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    VWVortex


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    Thread: MK4 Jetta Wagon 16vT build

    1. Member elRey's Avatar
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      16vt 2.0L MK4 Jetta Wagon | B6 A4 Avant
      04-18-2009 10:18 PM #51
      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

    2. Member nairmac's Avatar
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      04-19-2009 07:34 AM #52
      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?
      If you make something idiot proof, a better idiot will come along.

    3. Member elRey's Avatar
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      04-19-2009 10:36 AM #53
      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.

    4. 04-19-2009 07:00 PM #54
      great progress... maybe I missed this but what are you doing for fueling?
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    5. Member elRey's Avatar
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      04-22-2009 10:43 PM #55
      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.

    6. Member automan89's Avatar
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      05-03-2009 09:46 PM #56
      damn rey..im jealous...when i need fab help i kno just the man to talk too!!!!
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      Quote Originally Posted by Rutledge View Post
      Well, then, I'm here to "ruin" the vortex for you. I'm sorry you hate fun.

      Also, not to sound like a turd, but just mute it when I talk or something...the next 8 shows are really fun. But again, I think you might hate fun...oh well, try it any way.

    7. Moderator askibum02's Avatar
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      05-06-2009 08:23 AM #57
      Very cool build thread...
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    8. Member GTijoejoe's Avatar
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      05-06-2009 08:29 AM #58
      Quote, originally posted by askibum02 »
      Very cool build thread...

      x2
      2.0T+034efi+meth = 300+whp = Part out PM me for anything

    9. Member elRey's Avatar
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      05-08-2009 04:16 PM #59
      Quote, originally posted by askibum02 »
      Very cool build thread...

      Thanks guys!! [IMG]http://**********************/smile/emthup.gif[/IMG]
      It's all down hill from here. Just got all the welding done.




    10. Member 85gli8v's Avatar
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      05-09-2009 03:33 AM #60
      Don't stop with the coolness. I've almost got the wife convinced to let me build her wagon. [IMG]http://**********************/smile/emthup.gif[/IMG] It has to wait until the Helios is done, though.

    11. Member elRey's Avatar
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      05-10-2009 11:26 PM #61
      more updates tomorrow.

    12. Member elRey's Avatar
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      05-11-2009 02:04 PM #62
      Some weld closeups:






      ---------



      ---------



      ---------


      -----------




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

    13. Member elRey's Avatar
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      05-11-2009 02:14 PM #63
      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

    14. Member elRey's Avatar
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      05-11-2009 02:18 PM #64
      I little dress-up:









      before:

    15. Member elRey's Avatar
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      05-11-2009 02:20 PM #65
      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

    16. 05-11-2009 03:00 PM #66
      awesome build...
      cant wait to see numbers..
      1995 GTI VR6 - 90s project...
      2003 B5.5 Variant - Swagz - sold in 6s
      1998 Jetta GT - Bluey - RIP
      1990 Golf - Der Turd - PVW May'05

    17. 05-11-2009 04:13 PM #67
      Nice work. I love your attention to detail.

    18. Moderator askibum02's Avatar
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      05-11-2009 10:47 PM #68
      Definitely some cool progress!!
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    19. 05-12-2009 06:04 AM #69
      Quote, originally posted by sgolf2000 »
      you definitely love some OE parts.

      Clearly. Great build; what attention to detail.

    20. 05-12-2009 04:40 PM #70
      CAN I GO FOR A RIDE WHEN ITS DONE ?

    21. Member elRey's Avatar
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      05-18-2009 02:06 PM #71
      Drove the car to SOWO and on the MT. run Sun morning. Car rode great. I have the wastegate adjusted open, so I'm only making 5psi up top. And I have timing pulled back ~6* via unisettings on stock 2.0L AZG management. Just breaking it in.
      Finally mock-up to clean and tighten everything before finally assembling it on the car.









      Turbo, manifold, and DP on car:



      Modified by elRey at 2:10 PM 5-18-2009

    22. Member elRey's Avatar
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      05-20-2009 12:02 PM #72
      Just a running update....
      I've been running ~7psi up top and car runs fine (not ideal) on stock 2.0L AZG managament with VR6 MAF housing and 1.8T 317cc injectors.
      I have unisettings @
      Primary fuel -> ~ -15%
      Ign offset -> ~ -6*
      Did some logs and trims are 0.8% and 1.6%
      The most timing pull I see is 5.3* and that's randomly stepping on throttle a little from cruise. During a run I see maybe 4* up top.
      Inj. duty peaks @ 63%
      I only wish I could get a true MAF reading. Anyone know a somewhat accurate calculation on for a VR6 MAF vs 1.8T/2.0L MAF housing reading? I know the VR reads 34% less air, but I don't think that dividing the MAF value by .66 is accurate. Anyone?

    23. Member Blu_Hare's Avatar
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      05-28-2009 02:42 PM #73
      Quote, originally posted by elRey »
      I know the VR reads 34% less air, but I don't think that dividing the MAF value by .66 is accurate. Anyone?

      I don't have any idea, but you would multiply by .66, not divide.
      either way, AWESOME build!! just read through both builds, great work!

    24. Member elRey's Avatar
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      05-28-2009 08:29 PM #74
      Quote, originally posted by GTrabbIt »
      either way, AWESOME build!! just read through both builds, great work!

      Thank you.
      Quote, originally posted by GTrabbIt »
      but you would multiply by .66, not divide.

      Are you sure about that? If VR housing reads 34% (smaller value) less air and then I multiply that value by .66 I get an even smaller value.
      If 100g/s is the actual amount. VR reads 66g/s (34% less). 66g/s * 0.66 = 44g/s
      but
      66g/s / 0.66 = 100g/s

      Thanks for looking.

    25. Senior Member MFZERO's Avatar
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      06-01-2009 02:51 PM #75
      you are one crazy dude! congrats on making a sweet build sick!

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