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    Thread: alaincopter's brasil-style AP turbo fox build

    1. Member
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      '90 VW Fox Turbo, '93 Grand Cherokee V8
      10-25-2010 05:06 PM #1
      Since my original thread got deleted when the forum changed, I've decided to make a new one showing everything that has been happening to this car since day one. It is a lot of stuff, so please be patient!

      Let me start by saying that I've always wanted to have a nice Voyage, ever since I was a kid. I was born and raised in Brazil so I really grew up around BX platform cars. My first favourite car was my aunt's white Voyage.

      Anyways, onto the fox-coloured Fox. This is when I first got it in 2007.









      The 87 Trans AM you see beside it eventually got sold to fund the Fox; the grand cherokee was my first vehicle and I still drive it to this day.

      At 318,000 km, this Fox appeared to be in good shape... until you looked at the engine bay. Many would say this is not a good candidate for a turbo project; but this car caught my eye and I could really see its potential underneath all the dirt and rust.





      I sort of knew what I was getting into. This was a very inexpensive car to begin with and I knew that making it nice would be a neverending story, but I was really set on saving this one, one little thing at the time. First thing to do was to get some new wheels for it. I was always set on following a brazilian OEM+ style with this car so I decided on similar wheels to the Voyage Sport - the BBS 14" basketweaves from the late '80s BMW 325. Pics:









      Then right before winter came (bad idea but whatever) I decided to cut the springs.

      Ghetto thing to do, but Foxes ride surprisingly well with cut springs.



      First actual brazilian goodies on the car: '91-94 Voyage Sport smoked tail lights and clear markers:



      Last edited by alaincopter; 04-17-2014 at 12:22 AM. Reason: new picture hosting

    2. Member
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      10-25-2010 05:09 PM #2
      Believe it or not, this car made it to New York City and back. It also made it to Chicago, and to Montreal several times.



      Last edited by alaincopter; 04-17-2014 at 12:18 AM. Reason: new picture hosting

    3. Member
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      10-25-2010 05:17 PM #3
      then the real fun (and lots of work) was about to begin. Took a trip to Brazil in '08 and came back with a turbo kit and some other goodies.
      Here's my cousin holding the box with my biagio .48/.50 turbine, outside the Fast Street performance shop in Campinas, São Paulo (those folks are awesome to deal with and very knowledgeable in anything related to adding horsepower to AP engines)



      A couple of pics from inside their shop





      And then back home with the goodies waiting to be installed.



      Last edited by alaincopter; 04-17-2014 at 12:17 AM. Reason: new picture hosting

    4. Member
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      10-25-2010 05:26 PM #4
      Well, you gotta start somewhere. I knew I would have to revisit most of my install to clean everything up and do things right, but I was really eager to get the car back on the road and feel some power/hear that blow-off sound that I decided to leave some things for later (ie do a dirty install) and get the car working quickly. Yes, this involved a "custom exhaust" made mostly of flexpipe!







      Luckily I then moved out of student housing, into a house with an actual garage!
      Last edited by alaincopter; 04-17-2014 at 12:14 AM.

    5. Member
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      10-25-2010 05:31 PM #5
      Flexpipe exhaust, PVC plumbing: I really had it all! Fun times though. I could finally enjoy driving a rough turbocharged Fox. It wouldn't be long till it was back into the garage for some more work.







      Last edited by alaincopter; 04-17-2014 at 12:13 AM. Reason: new picture hosting

    6. Member
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      10-25-2010 05:36 PM #6
      Homemade AFR meter, following the schematics on the scirocco.org website... using a DVD case!!



      Last edited by alaincopter; 04-17-2014 at 12:11 AM. Reason: new picture hosting

    7. Member
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      10-25-2010 05:42 PM #7
      Then, rough as it was, the Fox made it to Columbus, OH for the Odd School Class Reunion '08. Met some of you awesome folks, and sure got some mixed opinions on what my Fox had become so far.









      Last edited by alaincopter; 04-17-2014 at 12:10 AM. Reason: new picture hosting

    8. Member
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      10-25-2010 05:49 PM #8
      I had gone to OSCR with hopes of having Jonathan build me a proper exhaust; unfortunately, he was incredibly busy with preparations and with other people's cars. He did help me a lot by tuning my DPR and giving me a ignition advance/retard diaphragm from an Audi turbo; but then back home something had to be done about my exhaust. So I got myself a pipe bender, got the downpipe welded, ruined many feet of pipe, and eventually got it done.





      Last edited by alaincopter; 04-17-2014 at 12:06 AM. Reason: new picture hosting

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      10-25-2010 05:58 PM #9
      Then I did a few more things... replaced the rear drums for wagon-sized ones and cleaned up rust back there, also cleaned up more rust in the engine bay, and got a fuel distributor from a 5cyl Audi, since the car was leaning out in the very top end.



      Last edited by alaincopter; 04-17-2014 at 12:05 AM.

    10. Member
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      10-25-2010 06:15 PM #10
      Next was an adjustable cam gear, new alternator, and finally the brazilian fog lights got installed. New foxes found their way into my house, too.

















      Went to my friend's cottage which is called the "Fox Farm" too



      Last edited by alaincopter; 04-17-2014 at 12:04 AM. Reason: new picture hosting

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      10-25-2010 06:33 PM #11
      Up until that point the car still had a 4-speed on it. Shortly after having acquired a limited slip differential from Brazil, I got a hold of the first PSA 5-spd tranny I could find and installed it. Turned out that transmission had a bad synchro on 2nd gear.



      Turned out being okay, since I had an excuse to install this ceramic clutch that arrived shortly after. The stock clutch had been slipping the whole time since the turbo had gone in.
      Last edited by alaincopter; 04-17-2014 at 12:01 AM. Reason: new picture hosting

    12. Member
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      10-25-2010 06:39 PM #12
      So I pulled the known good PSA from the blue 4-door Fox I had, cleaned it all up, painted it and installed it.

      The installation can be seen in more detail in this thread "Transmission and clutch swap DIY"











      Last edited by alaincopter; 04-16-2014 at 11:59 PM.

    13. Member
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      10-25-2010 06:48 PM #13
      Finally got the centercaps for my wheels:







      Some new parts, mercedes V8 fuel distributor (cause more fuel is always good), callaway valve cover:







      Last edited by alaincopter; 04-16-2014 at 11:57 PM. Reason: new picture hosting

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      10-25-2010 06:53 PM #14
      Some pictures with my friend Andrew's jetta



      Last edited by alaincopter; 04-16-2014 at 11:54 PM. Reason: new picture hosting

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      10-25-2010 07:04 PM #15
      Now the new teardown. Time to do things right!





      Last edited by alaincopter; 04-16-2014 at 11:52 PM. Reason: new picture hosting

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      10-25-2010 07:08 PM #16
      Some new and refinished parts... big valve head back from the machine shop, multi-layered steel head gasket (corrado G60), freshened up distributor, manifold cleaned up and flameproof coated, and my turbo next to a K03 for comparison







      Last edited by alaincopter; 04-16-2014 at 11:51 PM. Reason: new picture hosting

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      10-25-2010 07:09 PM #17
      I think this is too much for one page!

    18. Member
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      10-25-2010 07:19 PM #18

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      10-25-2010 07:19 PM #19

    20. Member
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      10-25-2010 07:23 PM #20

    21. Member efritsch's Avatar
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      10-25-2010 08:48 PM #21
      Wow Dude!! Your car is looking good!!!

    22. Member DubbinChris's Avatar
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      10-25-2010 11:00 PM #22
      Great thread man....way to recap

    23. Moderator the brit's Avatar
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      10-25-2010 11:49 PM #23
      Love it
      | œ Orchid Euro Importation œ |

      Currently driving or working on too many cars...
      | '93 Fox 16v - PVW | '99 Greenland Polo Diesel | '89 Rallye Golf | '83 Golf GTi RHD | '75 Swallowtail |
      | '82 Caddy 1.9D | '85 VW LT Car Transporter | Mk2 Jetta Limo | '90 Jetta 8V | '96 VW LT35D | '03 SpintLT35 | '02 GTI 337 | '03 GTI 20v |
      | '09 Aprilia RS125 | '81 Kawasaki AR80 | '59 NSU Quickly | '64 Honda Cub C65 + '65 C105 | Trek Madone 7.9 | Trek Crockett 9 |

    24. Member oRANGEJULIUS's Avatar
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      10-25-2010 11:59 PM #24
      so cool

    25. Member QuantumSyncro's Avatar
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      10-26-2010 02:06 AM #25
      awesome!

    26. Member
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      10-26-2010 02:23 AM #26

      nice fram filter
      are you running 8 fuel injectors or 4?
      I really suck at smog.

    27. Member ianwilson's Avatar
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      10-26-2010 09:06 AM #27
      are you still driving on your cut springs?
      well, i know your not driving it at this point but you know what i mean
      My car is slower than yours.

    28. 10-26-2010 11:02 AM #28
      muitoo massa cara...não sabia que tu viria pra o Brasil, senão já ia ve se tu negociava a frente dele cmg hehehe

      abraçoss

    29. Member reddfoxx's Avatar
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      10-26-2010 11:45 AM #29
      Great pix and writeup, and thanks for reposting it all. Hope it's not long till it's on the road again.
      Not red, not blue- red, white, and blue

    30. Member
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      10-26-2010 12:02 PM #30
      Thanks for the comments, folks!

      Yes the car still has cut springs believe it or not. I keep meaning to have some coilovers brought from Brazil but it hasn't happened yet. Soon enough.

      I am running 4 injectors for now, which may change to 8 in the future. Let's see how the car does on the road and if it starves for fuel at the psi setting I want first. I have a feeling that it will be fine with 4 for now, and that I'll be able to move to 8 in the future when I rebuild the engine with forged pistons and crank the boost some more.

      Anyways, I thought the thread would move to 2 pages after post #20; guess it takes a bit more than that. I'll keep going with the pictures!

      Last edited by alaincopter; 04-16-2014 at 11:49 PM. Reason: new picture hosting

    31. Member
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      10-26-2010 12:07 PM #31
      Disbritutor and spark plug cables in:

      Last edited by alaincopter; 04-16-2014 at 11:47 PM.

    32. Member
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      10-26-2010 12:13 PM #32
      Exhaust manifold and turbo in:

      Last edited by alaincopter; 04-16-2014 at 11:46 PM.

    33. Member
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      10-26-2010 12:18 PM #33
      Water pump, rad, oil filter support



      The body of the wastegate also got the same flameproof coating (i love bbq'ing my parts)

      Last edited by alaincopter; 04-16-2014 at 11:44 PM. Reason: new picture hosting

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      10-26-2010 12:19 PM #34
      Started refinishing the wheels in silver one by one - first stripped them completely with paint stripper spray then sanded them free of what little residue had stayed



      Last edited by alaincopter; 04-16-2014 at 11:43 PM. Reason: new picture hosting

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      10-26-2010 12:24 PM #35
      That's because the goal is this:



      This is a photoshop on this picture Adam took of my fox back in OSCR 2008

      I still prefer the BBS basketweaves to orbitals, but it'd be nice to have orbitals as a 2nd set

      Last edited by alaincopter; 04-16-2014 at 11:42 PM. Reason: new picture hosting

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