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    Thread: my aba/16v turbo build..

    1. Member JustTheTip's Avatar
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      04-08-2009 02:02 PM #1
      My aba/16v turbo build...finally..

      The car is a 1998 t-red 2.0GTi, believe it or not its rust free,garage kept her whole life...Ive been assembling parts for a long time now so hopefully it will all go smoothly and quickly. My goal is to have her on the road again by waterfest but im not getting my hopes up b/c I still have some large hurdles to tackle...I should add that this is a starting point, after h20 im planning on taking it all back out and shaving the bay,etc..Enough of the b.s ill get on to the good stuff...

      Engine:

      obd1 block (forged internals and oil squirters)
      wossner custom abf pistons with valve cutouts
      lightened and balanced crank
      shot peened rods
      kent cams heavy duty longblock 16v t-belt
      new t-belt tensioner
      new waterpump
      low temp thermostat
      new main,rod, and intermediate shaft bearings
      once assembled it will be balanced
      vf engineering mounts
      (im probably forgetting some things but its a start)
      im working on making my own "dizzy gizzy"...ill update on that later

      Induction:
      Bought a Holset hy35 and a rebuild kit flows 60lbs/min(600+hp)
      log style t3 flanged ext. gated manifold
      cx racing 38mm wastegate w/external dump
      greddy type rs bov
      cx racing intercooler and piping (to start)
      Water/Meth injection to top it off..
      Software:
      MsNsE w/Sequential C.O.P
      Transmission:
      02a Corrado
      Limited slip Diff...
      vr6 stage 2 clutch kit
      vr6 lightened flywheel

      Suspension:
      H&R cup kit(NEED)
      Front and rear upper and lower sway bars(NEED)
      Alot of other stuff eventually...
      ...will edit post to add more..enjoy
      *Anything that has (NEED) next to it I would appreciate help sourcing*
      TIA



      Modified by JustTheTip at 11:27 AM 11-23-2009

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    2. Member 20B_envy's Avatar
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      04-10-2009 09:11 AM #2
      all you'll need is a 38mm unless you go bigger on the turbo... everything else looks pretty good... whats the comp ratio yield on the wossner abfs?

    3. Member JustTheTip's Avatar
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      04-10-2009 09:24 AM #3
      8.0-1...high boost...
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    4. Member 20B_envy's Avatar
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      04-10-2009 09:32 AM #4
      damn... i was thinking about getting pistons done for mine, but probably closer to the 9.5:1 range

      you getting any headwork done?


    5. Member JustTheTip's Avatar
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      04-10-2009 09:48 AM #5
      For now its gonna be stock brand new head,i wanna break in the block/tune the megasquirt i just ordered yesterday (and give the wallet a break).while she is still on the road im going to build up one of the other heads I have laying around w/titanium springs/retainers,oversized valves..etc..


      Modified by JustTheTip at 6:35 PM 4-28-2009
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    6. Member JustTheTip's Avatar
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      04-10-2009 09:51 AM #6
      edit: im going to be running 10psi this year,then going for high boost and over 400 whp next year..just hope the corrado 02a can handle it..
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    7. Member JustTheTip's Avatar
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      04-11-2009 08:59 AM #7
      so the front end is off ready for the engine/trans to slide right out when i borrow my buddy's hoist..got some ****ty pictures from my iphone...ill try to get them uploaded..
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    8. Member JustTheTip's Avatar
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      04-16-2009 07:20 PM #8
      up top to help source parts to get this going..!


      Modified by JustTheTip at 2:16 PM 4-21-2009
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    9. Member JustTheTip's Avatar
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      04-21-2009 02:19 PM #9
      im planning to get this as much together as possible may 1-3rd..any help finding the manifold and other stuff is appreciated!!
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    10. Member JustTheTip's Avatar
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      04-24-2009 10:54 PM #10
      here are some teaser shots from my iphone of the intake manifold and the short block that finally came back from the machine shop..but was worth the wait.



      rmr did a great job on the manifold thanks to Issam



      enjoy...

      Modified by JustTheTip at 10:57 PM 4-24-2009


      Modified by JustTheTip at 10:58 PM 4-24-2009


      Modified by JustTheTip at 11:00 PM 4-24-2009

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    11. Member dub101's Avatar
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      04-25-2009 10:15 PM #11
      WOW

      that manifold looks awsome. I hate that I missed that buy. Are the wossner pistons forged turbo units? Looks sick! cant wait to start my abf build.
      Stan

      Stan
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      11.65@123.5 and all motor cars are still faster...
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    12. Member 20B_envy's Avatar
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      04-25-2009 11:15 PM #12
      it's been over a year, no need to beat a dead horse. i was bummed out that i couldn't get on with the group but that's it, other opportunities will arise!


      Modified by 20B_envy at 9:17 AM 4-26-2009

    13. Member Issam Abed's Avatar
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      04-26-2009 03:02 AM #13
      Quote, originally posted by 20B_envy »
      i'm pissed too man... i was originally on the list then got hit with a dui and couldn't pay right away even though i had guaranteed money coming in another 2 weeks and issam bumped me off the list

      You asked to be taken off the list?

    14. Member JustTheTip's Avatar
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      04-28-2009 05:17 PM #14
      well thanks to issam I should have my turbo manifold very soon

      The msnsv3.0 board is about half way done..

      Once i get my arp headstuds(tomorrow) ill bolt the head on and time it..

      before I put the new engine and 02a in Im going to convert the shifter/clutch setup, clean the bay and re-wire the entire bay from relay board to headlights I cant wait for that part...

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    15. Member JustTheTip's Avatar
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      04-28-2009 06:28 PM #15
      Quote, originally posted by dub101 »
      WOW

      that manifold looks awsome. I hate that I missed that buy. Are the wossner pistons forged turbo units? Looks sick! cant wait to start my abf build.
      Stan


      yes..they are the wossner low compression forged pistons...sorry must of missed your post for a minute..
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    16. Member JustTheTip's Avatar
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      05-07-2009 08:28 PM #16
      Never loaded pics of the progress so far so:

      I purchased a hy35 off a guy in ohio and he never shipped it and was ignoring me so im waiting on paypal to refund my money..F'ing dirtbag
      In the mean time I bought another hy35 and when I took it apart to rebuild it this is what I found..



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    17. Member JustTheTip's Avatar
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      05-07-2009 08:29 PM #17
      obviously that used to be the turbine wheel..another F'ing dirtbag..
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    18. Member 20B_envy's Avatar
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      05-07-2009 08:44 PM #18
      ouch... that's one haggard turbine wheel

    19. Member JustTheTip's Avatar
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      05-08-2009 07:47 AM #19
      yessir it is, Its gonna cost me 400$ to replace my turbine wheel/shaft then send out both wheels,shaft, the two thrust washers and piston rings to be balanced. Itll take about a week turn around (hopefully) but the good news is that I can remove everything from the the center section, acid dip it,then rebuild it/polish compressor housing and acid dip the turbine housing while they have the shaft and wheels. I am going to try out this ceramic coating I found, they say its good to over 1500 degrees but we'll see. The compressor wheel still looks brand new:


      So when this process is complete this thing should look/perform like brand new..


      Modified by JustTheTip at 8:03 AM 5-8-2009

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      05-09-2009 02:47 PM #20
      For another 195.00 you could have a new T3/T4 shipped to you.
      I have one of these, 15 psi for a while, no problems...
      http://forums.vwvortex.com/zerothread?id=4056485


      Modified by tg60dd at 11:53 AM 5-9-2009

    21. Member JustTheTip's Avatar
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      05-10-2009 02:09 PM #21
      thanks but im sticking w/my holset. I love there technology..
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    22. Member 20B_envy's Avatar
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      05-10-2009 02:59 PM #22
      holset FTW

    23. Member JustTheTip's Avatar
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      05-14-2009 09:51 AM #23
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    24. Member JustTheTip's Avatar
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      05-21-2009 09:54 PM #24
      the head is bolted on and torqued,waiting on machine shop to finish w/my intermediate shaft conversion to time it, until they get done w/it i have plenty of other things to finish; wiring, msns/e board, polishing compressor housing..etc..
      here's some more eye candy









      Here's the compressor housing:




      ..more to come soon...





      Modified by JustTheTip at 9:50 AM 5-23-2009

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    25. Member JustTheTip's Avatar
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      05-21-2009 09:58 PM #25
      Forgot two...





      Modified by JustTheTip at 9:54 AM 5-23-2009

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    26. Member 20B_envy's Avatar
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      05-21-2009 11:19 PM #26
      mmmm anti surge corona

    27. Member JustTheTip's Avatar
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      05-22-2009 07:29 AM #27
      I like cars.

    28. Member JustTheTip's Avatar
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      05-23-2009 10:02 AM #28
      found out some more disappointing news,when the turbine wheel went it took a thrust washer with it and the thrust washer destroyed the bearing housing on turbo, Im buying a new complete center section for about 350$ more, so the turbo will be brand new w/used housings that should look better than new.. Im also going to drive to kentucky to beat the guy who sold it to me w/a bat...
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      mk3 aba/16vt
      05-24-2009 07:50 PM #29
      That's pretty shady. What's the reason that you didn't decide to go the 20v route?

    30. Member JustTheTip's Avatar
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      05-25-2009 07:53 PM #30
      Shady to say the least, the 16v head is proven to flow higher cfm vs 20v head, plus its a way to keep the mk2 16v alive...
      I have been thinking about doing a 20/20 swap on my daily but idk yet..
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    31. Member JustTheTip's Avatar
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      05-26-2009 07:16 PM #31
      I got the clutch cable out and the master cylinder in, about 1 hour w/ a stubby 13mm wrench at about a 1/4 turn at a time to get one nut tightened up on the master cylinder..that was a little irritating...so then i figured id install the vr throttle cable while i was under the dash, looked for it for about 20min untill i realized I forgot to bring it home from work..it was sitting in the parts department the whole time...
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    32. Member JustTheTip's Avatar
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      06-02-2009 08:41 AM #32
      I got the vr throttle cable installed and the shift box/cables installed after a little more wiring I can put the dash back together..
      The intermediate shaft came back from the machine shop and I got the motor timed, Im using the 16v cam gear on the aba intermediate shaft to allow a correct cam signal to the MsNsE for sequential COP and the kent cams belt was to small , it took about an hour to get on then was tighter than a guitar string, so it took another hour to get it off. I ended up using an AEB belt and it fit like a glove...

      The best news is that the company I bought the bearing housing for my turbo from screwed up and sent me a brand new complete turbo instead..! So looks like all the b/s I had to put up with ended up w/me getting a new turbo for less than half price...

      Ill update w/more pics later..

      Also If anyone wants to buy a kent cams heavy duty t-belt I now have one for sale...




      Modified by JustTheTip at 11:24 AM 6-2-2009

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    33. 06-02-2009 09:15 AM #33
      what head did you use?

      thanks


    34. Member JustTheTip's Avatar
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      06-02-2009 09:21 AM #34
      2.0l 16v
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    35. Member JustTheTip's Avatar
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      06-02-2009 11:33 AM #35
      Looking for some opinions here...
      Im making a cap for my cam position sensor on the aba distributor...

      Im thinking a cut down beer can but I cant decide.. Any idea's?

      I think this will work well but would like other opinions/alternatives...

      I like cars.

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