my 67mm sfwd build

[1.8t67]

i figured i would finish up my build here in this thread. Most of the guys who have been around for a while know what i have been building. this build has been going on for a while now, and is just about finished up.

i started out like 99% of you guys. did some basic mods to the oem turbo, and upgraded the k03 to a 50trim t3/t4. went through the headaches of having a custom tune, and enjoyed the car as much as possible for the season. i had built a completely custom system. unfotunately, i was naive then, and had the wrong people involved in helping me make the most of my car. i started talking with other companies, and got my wheels spinning. i decided, i wanted power. but more importantly, i wanted a number. a single digit number. there were alot of things i wanted in this build which haven't been done before. when i say alot, i mean ALOT. i didn't want a cookie cutter set-up. i wanted simplicity, ease of working on, and something that would make people lean forward at.

there are alot of small details i've done to help with simplicity, or increase functionality, that i'm sure i'm missing. this build has been a blast. most of all, this car was built to still be driven on the street and be a sleeper. when i say sleeper, i mean SLEEPER. there has been around 450lbs removed from the car, yet it still looks like a street car inside. there are so many custom parts in this build it makes my head hurt. i have engineered, helped engineer so many parts...ugh. but the end result is exactly as i pictured. vision to reality. all of this takes time. there have been many of changes to the car. we may have engineered a part, and made multiple changes to it before i was satisfied. well, the time has come that i think i'm satisfied. haha.

before i get on with the pictures, and build details, i need to thank the people who have helped me, and have been tortured through out the years of this build. if you want a powerful, reliable, fast car...these are the people to get up with. the companies listed below are the same names you see on alot of builds. there is a reason. they listen, and help you achieve. i cannot thank these guys enough. i will be putting together a race schedule with the companies below, look for that soon.

paul calado@boostfactory "killa" on the tex
arnold lee@pagparts "al@pagparts" on the tex
kevin black@lugnuts tuning "lugnuts" on the tex
bob quindazzi@qedpower "bobq"on the tex
ron shearer@shearer fabrications
brad campbell@brewspeed
ed woolsey@forcefed "ed@forcefed" on the tex

Car:
2002 VW GTI

Engine:
1.8t, 06A engine block
83.5mm bore (1.9t now)
pauter rods
wiseco pistons 9.5:1 c/r
polished crank
AEB 60-2 trigger wheel
steel tool pin t-belt cog
ARP main studs
ARP rod bolts
ARP head bolts
AEB head, ported and polished
supertech 1mm O/S inconel exhaust valves, single groove keepers
oem intake valves
cat gold springs
roston titanium retainers
cat billet cams
cat cam pulley
ross machine racing intake manifold
obdI vr6 tb
calico coated main bearings
calico coated acl +.001" rod bearings
brewspeed billet motor mounts

Turbo system:
custom PTE t67 dbb, .68/t4/ptrim
shearer fabrications custom t4 manifold
shearer fabrications downpipe
shearer fabrications charge piping
PTE 750 intercooler
tial 44mm wastegate
tial 50mm bov
ffe catch can

Engine Management/Boost control/Monitoring:
autronic sm4 ecu
lugnuts tuning race harness
mac boost solenoid
ptc nylon tubing/fittings
vss input for boost ramping
stewart warner maximum performance 0-10k rpm tach
stewart warner maximum performance -30/40psi boost gauge
aem wideband

Fueling:
10 gallon aluminum fuel cell
twin bosch 044 fuel pumps
-8 feed to pumps, blend into a "Y" block to a single -10
-10 fuel rail
aeromotive fpr
-8 return
injector dynamics 1000cc injectors

Engine/Oil cooling:
cxracing aluminum honda civic 1/2 rad
custom head flange with -16 AN return fitting
custom t-stat flange with -16 AN inlet fitting
b&m racing oil cooler
mocal non thermostatical oil filter housing adaptor

Transmission/Clutch:
oem oj2 trans
clutch masters fx700 twin disc clutch
oem axles

feel free to ask any questions while i keep this thread updated.

the car,

the build,

parts pile building up,























Modified by 1.8t67 at 9:47 AM 4-21-2010

[Budsdubbin]

its gonna be a beast

[Mike Pauciullo]

a lot of 67mm turbos this summer.

[Dub-Nub]

Yup i just let go in my pants

nice build. Im trying to get my set of mounts from him.

[zerb]

that poor o2j doesnt stand a chance.

[Ronnie@Eurojet]

Looks dope man!!!

[1.8t67]

no it doesn't, but i'm not upgrading the box until next winter. for now, i'm done putting money into the car.

[GLI_jetta]

Quote, originally posted by zerb »

that poor o2j doesnt stand a chance.

[EF9Si]

Nice build! All those goodies and you still running an open diff?

[VW1990CORRADO]

sexy mounts. where?

[1.8t67]

Quote, originally posted by EF9Si »

Nice build! All those goodies and you still running an open diff?

yup. a diff will be thrown in before the first track day.

[dj givv]

niiiice.....waitin to see what you had up your sleeve. Lookin good thus far.....u takin that thing on the street at all?

[cincyTT]

Jason, you crazy. Even from behind its intimidating with the dual pumps poking out

[VW1990CORRADO]

v84lnch?

[Boomdaddymack]

i really like what you have done here

[NOLA_VDubber]

you sold me my first turbo kit

It's about time this thing get goin

[dubinsincuwereindiapers]

Glad to see you posted this over here too

[dj givv]

Quote, originally posted by dubinsincuwereindiapers »

Glad to see you posted this over here too

whereelse you readin? audizine?

[1.8t67]

Quote, originally posted by VW1990CORRADO »

v84lnch?

[dubinsincuwereindiapers]

Quote, originally posted by dj givv »

whereelse you readin? audizine?

I can't divulge that info... Not the zine

[1.8t67]

Quote, originally posted by dj givv »

whereelse you readin? audizine?

vwsport. been posting about this build for 2 years? lol.
cincy, it's tucked up a bit more now. i think maybe next year i'll pull the cell and shoot it in black, and do black fittings/lines to the pumps. hide them a bit.

[Richard_Cranium]

so you are running solid cams.... what shims? and who set it up?

and why OS exhaust and not OS intakes? when i set mine up, Bob told me OS ex would not net me anything gain-wise, and to just stick with OS intakes only.... i realize you changed the ex valves cuz they suck, just wondering why not stock size is all.

and you arent worried about the stock intake valves not keeping up with the rest of the setup (IE: triple groovers versus single groover)???

[TeaEightySix]

I think the exposed fuel pumps setup might give away the sleeper look Ever think about switching to steel braided lines for the pumps? Looking good man

[1.8t67]

Quote, originally posted by Dick_Head »

so you are running solid cams.... what shims? and who set it up? yes, solid lifter profile cams. i decided to try something different. our hydro lifters are really nice units, so i went back and forth with bob, and we both felt these cams would be ok on hydro lifters. only plan on spinning to 9500-9700. this is one of those things that we decided to try out. if it works, this will open up our selection of cams. if it doesn't....well, lol. my machine shop assembled the head, minus the cams/lifters. bob timed the cams in. and why OS exhaust and not OS intakes? when i set mine up, Bob told me OS ex would not net me anything gain-wise, and to just stick with OS intakes only.... i realize you changed the ex valves cuz they suck, just wondering why not stock size is all. i went with OS exhaust valves to try and move the exhausted air quicker than oem sized. i have a large turbo to light off, so anything to help me extend the powerband, is what we looked for. while i agree using OS intakes would prolly net more power, the cams i choose will allow for plenty of air to come into the cylinder. and you arent worried about the stock intake valves not keeping up with the rest of the setup (IE: triple groovers versus single groover)??? nah, i'm confident the oem intakes will keep up. this is something else that will be swapped out after this season. the intakes don't require nearly the seat pressure the exhaust valves do, so keeping the triple grove keepers wasn't a concern. now i have seen the single grove keepers pull WAY down inside the retainers, because of the incresed seat pressure.

[EF9Si]

Quote, originally posted by 1.8t67 »

yup. a diff will be thrown in before the first track day.

Awesome!

[EF9Si]

Quote, originally posted by cincyTT »

Jason, you crazy. Even from behind its intimidating with the dual pumps poking out

Looks like those beastly domestic drag cars roaming around here! Bad ass!

[avihai-t]

which cams you use?

[schwartzmagic]

SHWING!!!

[gdoggmoney]

Hope you cleaned that deck surface again before putting it together.

The force rust exerts is pretty impressive as it spreads.

[O2VW1.8T]

Build looks awesome jason, can't wait to see this beast run.

[1.8t67]

Quote, originally posted by gdoggmoney »

Hope you cleaned that deck surface again before putting it together. The force rust exerts is pretty impressive as it spreads.

if any rust comes flying through the engine off the deck, i've got more to worry about than flying rust...............thanks for the input. i've only built about 12 of these engines. think i'm getting pretty good at it.

Quote, originally posted by O2VW1.8T »

Build looks awesome jason, can't wait to see this beast run.

thanks pete.

ordering my injectors here in a bit. got a ton of wiring wrapped up today. just gotta plug things into relays and the sm4. wiring should be wrapped up tomorrow. i had to pin out my power windows. lol. but, i also powered everything, and good thing i did. only one brake light was coming on. fixed.

[gdoggmoney]

Quote, originally posted by 1.8t67 »

if any rust comes flying through the engine off the deck, i've got more to worry about than flying rust...............thanks for the input. i've only built about 12 of these engines. think i'm getting pretty good at it.

It is what it is.

I'm not trying to harsh your mellow here, but realize that rust is not going to fly off, it is going to exert force where it should not be.........

Just think about it for a while. It may sink in.

[1.8t67]

Quote, originally posted by gdoggmoney »

It is what it is. I'm not trying to harsh your mellow here, but realize that rust is not going to fly off, it is going to exert force where it should not be......... Just think about it for a while. It may sink in.

right.......well, i'm fairly certain that the deck was clean when i assembled this engine. but if it makes you feel better, you can paypal me $100 for a new head gasket, and i'll take clean pics for you.

[Richard_Cranium]

so, solid profile cams (1003775 BTW for you who asked) and hydro lifters....

hmmmm. oh well, i hope it works for you.... i already had the solid lifters so i used them.

you know i am hoping you get it done in a big old bad fashion

[Ed@ForceFed]

nice let me know if you need any last minute things

-Ed Woolsey