SirSpectre's White Jetta build

[SirSpectre]

Its about time I start up on a long-ish term build thread for my 98 Jetta GT. Plans are to have it completed by May 2012, at least the engine portion. It will need a paint job, rims, window tint, and some front end style to call it done

Here is how she stands as it is:





Currently stock exterior.

Engine has 2.0 8v, OBX header, Supertech high flow valves, Intake cone, MAF deleted. LW Flywheel, Ported and decked head, 270 Cam, LW lifters, 2.25 TT SS Exhaust.

Software is Megasquirt 3/3x running EDIS wasted spark. Plugs gapped at .054 and running e85.
This was the first stage of the process. Installed and tuned by yours truly. Dyno'd at 133 whp with 135 wtq. Shes real fun to drive currently, but I want more!

Megasquirted:



And mounted in the interior:



Under the hood it doesn't look that great currently. It will be cleaned up as time goes on.

Plans for the build:

2.0 ABA to 16v swap
Rebuilt head with stock valves, stock cams (for now) Dual springs, LW lifters, adj cam gear
T3/T4 turbo to be decided
Tubular exhaust manifold
2.75" Turbo back cat delete
630cc injectors @ 4bar (may need to go bigger)
Custom designed SRI. (Design is completed and flow simulations are being run and design refined through solid works and CUDA flow designs.)
OBDI ABA throttle body <-- NO!!!!! Mustang TB now!!!!
Air/water IC
O2A tranny swap with 6 puck clutch and LW flywheel
Snow white paint job (BLINDINGLY WHITE!!!)
Window Tint
Rims to be decided, But they will be 16x 7.5"
Engine bay as shaved as much as I feel like putting effort into.

Looking to get 300 whp after all is said and done.

So Lets get to work:

Found an OBD I ABA on craigslist for $100 and o2a tranny for $175. Tranny will go in much later so lets get to work on the engine.

Your Basic ABA engine:


Stripped down and cleaned:




Guy I bought the engine from didn't know if it ran so I was taking a risk with blown engine. The head gasket was blown, but more concerned about the piston walls

They appear to be all good. WHEW



Part Pile!:


Few days later got the sucker all stripped and painted up. Engine design I know some of you will scream at me, but the block is aluminum and the rest of the parts are going to be high gloss black or polished. Plan on polishing the alternator, valve cover, A/C compressor, intake, IC piping and turbo housing.





Got everything off and the oil drain return welded on the pan. Crappy weld job but she seals. And painted:



Next up: Waiting for oil pump, IM shaft, gear and pulleys to arrive before I can put the bottom end together.

[Dmoneythegreat]

I aba/16vs

Do work. Watching this.

[mkIIIVDUB]

I aba/16vs

Do work. Watching this.

x2

[BigJohneyK]

...alright im in.

[AJmustDIE]

Been waiting!

[98JettaGT2011]

definitely gonna follow this one.

[SirSpectre]

Been waiting!

You can't post until your car is done

[SirSpectre]

Got the 16v head in. Got to remove the valves and its off to the shop!



Then got a call from UPS saying my delivery of crank gear and pulley is going to be 2 days late due to train crash!

[thatcrazylaxdude]

Subscribed.

[jbigs268]

In

[vento86]

Thats a healthy dyno number for that aba.. Props dude.

And watching, I love aba builds. Best motor vw ever made

[skateboards and mk2s]

Not really an ABA build. I think that 300 sounds very easy for a 16vT. There was or maybe still is a crazy fast rabbit in england that was around 400.

[SirSpectre]

Small update.

I got the crank gear and pulley in from BBM already modified for the conversion, and the IM shaft and Oil pump with drive gear are here. Not pictured is the timing sprocket for IM shaft, already got that painted and sitting with the engine. Tomorrow if its not raining (finally I hope) it all goes on and the bottom end gets buttoned up and moved to my living room for assembly over winter in a nice warm place. Also a good conversation piece for guests

[95jetta17]

watching this

[brandon0808]

watching this

X2. Don't think we've met yet before though?

[SirSpectre]

Doubt it, unless you were at Late model throttle the other weekend. Haven't been able to get out much at meet with the other locals.

As for updates, I broke my impact wrench so nothing done on it since.

[BigJohneyK]

Doubt it, unless you were at Late model throttle the other weekend. Haven't been able to get out much at meet with the other locals.

As for updates, I broke my impact wrench so nothing done on it since.

Cause you need an impact to work on your car...

[SirSpectre]

Only for that damn crank bolt. If you have an idea how to keep the engine from spinning while a breaker bar does the work, I'd love to hear it. Seriously, I've tried everything

[AJmustDIE]

2x4 wedged against crank and block.

[zrace07]

Cha.
































Boi.

[AJmustDIE]

Update sir.

[riddie]

In and local. May have to ask you for some help if I megasquirt my cabby

[SirSpectre]

In and local. May have to ask you for some help if I megasquirt my cabby

Be happy to help with that.

No updates yet, I have been incredibly lazy this past week, and Skyrim came out. I may do some work tomorrow, well today now I guess. Gotta get everything buttoned up and inside to warm before it snows!

[flat6guy]

Only for that damn crank bolt. If you have an idea how to keep the engine from spinning while a breaker bar does the work, I'd love to hear it. Seriously, I've tried everything

Set car down and place into gear. Then you hit it with the wrench

[SirSpectre]

Set car down and place into gear. Then you hit it with the wrench

Would work if the engine wasn't outside the car ^_^

[BigJohneyK]

hahaha...

[PKstrategy]

you need heat.
light that sucker up and hit it with a good impact wrench.

[vacuumnoise]

Thats a healthy dyno number for that aba.. Props dude.

And watching, I love aba builds. Best motor vw ever made

this.

[DGR33]

Good thread and I'll be watching your progress. I'm very interested in the 16 v head swap. I am curious as to why you didn't pull the crank, and rods. For a couple hundred bucks you can replace the bearings and rings and have the block hot tanked. You're right there. Go for it!

[SirSpectre]

Good thread and I'll be watching your progress. I'm very interested in the 16 v head swap. I am curious as to why you didn't pull the crank, and rods. For a couple hundred bucks you can replace the bearings and rings and have the block hot tanked. You're right there. Go for it!

I am very tempted to do such. Engine is lowish mileage (65k) and everything looks great on the inside. I don't think its needed. But since its still pretty stripped, if I come across a few extra bucks I will do it and replace bearings and rings just to be sure. There is a fantastic automachine shop 4 blocks away that do great work, so its still on the table. I did just start a new job with a nice pay increase so it very well may happen over the winter if the budget allows.

As for updates I got everything together on the bottom end (no pics sorry ) But then I realized this engine doesnt have A/C so the brackets to mount the compressor arent there. I can't get a good look at my car to view how its mounted. Any idea which brackets are different or what needs to change? And no, A/C delete isnt an option! Its a daily driver and I like the cold!

[SirSpectre]

Ok update time. Snapped some pics of the 16v internals going in. Few people have asked about the differences in the parts needed. Well here ya go:



IM Gears. On the left is your ABA gear and on the right is your 16v one. There are ways to use the OEM one, but good luck with that. Very hard. The Shafts themselves are identical EXCEPT for the bolt thread for the gear. There are ways to use the ABA shaft but its just easier to use the 9a one. I dont have a good picture of the crank gear, but the gear to be used is 5mm wider so the serp pulley must be shaved to compensate. Luckily BBM sells the pulley pre-modified

Then you use the 9a oil pump



Its a bit different than the ABA pump as the drive shaft goes above to where the dizzy is (was):



And with the IM shaft to oil pump drive gear installed:



@AJmustDIE 2x4 jammed in the crankshaft worked like a charm. Though had a casuality of war:

yes thats 3/8 drive socket. I didnt have a 19mm 12 point in half inch So that didnt work. After a nice conversion 3/4 socket is .002" difference and 12 point. Took a 4' bar to break it loose. Got it done though:



V belt on the pulley is stuck. The old one got a stripped bolt so I'm just gonna buy a new one. Seems far easier than trying cut it off or get the bolt off, so the serp pulley is just finger tight on currently.

In other news, I have decided on rims and which turbo!

Going with 17x7.5 BBS LMs. Friend of mine has a set for sale and I always came back to them when searching for a nice looking set.

And the turbo will be GT2876r with 64 A/R

[AJmustDIE]

Wooooooooo!!!!!!1

[BHCgreene]

I like what your doing..

Just a couple concerns..

You should probably clean the block better. I see a lot of bubbled up rust under that paint. It will chip off like a mother not that long down the road... ALSO. those piston walls look a little shiny to me. I would suggest getting it ridge reamed and some honing.. You can do it yourself if you buy the tools and read up on it. Or just take it to a machine shop.

Also.. bearings are only rated at 130k miles before they fall out of spec... I would highly suggest putting some new bearings in there and also buying some arp hardware..

There is one motor I know inside and out and everything that can or will or should happen. That motor is the aba. I have fully built 6 of them for personal cars. I have made aba/16v and 5 of the 6 were obd1 aba motors... because they are the best.

Just trying to save you from some future headache.

[MrCypherr]

I'm watching this thread. Can't wait to see what you do with this.

[Bariman82]

I like what your doing..

Just a couple concerns..

You should probably clean the block better. I see a lot of bubbled up rust under that paint.

If you're referring to the textured surface on the pulley end of the block, no, that's just pitting. Mine looks like that in places. I had the machine shop burn the thing in the oven, so it's clean, but that pitting was hidden under all the rust.