much buildup in the galleys?


Modified by Urieal at 12:13 AM 2-8-2007

[sdezego]

Quote, originally posted by Urieal »

how much did you machine off after the welding?

.010" to clean things up and re-true

Quote, originally posted by Urieal »

sure your pistons aren't gonna hit the valves?

Yes

Quote, originally posted by Urieal »

why so much buildup in the galleys?

Not sure what you mean by "So Much Buildup". There was a bit more welding there than I initially planned, but it was necessary because of limited space in trying to get the Tig torch in there to flow material.

I mentioned in the 20v thread that if I had to do it over again, I probably would not do the oil galleys again. Just because of the amount of work involved for something that is questionably needed. Technically, having the drains will prevent oil pooling by #2 &#3 cyl's exhaust valves. The other mods and the bridging are necessary IMO.

Shawn

[d-bot]

Quote, originally posted by brilliantyellowg60 »

It is good to see people do things right for a change

definitely. Keep this baby rockin!

[sdezego]

Head Modifications progression recap. (Before-During-After)

- Welded and block 3 rear oil drains
- Welded and re-machined 2 rear corner drains
- Welded and re-machined Front left Oil Drain
- Bridge welded rear head to cyls and modified rear cooling circuits
- Welded material on rear of head to interconnect Oil Drains that were blocked off to each corner drain via Drilled oil galleys
- welded and redrilled head dowel Line up holes

Before and after:
Click to enlarge

Modified by sdezego at 11:03 AM 2-12-2007

[sdezego]

Now that the head modifications are pretty much done on to other head work

Teaser - Click for larger pic

Edit: I should add, the left two intake ports are unmodified in that pic. Look at the transitions to the bowl area. If the head flows as well as it does stock, imagine what it will do with a little port work.



Modified by sdezego at 10:57 AM 2-12-2007

[Retrographic]

to make this project even better you should add a t to the end of the title.... like

sc2020t

that

[Shawn M.]

wow
amazing buildwork.

[Urieal]

any way you could post up a pic of the head with the ABA head gasket sitting on it, so we can see how it matches up

thx

[sdezego]

Quote, originally posted by Urieal »

any way you could post up a pic of the head with the ABA head gasket sitting on it, so we can see how it matches up thx

Not really sure what you are asking for. You want to see the how the HG lined up before the mods or after?

The HG Lines up perfect with the corner drains and is the exact same diameter now. All cooling holes line up. So, If I place the HG on the head an take a pic you won't see much. Also, laying the HG on the head is deceiving because a lot of the issues were with the HG crush zones, so that is/was hard to illustrate with a pic.

Let me know what exactly what you want to see and I can take a pic.

[TehLonz]

wow

massive props!

[nomad1721]

Quote, originally posted by golf198v3.0 »

wow massive props!

X2

[sdezego]

Thanks guys! If there were 30hrs in the day life would be good

Too many projects that are taking precedence which is why there is not much progress in the last few weeks

Like this one for example (Not related to this build).

[Urieal]

its time for updates! lets see how it's going!!!

[32176G60]

Quote, originally posted by Urieal »

its time for updates! lets see how it's going!!!

Ditto.... What have you been up to?

[Issam Abed]

Quote, originally posted by 32176G60 »

What have you been up to?

Busy doing NADA...

[sdezego]

Just too damn busy in general. I spent the last 36hrs alone in Tax preparation hell

And, as usual, other people stuff takes precedence over my own. But that is done and here are some pics of some 8v love (full thread to come).

...Letting the owner do the fine finishing inside if desired.

...
...
..
.

However, with all that said, last weekend I made good progress on the head and have all of the intake ports ported (Yes all 12 of them :bandhead: ). Not all polished yet, but I will take some update pics.

I am also questioning my Trans heavily and am seriously thinking about an 02m with maybe a 3.94 of 4.11 'ish Ring and Pinion. I hate the G60 gearing. I just need to find someone that will either make some form of a trade trade for my Silver Corrado or buy it outright, etc.

Shawn


Modified by sdezego at 10:53 PM 4-4-2007

[brilliantyellowg60]

Quote, originally posted by sdezego »

I am also questioning my Trans heavily and am seriously thinking about an 02m with maybe a 3.94 of 4.11 'ish Ring and Pinion. I hate the G60 gearing. I just need to find someone that will either make some form of a trade trade for my Silver Corrado or buy it outright, etc. Shawn

just get some VR gearing and a diff

[sdezego]

Quote, originally posted by brilliantyellowg60 »

just get some VR gearing and a diff

I am most certainly considering that as an option. Unfortunately, I sold the Vr trans that I had as part of the swap Might need to look what I can get the gears for. In addition, if I stay 5spd, I definitely want a .72ish 5th. I miss that from my Turbo Scirocco.

..the 02m though, adds just enough complications that could quench my OCD briefly Realistically, the 02a with Vr gears makes the most sense.

LSD is happening regardless of the choice.

[brilliantyellowg60]

Quote, originally posted by sdezego »

I am most certainly considering that as an option. Unfortunately, I sold the Vr trans that I had as part of the swap Might need to look what I can get the gears for. In addition, if I stay 5spd, I definitely want a .72ish 5th. I miss that from my Turbo Scirocco. ..the 02m though, adds just enough complications that could quench my OCD briefly Realistically, the 02a with Vr gears makes the most sense. LSD is happening regardless of the choice.

i got 2 sets of vr gears for free

there are plenty of vr trannys with blown diffs out there

my .7 5th cost me $300, well worth it, i will save that in fuel eventually

[sdezego]

Quote, originally posted by brilliantyellowg60 »

i got 2 sets of vr gears for free

LOL nice. For that price, problem would be solved and decision finalized

[brilliantyellowg60]

i'll give you one of my old sets

just needs third gear

[SameoldVW]

How's the header coming along - looking forward to seeing some pics of it with the 20v flange. I was wondering, if the Supersprint 16v header is Stainless, how are you going to unstress the primaries? so there is no added force on them when they heat up, because stainless likes to expand.


Modified by SameoldVW at 7:27 AM 4-5-2007

[sdezego]

Quote, originally posted by brilliantyellowg60 »

i'll give you one of my old sets just needs third gear

are both the Main and Counter 3rds toasted? That's close to $300 alone no? Maybe that's the reason for the LOL

If you have a good complete set that you might be interested in selling, LMK. I would need the shafts, etc too though (at least the mainshaft I know) since they are different than the ATA/AYL. If the set only needs one gear, I may be interested and have something that may be of interest to you

[sdezego]

Quote, originally posted by SameoldVW »

How's the header coming along - looking forward to seeing some pics of it with the 20v flange. I was wondering, if the Supersprint 16v header is Stainless, how are you going to unstress the primaries? so there is no added force on them when they heat up, because stainless likes to expand.

I won't be getting to that for a little while. I may even wait until last so that the engine is in the car and I can get it positioned precisely. I am not one that like exhausts hitting the tunnel or Rack

The Supersprint header is SS and super high quality. They use separate Mild steel flanges on each primary as pictured earlier. The Flange I have is actually SS and one big piece as you can see from the pics. I assumed that Supersprint used Mild steel for cost savings, but that may not be the whole case. I am undecided and have read a lot of conflicting opinions on the latter in regards to Turbo Manifolds. I am always open to opinions and suggestions from experience. All of the headers I have ever made were all Mild steel. The welding will no doubt be back purged and TIGed regardless.

Shawn

[WolfGTI]

Cool work Shawn, looking forward to seeing your project all done, my header doesn't rub the tunnel or rack.

[brilliantyellowg60]

Quote, originally posted by sdezego »

are both the Main and Counter 3rds toasted? That's close to $300 alone no? Maybe that's the reason for the LOL If you have a good complete set that you might be interested in selling, LMK. I would need the shafts, etc too though (at least the mainshaft I know) since they are different than the ATA/AYL. If the set only needs one gear, I may be interested and have something that may be of interest to you

yeah both are toasted

[leebro61]

Quit it with the yardwork and get back on this project, we want updates!

[sdezego]

haha, yea no doubt. I have some updated pics that I need to post, but was hoping to get all of the PnP finished...

As it stands, everything is now ported. I just need to sand and then polish.

[skaterhernandez4]

i hope you have a flowbench

[sdezego]

Quote, originally posted by skaterhernandez4 »

i hope you have a flowbench

Why do you hope so? ..and why the sad face before even asking?

flowbench provides validation to you and others that I know what I am doing, and I don't need that sort of validation. Lets just say, that I am not new at this.

Look above at the one finished port on the right, and if you see any flaws in my work, please be sure to comment.

Shawn