DarkSideGTI Big Turbo Build Round 2

**huichox4** · 03-21-2011 10:22 AM

wow that is amazing

hey Could you check the thickness of the bushings before they are thrown back at the car? Thanks man

**DarkSideGTI** · 03-25-2011 02:05 PM

I will try to measure those bushings for you this weekend.

So I am trying to work out my new coolant system. I am deleting the coolant ball and instead running a filler neck with a coolant catch tank. I was previously running my turbo coolant lines from the lines that used to go to the TB heater. I am looking for a way to clean this whole thing up and will be running -6 stainless braided lines for my turbo feed/drain. I am also looking into running the IE billet heater core fittings but stopping down from a -10 to -8 from the IE SAI blockoff plate to the heater core feed. It seemed like my old setup didn't have the best flow and my coolant would boil a bit in the expansion tank sometimes. Where is the best place to tap into for the turbo feed? would right between the block and the heater core work well?

Here is a diagram.

Also I am not sure how to go from the AN hose on the heater box outlet to the t-stat housing.

**spitfire481** · 03-25-2011 08:40 PM

hey buddy

**DarkSideGTI** · 03-26-2011 01:28 AM

is that epoxied in?

**spitfire481** · 03-26-2011 08:48 AM

Tapped and a smear of 3m panel bond on the threads for a good seal and piece of mind that it can never come apart lol

**dave13s4** · 03-27-2011 02:18 AM

I'm working on getting a full tstat housing made in billet aluminum, it may be a few weeks but I'll keep you posted.

**spitfire481** · 03-27-2011 11:31 AM

that sounds awesome but ridiculously expensive to have it built because of the complex shape

**DarkSideGTI** · 03-27-2011 11:35 AM

For sure. Your solution looks like it will work perfectly. Is that -8 line?

**spitfire481** · 03-27-2011 11:40 AM

its already been up to temp a few times, everything sealed up nicely. actually i feel that just the housing tapped with teflon on the threads would have been just fine since its such a rigid plastic but i preferred a little extra security and used the panel bond on the threads since i know how strong it is. if something where to ever fail on the housing and it needed to be replaced that fitting is only a $7 part so its no loss not being able to remove it

-10

**DarkSideGTI** · 03-27-2011 09:20 PM

Thanks man, I think I will do the same. I got another question for you. I painted my block with POR15 and was planning on using their engine enamel on top of it. Well it was like 40* this weekend so too cold to paint the block. Do you think I need to paint the block with the enamel? I know the POR15 fades in sunlight, but the motor won't be seeing much sun.

I got a little work done today. I accidentally left my torque wrench at IE so I wasn't able to torque any of the bolts yet. Today I got the crank damper and front cover installed. I also got the new lower timing chain on with new guide and tensioner. I also cleaned up all the gasket surfaces on the block, oil pan, and head. Once everything was nice and clean I put the new head gasket on followed by the head. I installed the head bolts just finger tight for now.

My ECS timing chain/guide kit didn't include the guide that goes in between the cams. My old one looked pretty bad so I want to get a new one, but I can't find it at ECS or on WorldImpex. Does anyone know the part number? The Bentley just refers to it as "guide rail".

#1 in this pic.

**spitfire481** · 03-27-2011 09:58 PM

id use the enamel over it. it kind of browns out from uv rays and heat might cause it to do the same

**DarkSideGTI** · 03-28-2011 11:09 AM

Will do.

Can anyone help me with the part number for that rail guide?

**huichox4** · 03-28-2011 11:31 AM

Originally Posted by DarkSideGTI

Will do.

Can anyone help me with the part number for that rail guide?

No idea about the part number, but are you sure the kit you bought was not supposed to bring it? When I bought mine it came with all new rail guides, chains, tensioners even all the bolts for it.

**DarkSideGTI** · 03-28-2011 11:55 AM

Originally Posted by huichox4

No idea about the part number, but are you sure the kit you bought was not supposed to bring it? When I bought mine it came with all new rail guides, chains, tensioners even all the bolts for it.

no it doesn't include that part, but mine def needs a new one as the old one is all brittle and has some nice grooves in it.

**DarkSideGTI** · 03-28-2011 04:03 PM

I called the dealer and got the part number. They have to order it from NJ though so it won't be here til later this week or early next week. I think I am just going to time the motor with the old one on there and then swap the new one on once I get it.

**Hybrid_Hatch** · 03-28-2011 04:11 PM

Originally Posted by DarkSideGTI

I called the dealer and got the part number. They have to order it from NJ though so it won't be here til later this week or early next week. I think I am just going to time the motor with the old one on there and then swap the new one on once I get it.

you should, that engine needs to be inplace and up and running for the dyno this weekend!

**DarkSideGTI** · 03-28-2011 04:30 PM

Originally Posted by Hybrid_Hatch

you should, that engine needs to be inplace and up and running for the dyno this weekend!

Sadly that is not going to happen.

**JamesO** · 03-28-2011 07:43 PM

Originally Posted by DarkSideGTI

I called the dealer and got the part number. They have to order it from NJ though so it won't be here til later this week or early next week. I think I am just going to time the motor with the old one on there and then swap the new one on once I get it.

Sorry, I was digging through some boxes to no avail. Looks like you got it sorted out. In my experience that guide does NOT come with "chain & guide" kits. It doesn't usually see as much wear as the other guides.

**DarkSideGTI** · 03-28-2011 11:11 PM

Originally Posted by huichox4

hey Could you check the thickness of the bushings before they are thrown back at the car? Thanks man

21mm top and 26mm bottom. I need to re-paint the top bushing now. I tried removing it and the paint cracked. Hope they hold up in the car.

**spitfire481** · 03-28-2011 11:23 PM

they are more than likely going to stress crack when you put the motor/trans weight on them. if you got them prepped enough it should not flake off though. mine have a few stress cracks in the paint but its sticking just fine.

**DarkSideGTI** · 03-29-2011 01:03 AM

Originally Posted by spitfire481

they are more than likely going to stress crack when you put the motor/trans weight on them. if you got them prepped enough it should not flake off though. mine have a few stress cracks in the paint but its sticking just fine.

They didn't have krylon fusion at Home Depot so I bought Rustoleum for plastics, figured they were about the same. I figured if it flexes it will crack a bit no biggie.

**Hybrid_Hatch** · 03-29-2011 10:32 AM

wal-marts in utah carry the krylon fusion. for future reference.

**DarkSideGTI** · 03-29-2011 10:55 AM

Originally Posted by Hybrid_Hatch

wal-marts in utah carry the krylon fusion. for future reference.

Yeah, I was about to drive down the street to Wally World, but figured the Rusto would be about the same. we will see how they hold up.

**huichox4** · 03-29-2011 11:08 AM

thanks for the numbers man, sorry about the paint

**DarkSideGTI** · 03-30-2011 05:04 PM

I was bored at work so I made a diagram of my new coolant system with a parts list I need to order from Summit.

this should be cheap. add this to the new lines for the BOV and WG as well.

**spitfire481** · 03-30-2011 07:49 PM

yea but when you get it all together you will be happy you did it.

**Draxus** · 03-30-2011 08:06 PM

INA Engineering is making a billet T-Stat housing right now. Should be out soon.

Where did you find the diagrams of the coolant system?

**DarkSideGTI** · 03-30-2011 08:13 PM

Originally Posted by Draxus

INA Engineering is making a billet T-Stat housing right now. Should be out soon.

Where did you find the diagrams of the coolant system?

I'm good with the plastic housing.

I got the diagram from the Bentley.

Well I made a couple changes grand total for all fittings/hoses shipped was $242.72.

Spitfire, do you have any more pics of your setup?

**Draxus** · 03-30-2011 08:17 PM

Originally Posted by DarkSideGTI

I'm good with the plastic housing.

I got the diagram from the Bentley.

Well I made a couple changes grand total for all fittings/hoses shipped was $242.72.

Spitfire, do you have any more pics of your setup?

A Bentley CD manual, online, where? I am looking for some.

Thanks!

**DarkSideGTI** · 03-30-2011 08:20 PM

It's a MKIV PDF one with an R32 Addendum.

**Draxus** · 03-30-2011 10:06 PM

Originally Posted by DarkSideGTI

It's a MKIV PDF one with an R32 Addendum.

Hmm, I'm hunting around for it. What is the file size?

**spitfire481** · 03-30-2011 11:13 PM

Originally Posted by DarkSideGTI

Spitfire, do you have any more pics of your setup?

nah just what i posted. after i got that together i threw the cover back on it since its raining all week. i dont have ac or heat so it just runs to the back of the head.

**dr. b** · 04-01-2011 01:54 PM

Originally Posted by DarkSideGTI

It's a MKIV PDF one with an R32 Addendum.

if this is less than the $1M Bentley, i'd be interested as well.
(isn't that funny that i'll spend millions on parts, but hesitate to spend $150 on the manual?)

**DarkSideGTI** · 04-01-2011 11:44 PM

got my fittings and hose from Summit today.

I tapped the thermostat housing with a 1/2" NPT tap and threaded the 1/2" NPT to -10 AN adapter.

**spitfire481** · 04-02-2011 12:17 AM

nice. your pics are better than probably any parts supplier i have dealt with

VWVortex

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