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    Thread: Build Thread not necessary

    1. Member Snitches Get Stitches's Avatar
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      2002 Hybrid VR6T Jetta, 1997 Lifted Subie Outback
      06-07-2011 12:34 AM #76
      It has been a test of patience to get to this point. I am hoping we are rounding the corner on everything, and it should start to come together quickly in the next couple weeks.

      In my large order, I found a coolant filler neck that allows me to plumb my AN lines right on through. This billet piece will be plumbed on the top coolant line from the top of the radiator to the biggest port on the t-stat. I also ordered a billet piece from Gruven, to hold the auxilary coolant pump. Does anyone have any pictures of where their aux pump resides in the OEM area? Gruven only has a pic of the 12v AAA. I am going to plumb my turbo coolant lines from the crack pipe and the port on the front of the block. The crack pipe is a billet piece I bought when I originally swapped my 24v in. I removed the barbed fitting and will be installing 1/4NPT to -6AN adapter. The block will have the OEM hose end pulled out, and we will tap the block to 1/4NPT to use the same adapter piece. The majority of my plumbing is Earl's braided nylon hose. Turbo lines will be braided ss.
      Should be a pretty, yet extremely functional bay.
      Thanks for the support guys!!

    2. Member GRN6IX's Avatar
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      06-07-2011 09:30 AM #77
      I think this is what you need. It's in the rubber isolators to the left of the heat exchanger:



      (Not my car, & the crack pipe is on backwards in this pic)

    3. Member Snitches Get Stitches's Avatar
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      06-10-2011 01:03 AM #78


      Some rather large plumbing fittings here...-16AN inline filler neck, a bigger adapter necking things up to
      -20AN for the t-stat housing, and some -16AN to 3/4NPT fitting for the t-stat housing.

      Still waitin for more......

    4. Moderator DannyLo's Avatar
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      06-10-2011 04:18 PM #79
      Definitely interested in seeing how you modify the cooling system to accept AN instead of OEM rubber. I'd love to do this in the future if I could to my VRT

    5. Member Snitches Get Stitches's Avatar
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      06-10-2011 05:40 PM #80
      We are adapting to the AN lines by tapping the inside of the plastic t-stat housing and threading in NPT to AN fittings. The radiator was adapted with weldable AN fittings. It is a pricey change over, but should supply years of worry-free and leak-free use. Plus all hoses and fittings are rebuildable if we do see any leaks or melt a hose.

    6. Member Snitches Get Stitches's Avatar
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      06-10-2011 06:01 PM #81


      This is a billet coolant filler neck for the top hose coming off the radiator. This top hose comes off the rad at -16AN where it connects to this filler piece. From there is goes up to -20AN thanks to the blue fitting. It is -20AN hose to the biggest port on the t-stat housing...tapped for -20AN to 1 1/4NPT adapter fitting. Its complicated and expense doubles as the size increases. Its a small fortune after an already pricey build...but i felt this build deserved the personal touch.

      Here is some of my intake plumbing...gotta love AWIC....i have maybe 3 feet total in plumbing. I will be running 2.5" piping off the turbo to the intercooler..coming out of the intercooler is straight 3" piping to my 80mm TB. The intercooler will be mounted in the OEM battery location. Only thing to figure out is where to plumb my Godzilla DV...that puppy is huge.

    7. Member GTIVRon's Avatar
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      06-10-2011 11:42 PM #82
      Why only 2.5" in?
      2002.5 Jetta 1.8T - TOTALED (dodging deer)
      2002.5 24v GTI - TOTALED (rear-ended by a Jeep)
      1992 Corrado SLC - Daily Driver Status
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    8. Member Snitches Get Stitches's Avatar
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      06-10-2011 11:59 PM #83
      2.5" is the size of the turbo outlet on my T4 GT3582R turbo...looking back at some of Foffa's threads, he gave us the equations to calculate adequate piping size for horsepower goals. 2.5" off turbo with 3" coming out of a 1000hp intercooler core is adequate for expansion of the cooled dense air mass post-ic, and it matches up almost perfectly to the 80mm Hemi Throttle Body with 3.25 to 3" silicone reducer....no need for anything bigger pre-intercooler with the size of this turbo. Unlike Rictus, i will have a couple pieces of silicone in the bay here and there.
      When this motor is dropped in an S4 in a couple years with a GT40/42, then we will see what 8-900 whp requires for piping. However, for my build, and my hp goals, 2.5" to 3" is more than adequate.
      Last edited by Snitches Get Stitches; 06-11-2011 at 01:55 AM.

    9. Member GTIVRon's Avatar
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      06-11-2011 04:11 PM #84
      Just seems like a restriction that won't yield any benefit.. Why not just go 3" in 3" out (at the IC)? I guess it may not be necessary but it won't hurt..
      2002.5 Jetta 1.8T - TOTALED (dodging deer)
      2002.5 24v GTI - TOTALED (rear-ended by a Jeep)
      1992 Corrado SLC - Daily Driver Status
      2012 Golf R - Weekend/Need A/C Status

    10. Member Snitches Get Stitches's Avatar
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      06-11-2011 05:16 PM #85
      Really no need to...its not a restriction at all...2.5" pipe can flow more than enough pre-intercooler...and post-intercooler it necks up to the size TB.

      For those interested in the t-stat housing...




    11. Member Snitches Get Stitches's Avatar
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      06-18-2011 02:24 PM #86
      Worked on front subframe, front sway bar, and steering rack. Also finished some of the fittings on the t-stat housing. Got to save a couple hundred bucks in fittings and hose by staying with
      -16AN hose from biggest port on t-stat housing.




      Tommorrow we finish front brakes and tighten all lines. Moving right along.......
      Last edited by Snitches Get Stitches; 06-18-2011 at 04:18 PM.

    12. Member Snitches Get Stitches's Avatar
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      06-19-2011 01:29 PM #87












      Bleeding brakes and all lines....motor goes in next weekend.
      Last edited by Snitches Get Stitches; 06-19-2011 at 04:04 PM.

    13. Member GTIVRon's Avatar
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      06-19-2011 07:18 PM #88


      Can't wait to see it finally together!
      2002.5 Jetta 1.8T - TOTALED (dodging deer)
      2002.5 24v GTI - TOTALED (rear-ended by a Jeep)
      1992 Corrado SLC - Daily Driver Status
      2012 Golf R - Weekend/Need A/C Status

    14. Member Snitches Get Stitches's Avatar
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      06-19-2011 10:18 PM #89
      Very excited here as well.....if we can get her running before August, then the build took a month shy of two years....

      Its such a great feeling to see parts, purchased or powdercoated a year and a half ago and put on a shelf, finally be bolted onto the car. We still have a ton of work to do, but the finish line is in sight.
      Thanks for following the build and supporting the work being done. This is a backyard build being done by a professional mechanic and an inept owner--just the two of us, every weekend for the past 7 months or so...Our time and tools are limited, but we are doing work.

      Thanks for the well wishes....here is to hoping my motor will be in my bay this time next week.

    15. Moderator DannyLo's Avatar
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      06-20-2011 04:18 AM #90
      May I ask where one can get that gold bar that's tying together the mount points on your subframe?

    16. Member Snitches Get Stitches's Avatar
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      06-20-2011 10:53 AM #91
      That gold bar is the front sway...it is a Neuspeed 25mm front sway bar kit that i've had on the car for years. I had it powdercoated with the brake calipers and rear sway....also got new mounting hardware from MJM autohaus to refresh bushings, links, etc...

    17. Moderator DannyLo's Avatar
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      06-20-2011 01:34 PM #92
      Oh wow, my eyes were messing with me last night I didn't even notice it was the FSB

    18. Member Snitches Get Stitches's Avatar
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      06-20-2011 01:42 PM #93
      Yup...thats the sway....its just powdercoated gold cause i had to much time on my hands during the past two years. I will also be running a powdercoated Neuspeed lower tie bar...just to stiffen the subframe up a bit more. This is similar to some of the OEM audi TT subframe connectors and does the same job. Anything to tighten up that subframe and help put power down to the ground.

    19. Member Snitches Get Stitches's Avatar
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      06-24-2011 11:35 PM #94
      Gearing up for a big weekend. The car will be on the ground, with all brake lines and fuel lines cleared and buttoned up. Depending on weather and amount accomplished, the motor may be put in next weekend, to leave room for finalization of turbo and coolant lines. We are doin' work.
      I'll keep y'all updated.

    20. Member GTIVRon's Avatar
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      06-25-2011 01:45 AM #95
      Looks like you'll be able to have some "first start" videos up, maybe even some street pulls (hint).. by the end of July. Awesome project man.
      2002.5 Jetta 1.8T - TOTALED (dodging deer)
      2002.5 24v GTI - TOTALED (rear-ended by a Jeep)
      1992 Corrado SLC - Daily Driver Status
      2012 Golf R - Weekend/Need A/C Status

    21. Member Snitches Get Stitches's Avatar
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      06-25-2011 07:16 AM #96
      Yea....thats the idea. First start-up and break-in before end of July. I am off the entire month of August before my internship in September. I will be putting serious mileage on my rig during this time.
      I will certainly keep you guys updated. Still got a ton of work to go, but this is the rewarding part of getting new parts on to the car.

    22. Member GTIVRon's Avatar
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      06-25-2011 09:33 AM #97
      This is a seriously intense build. I can't help but be jealous of what the end result is going to be, lol. But man, you've really earned all the joy this monster of a car will bring you.

      I do have a quick question though... What are you doing about the trans? I can't remember. Did you get an LSD?
      2002.5 Jetta 1.8T - TOTALED (dodging deer)
      2002.5 24v GTI - TOTALED (rear-ended by a Jeep)
      1992 Corrado SLC - Daily Driver Status
      2012 Golf R - Weekend/Need A/C Status

    23. Member Snitches Get Stitches's Avatar
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      06-25-2011 10:52 AM #98
      Yup...stock 02M with Peloquin installed. Clutch is a Southbend stage 5+ with custom steel flywheel. Hoping this set-up will hold the 500+ wheel tourque spike.
      Peloquin was installed by Josh at Nothing Leaves Stock way back when we did the initial 24valve swap. When we decided to build the motor, the trans went back to Josh for a check-up. He replaced all seals, as well as synchros on 2nd and 3rd due to some slight marks on the brass from grindings. Drivetrain is completed with Vf mounts and DSS axles.
      Thanks for the kind words...i will be giving free rides anytime during the month of August.....

    24. Member GTIVRon's Avatar
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      06-25-2011 05:58 PM #99
      Make a trip down here to North Texas. You'd be the center of any monthly DFWeuros meet. Ha ha. Just bring a "build thread" photo album to show of the goodies that can't be seen. (Well, mainly, I'd be able to take you up on that ride, ha ha)

      Those DSS axles are expensive as hell. Haven't seen them on a 24v before, but USP (close to where I used to live) use them on their 10 sec 12v Jetta, so I'd put my trust there. I bet the trans gives out before the axles/clutch will, though. More than likely you'll only be breaking traction, ha ha. But that would be the perfect excuse to drop it into an AWD platform sooner.
      2002.5 Jetta 1.8T - TOTALED (dodging deer)
      2002.5 24v GTI - TOTALED (rear-ended by a Jeep)
      1992 Corrado SLC - Daily Driver Status
      2012 Golf R - Weekend/Need A/C Status

    25. Member Snitches Get Stitches's Avatar
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      06-25-2011 09:17 PM #100
      Atlantic City, NJ to North Texas would be quite the trip. I will probably be heading north to Vermont and Maine to see my brother return from Anchorage, AK in Mid-August. Either way...i will break this motor in locally for 3-500miles before contemplating highway miles. Break-in will be done violently, just as she will be driven.

      The axles i have are DSS stage 2.9 that i bought at least 3 yrs ago or so. I managed to bust up both side's cv joints at stock power levels; with DSS nice enough to honor a warranty. I see the drag guys using even pricier stage 5.somethings these days....$$$$ i don't have and wont really have for this chasis. In Fall 2012, when i start getting paid again, i am going shopping for an S4 as the next chasis for this motor. This GT35 will do for now, but i have ideas on a billet wheel'd GT40/42R and alot more power to the ground awd-styles.
      I'm hoping i can keep these puppies in one piece, but i have some extra oem axles lying around just in case DSS needs to rebuild my joints again. I wish they would take these back in partial payment towards those big boy axles.
      Last edited by Snitches Get Stitches; 06-25-2011 at 09:44 PM.

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