8V ABA/JH/ MSnS FrankenTurbo Build

[punchbug]

aka "The Extensive Rad Fan Clocking". Obviously I uploaded these when I had access to some speed!!!

This is a continuation of the build in this archived thread, but now we'll add boost:

http://forums.vwvortex.com/zerothread?id=3322625

Without boost, it was good for 110Hp to the wheels, and was very fun to drive. But boost was the goal and boost it must be. I took the car up to my friend's place in November 2007, and he's a great fabricator with considerable turbo experience. I really owe him bigtime!! This was taken New year's Eve, a "before" picture:

The turbo was donated by a 1.6TD, and surprise surprise, there was soot! (the manifold needed tapping for the EGT probe too):

The car got jacked up, leading to "extreme angle duckie":

Exhaust got ripped off, to be replaced by a TT 2.5"/Borla setup:

Drew's 77 "Inga" is the sexy model for this piping, it'll be her turn next perhaps ?:

Of course, the stock 4K had to come off:

Grip is nice too:

Stock diff? Outta there!

I headed for Ohio in February to do some powder coating on the case (makes sense, it's winter, may as well drive 7 hours... ):

Back home to get the gearbox assembled by the neighbour :

Obligatory shot of new parts in packages, and dead stuff in a tub:

The finished gearbox...SO pretty!

Up and in:

Drew spent a lot of time modding the integrated wastegate to go at less than 11 psi of boost. That level would have been disastrous with those RD pistons (10:1 CR). This bench tested at about 6 psi after assembly with an additional "collar" of metal added (not pictured here) Anyway, this is what a wastegate looks like inside:

New oil pump gets put in, and we'll need an oil pan that accepts an oil return line:

In between trips North, I did a few things, like had the seats recovered:

And chopped a chunk out of the bracing on the good stock hood. It'll go on once the car comes home, but clearance is needed for that sexy intake manifold:

Sending this in case of connection failure...more in a minute or five.

Okay, back at it! Seems like this car has been in the air for a while!:

Now on the the plumbing. The intercooler was from an A3 TD, and IC piping was a blend of Canadian Tire exhaust pipes, silicon bends, and even a bit of my Bug's ex-exhaust. Intake air passes through a TD airbx which rests on the PS where the washer bottle was. Lots of welding and grinding too:

The fuel fliter got relocated out of the engine bay to a spot under the car, and the battery was already in the trunk. This cleared up space for IC plumbing too.

So....now it's May. Time to test drive this thing. Since the injectors had been upgraded from 210s to 305s, MS needed to be informed, and otherwise we used the fuel and spark map I'd driven the car up on. (Dan had tweaked it though, knowing what we were up to.)

Initial trips were really enjoyable. Boost built as we'd expected, EGTs were fine, as were AFRs, etc. No detonation, all seemed good and the car felt strong and smooth. Until "the noise". So Cincy was a no go for this car. I scurried hime and got a gearbox rebuilt and mounted up on the 16V for that trip instead. Luckily, (since the silver car had eaten a number of her gears), I had that nice 4K to use.... My neighbour the tranny rebuilder loves me.

Anyway, we did a post mortem after Cincy in June. Compression confirmed what we'd expected, with readings of 90/165/90/165. Symmetrical enough, but not so good eh? Anyway, off with the head, but the valves seemed okay, next off were pistons, and number one was missing a good part of a ring land:

Of course, it also scored the cylinder wall, so the block was junk. I take complete blame for this, since I'd not recognized detonation soon enough, and had done damage from an ignition map that was way too advanced. Yeah, I'm an idiot.

So due to incompatible times available, and some purple distractions on my part, progress in the summer was slow. Drew located a suitable JH and I went up and painted it with some POR 15, but that was about it.

Anyway, things got rolling again in the fall, here's the pretty result. This time it's a real JH, with its lower CR pistons:

IN it went...:

And it ended up looking like this:

The ride home was actually relaxing; the sun was shining, and I'd opted to leave the map as it stood, since it was too rich and retarded, and that'd be safer than the other option.

As it was, the thing got a bit squirelly on boost, and i know there's a LOT more there to tune into. Which I'd refere to do a bit closer to home.

Anyway, again, thanks to Drew for all the hard work (and dare I say planning??) We'll see how it pans out, but the first three hours or so were great!

Modified by punchbug at 8:14 PM 11-2-2008

[motorlager]

NICE project! Can wait to see how this turns out

[gamblinfool]

Holy Sh!t, Cathy!! Lotsa goodies in there! Makes my setup look meager for sure! I wants moar pix of dem seats tho!!!

[zachste]

looks awesome can't wait for the rest of the pics. that trans turned out awesome!

[California 16v]

Great build

... very jealous, may have to see this one before Cincy

[jedilynne]

So does this mean that Klaus is up and running again?

[punchbug]

Quote, originally posted by jedilynne »

So does this mean that Klaus is up and running again?

It most certainly does! Hopefully I won't "tune him out of running"!! Hey Jedilynne, first, how the hell are ya, and second, IM me your new mailing addy!

[84SciroccoX-FLOW]

great looking car. i LOVE my 2.0t, it makes great power it our light sciroccos...too bad 4 me i still got my stock 4k lmao

[Neptuno]

I am so glad that the special "K" is home......
OH!!! and by the way thanks for the pics....many entrataining shots there, I guess you where visisting Julie?

Ok now to business....to things that we do not speak of....what typo of turbo is that Like is it a t3/t4.... or something like that. Oil cooled so forth and so on. Does it vooosh.......does it drive you crazy with joy?

[punchbug]

Quote, originally posted by Neptuno »

I am so glad that the special "K" is home...... OH!!! and by the way thanks for the pics....many entrataining shots there, I guess you where visisting Julie? Ok now to business....to things that we do not speak of....what typo of turbo is that Like is it a t3/t4.... or something like that. Oil cooled so forth and so on. Does it vooosh.......does it drive you crazy with joy?

K24. There is a whistling about it, yes...And crazy with joy? yep! Or maybe just crazy... I'm just happy I beat the salt. That was the main concern this season. How about tears of joy? Yeah, her silver sister is weeping those, she was so happy to see him, she started dripping what appears to be gear oil

[DrugsMakeMeCool]

Holy smokes! Very nice Mk1.

[Neptuno]

are k24's oil cooled? I am ingnorant and I am in much need of schooling in this department

[scirocco*joe]

I LOVE LOVE LOVE Frankenstein builds!

Cathy, I'm so happy your boy is home. Now, can you please conspire with Iroczgirl in the PNW to get me a MK1, PRONTO!

Seriously, congrats on getting Klausie back before the salt hits...

[punchbug]

Quote, originally posted by Neptuno »

are k24's oil cooled? I am ingnorant and I am in much need of schooling in this department

There's an oil feed line that comes off the flange at the front of the block under pressure, and an oil return line that dumps it back into the oil pan. Oil temps seem to rise when you get on it...oddly enough! ;D

[Neptuno]

Quote, originally posted by punchbug »

There's an oil feed line that comes off the flange at the front of the block under pressure, and an oil return line that dumps it back into the oil pan. Oil temps seem to rise when you get on it...oddly enough! ;D

Only like 4.5 hours to you right? Canadian weekend......

[vwdaun]

Quote, originally posted by punchbug »

How about tears of joy? Yeah, her silver sister is weeping those, she was so happy to see him, she started dripping what appears to be gear oil

I literally laughed into a coughing fit over that statement. That is just SOO typical

Congrats on having Klausie back home, that really is an awesome (if slightly early) b-day present!

So now that I'm back in the country, look for an e-mail....

[punchbug]

Quote, originally posted by vwdaun »

I literally laughed into a coughing fit over that statement. That is just SOO typical Congrats on having Klausie back home, that really is an awesome (if slightly early) b-day present! So now that I'm back in the country, look for an e-mail....

Heck, do I owe you one? And I noticed I got Klausie's gender messed up...must be that new female engine...another Carrots castoff I think. SO fire me one off and I will reply! And it's pretty sweet in my garage right now, I have such a great family

[sciroccojim]

Ahh, that lovely whistle....and the nice feel that goes with it.

Just wondering: did anyone suggest you install the drain higher than the pan; in the block, for example?

Callaway is/was pretty adamant about the oil drain being above the level of oil in the pan at all times. They claim that the cappuccino-like froth that drains from the turbo won't drain properly if it's trying to drain into the oil and backup/smoking will result.

[twardnw]

gah, all these motor build threads coming up, I really should get on building my ABA

[Patter$on]

Quote, originally posted by Rocco_julie »

Tell you what.... Want me to put him back in his place in the spring? Hehehe. Well once I have a new clutch

Do you plan on firing End Caps at him?

[Paul@VWvortex]