MK4 Jetta Wagon 16vT build

[elRey]

Quote, originally posted by elRey »

a little downpipe development: This is the part I dred the most because I don't have the means to fab it myself

With some better measurements from car, downpipe is getting more complicated

[Scuba2001]

Here's a suggestiong... Would it be easier to go to an auto parts store and buy a 4-6ft section of 3" flexible exhaust tube to try and bend/shape on the car to get the best fitment? It'll give you real-world sight of it on the car, and once you have that shape, tack weld some of the joints and then have a shop replicate it.

Sounds a little bit easier than spending hours in front of a computer and taking measurement after measurement.

[all-starr-me]

Quote, originally posted by vw_dred »

Oh ok.. I always thought they were. I wonder why they went back - those tall-blocks are smooth.

Its all about packaging, they had to fit that 2.0L under the hood in a NB, another reason mk4's suck.

[bjtgtr]

Very cool swap! keep us updated with your progress

[elRey]

finished the mk4 TB to 16v mani adapter. Had the profile waterjet cut and spent today grinding/forming the transition:

[jettadrvr94]

Great looking adapter!

[elRey]

downpipe mockup:

Super scientific way to check alignment and fitment:

inlet from stock airbox + vr6 tube:

hot side of IC route.. using 1.8T pancake pipe and smic for now, but planning ahead for big fmic. I still need to verify that the axle will clear the elbows when suspension is compressed.

Modified by elRey at 1:36 AM 4-10-2009

[Audi4u]

WoW

This is what I consider a "build" thread.

[elRey]

Quote, originally posted by Audi4u »

WoW This is what I consider a "build" thread.

Thank you.

Just recieved my cold side IC piping via a fellow Vortexer. just a little modification will be needed.

[elRey]

Quote, originally posted by Jay-Bee »

Watching this one... ElRey and his Frankenstein 2.0s are always great.

Oh and just as a Off-Topic, side note.... this is it's older brother:

1990 Jetta with a '02 AZG engine and 02J swap running off AEG ECU.
Plus an OEM K03s turbo (big brakes on all corners like the wagon):

it's build thread

Modified by elRey at 2:36 PM 4-10-2009


Modified by elRey at 2:36 PM 4-10-2009

[sin bar]

you don't mess around rey. can't wait to see this one around on the road, too.

[Skeil]

I agree this is definitely a "build" up thread. and a

[jwalker1.8]

Glad to see the charge pipe is working out for you...I will let you know asap about the other pieces.

[sgolf2000]

you definitely love some OE parts.

[M3aTwagon]

awesome!

[elRey]

started modifying the TT225 charge pipe.

cut it at 45*

then hacked off the by-pass (DV) bung:

I had originally planned to take one off a standard 180hp 1.8T charge pipe, but why ruin a perfectly good part when the TT225 pipe was already cut.

I'll relocate the by-pass port to under what;s left of the bend:

I'll have an aluminum bung welded to the inlet pipe right below where the TT225 pipe goes into the throttle body:

Some fine adjustments will be needed after I get a few parts in, but this is close to it will look like:

Also did some fine adjustments to downpipe... these are what's left after the adjustments cuts:

I'm really liking the hack saw.




Modified by elRey at 10:20 PM 4-18-2009

[nairmac]

I have a question- I see that you have had some clearance issues with the exhaust downpipe, and that the intake crosses over the turbo before it does a 180 and down to the inlet. Were there issues with mounting the turbo the opposite direction?

[elRey]

Quote, originally posted by nairmac »

I have a question- I see that you have had some clearance issues with the exhaust downpipe, and that the intake crosses over the turbo before it does a 180 and down to the inlet. Were there issues with mounting the turbo the opposite direction?

The DP clearance issues have been addressed.
There were two reasons for mounting the turbo this way:

1) this turbo on this manifold would interfer with the block a small bit mounted the other way when compressor was clocked the way I wanted. It may have fit rotating it differently.

2) the solution for the cross over inlet was much more elegant than the solution for the charge pipe, axle, and oil return line fitment.

[Jeebus]

great progress... maybe I missed this but what are you doing for fueling?

[elRey]

Quote, originally posted by Jeebus »

great progress... maybe I missed this but what are you doing for fueling?

No, I haven't mentioned anything thus far.

Just to get the car up and running, and to heat cycle the setup I'll adjust the wastegate so it's open all the time and run stock 2.0L management.

Then I'll probably close the WG a bit for ~3-5psi on same management.

Once I'm over that. I'll swap the harness, coils and ECU over to AWP 1.8T add needed sensors/solenoids like MAP, AIT, MAF, N75, etc. Still keeping boost really low. And I expect to hit limp mode once in a while.

Once I get it running on AWP wiring and ECU, I'll add 380-440 injectors with VR6 MAF + unisettings. And that's where it will stay until wife gives me back my wallet and I can get intank fuel pump, 550-630 injectors and software.

[automan89]

damn rey..im jealous...when i need fab help i kno just the man to talk too!!!!

[askibum02]

Very cool build thread...

[GTijoejoe]

Quote, originally posted by askibum02 »

Very cool build thread...

x2

[elRey]

Quote, originally posted by askibum02 »

Very cool build thread...

Thanks guys!!

It's all down hill from here. Just got all the welding done.

[85gli8v]

Don't stop with the coolness. I've almost got the wife convinced to let me build her wagon. It has to wait until the Helios is done, though.

[elRey]

more updates tomorrow.

[elRey]

Some weld closeups:

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Modified by elRey at 2:14 PM 5-11-2009

[elRey]

I couple of weeks back I spent a little time in a machine shop I use to work in and did a few pieces I needed:

I had a ISV block-off plate near FPR so I decided it would be good place for a VAC source:

flange/bung for IAT:

1" offset bracket for top IC pipe:

I had to notch the acc. belt tensioner to clear bracket:

flange for VR6 intake boot that was slid over, and welded onto turbo inlet pipe, then filed down.:

Modified by elRey at 2:16 PM 5-11-2009

[elRey]

I little dress-up:

before:

[elRey]

DV placement:

Look under IC pipe from Coolant res side:

As it stands now. Last on-car fit test before I take everything back off to mount on mock motor to clean and tighten everything. Then back on for finally assembly.

Modified by elRey at 2:23 PM 5-11-2009

[vwtoby]

awesome build...

cant wait to see numbers..

[ZeeuwVW]

Nice work. I love your attention to detail.

[askibum02]

Definitely some cool progress!!

[papichulo7]

Quote, originally posted by sgolf2000 »

you definitely love some OE parts.

Clearly. Great build; what attention to detail.

[SHOUTER]

CAN I GO FOR A RIDE WHEN ITS DONE ?