Wrong forum, but I know most of you all and don't know anyone on the A2 forum (nor have I even really read any of it) so I'm doing this here. I also have a thread going on the vwdiesel.net board but have not updated it in a while.
We are finally going into high-gear with this project. My Wife has been without a car for more than a year now, and since she has recently lost her job, she will probably need one soon. We were lucky in that we both lived pretty close to work so it was no problem for me to drop her off, but who knows what will happen with the job market the way it is, so it's time for her to have some wheels!
The goals here were to provide a cheap, fun to drive source of transportation, with ample creature-comforts. Since meeting me, she shares my passion for Diesel VW's, and really likes the notion of biodiesel as well, so a diesel car it is. Her previous car was a 2000 Toyota Celica GT, and she really liked the sporty ride so she wanted something with a similar driving experience. A nice A2 with GTI bits would fit the bill nicely- the Celica was a fun car to drive, it actually felt very Scirocco-ish, but the seating position sucked and the interior was typical Japanese-tupperware. So, here's where we are right now:
The Car: A 1986 Golf naturally-aspirated Diesel. A fairly clean example, found it really cheap from a nice guy (and VW enthusiast) in Columbus, the engine had bad rings and a blown tranny, but they were already pulled from the car.
It's a nice car! Came fully loaded for being a n/a diesel- AC and power steering, yeah! Both big positives for Laura. First order of business was to trade in the Westy grille and headlights for dual-rounds and euro-H4's- Done. (no pics yet)
Then we tore down the engine. Yuck!
Actually not that bad. No visible damage from anywhere, just really greasy. The cylinder head was an aftermarket replacement from Topline.
Found out why after we got into it. Each piston had a valve indentation in it. No biggie. Machine shop cleaned them right up, and they will be ceramic coated anyway.
Pile 'o junk:
Next up, I bead-blasted all of the brackets and external engine parts- and painted some of them.
And, after getting the block cleaned, checked, and honed, painted it too:
The crank was checked, balanced and polished, everything A-ok.
We managed to score locally a nice ACN-code tranny (.75 5th with 3.67 final) which is going to get cleaned up, re-sealed, and possibly a budget-peloquin kit installed.
This is all old news, but now we are going forward with it. We have ordered a bundle of parts from GAP and a local vendor and VW-diesel guru, Myke_W from Athens, OH. (keeping as much business local or as close to home as possible) The head is going to the machine shop soon to be cleaned and slightly ported and have a performance valve grind.
Here's the plan for the engine. I have a used T3 turbo and manifold from a VW TD engine, it's actually a big turbo for what it was used for, I was going to use it on my TDI but now it's getting rebuilt and used here. We have no intercooler yet, probably going with the cheapest one I can find, either stock 1.8T or G60 side-mount style. I'm gonna have to build my own downpipe and possibly exhaust. The pistons are going to have a top-coating applied from a company called Swaintech. It's a thermal-barrier type coating and I think it's good insurance since this block does not have piston oil-squirters. We are using an A2 gasser intake manifold. The injection pump is the factory N/A one that has been rebuild recently, so it has no LDA device for boost enrichment. I've been sketching up a design for a home-made device that should do just about the same thing, sorta based off of the old BAE turbo kit device. We'll have the full assortment of gauges- boost, EGT, and oil temp along with the factory gauges. We are going to toss out the non-tach cluster and replace it with either a GTI cluster or a proper diesel-cluster with tach. If using a GTI cluster we need to build a tach circuit. Other things that we already have coming: GTI wheel flares, GTI seats, GTI tail-lights, small-bumper chin spoiler, we are using the 16v disc brakes from my Scirocco (which is getting a 5-lug conversion) on this car, using the 14" teardrops from my Scirocco on this car. (already have 5-lug wheels for the Scirocco too) So when it's done, it will very closely resemble the Euro-only "GTD" model, which basically was a GTI car with a turbo and intercooled diesel engine.
Should be fun!!!
Brendan (and Laura)