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    Thread: **16vt Cabriolet Classic Budget Build**

    1. Member Stangy's Avatar
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      1999 Subaru R-STI, 1993 Cabriolet Classic 2.0 16vt on MS1 v2.2, 2012 Civic Si, 2004 VW Golf GTI BT
      12-15-2011 03:51 PM #1
      My budget cabby winter built. 16vt FTW! My budget for this budget turbo build was $2000 MAX-not including and Advil for the headaches. With patients and some luck i was able to purchase all the parts i needed via kijiji, ebay and most importantly the classifieds here on Vortex. The work was done by myself so this kept costs down. My goal is 220whp at 8.7psi- daily driver.

      Don’t mind the messy engine bay- it will be cleaned up before it hits the road!

      Specs:
      • 1993 Cabriolet Classic
      • 2.0 16v 9a (rebuilt 30,000km ago)- Full engine rebuild, incl new pistons, rebuilt cylinder head 3 angle valve job, block re-bored 1 size up
      • Precision 6031 60trim .63Ar
      • Rebuilt 020 w/80% Shim Kit & Bolted Diff- TDI 5th Gearing
      • 034 Motorsports 16v Turbo Header
      • Lightened Flywheel w/Sachs Sport Clutch
      • HKS SSQV Bov
      • RMR Fuel Rail
      • Autotech sport cams. I+E
      • Megasquirt V1-2.2. Spark and fuel. LC1 Wideband o2 sensor, for precise AFR integrated with Megasquirt.
      • Aeromotive Adjustable FPR
      • Precision FMIC
      • Tial Wastegate (8.7psi)- Open Dump
      • Neuspeed 8mm Ignition Wires
      • Jegster Rad Fan+ Shroud
      • CIS Fuel Pump
      • Braille 15lb Sport Battery
      • BFI Oil Catch Can
      • Custom SS 2.5” Exhaust and DP- exit out passenger side (incomplete)
      • 62lb Siemens Injectors (EVI)
      • 42DraftDesign Vacuum Log Manifold
      • BFI Short shifter
      • V-Maxx Coilovers
      • 16v scirocco calipers and rotors. HAWK pads
      • 3:1 power steering rack for tighter steering
      • Gold BBS RZ 15" wheels.
      • BFI lower control arm brace
      • BFI Rear Sway
      • Full Leather Carrado Front/Rear


      Missing a bunch of items I am sure!

      Started Like This:


      Surgery:


      Classifieds, KIJI Raid:


      In Progress.....Picture is dated- I will update soon!


      Engine is still a work on progress! I will post updates as they come.

      Enjoy!
      Last edited by Stangy; 04-01-2012 at 07:51 PM.

    2. Member Sr. Karmann's Avatar
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      91 Corrado 2.0l 16v on MS3X, Parked like Jurassic... 83 Cabby 1.8l 16v... 88 Powerplay XLT-185
      12-15-2011 06:46 PM #2
      8.7 psi on a 6031

      add another 1k for ...........
      Quote Originally Posted by crazynorweegian View Post
      Good luck, might want to get vaccinated for "while-I-am-in-there" syndrome.
      tek-euro.com SpoonFedTuning

      my Corrado's specs on corrado-database / My Corrado Build Thread / My Cabby Build Thread / My Boat Build: 18' Powerplay w/5.7l V8

    3. Member Stangy's Avatar
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      12-15-2011 08:21 PM #3
      Haha odd pairing yes, engine will get more boost in the future! Turbo is good for 550hp at 30psi. For what I want at 250whp its matted perfectly.

    4. Member Stangy's Avatar
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      1999 Subaru R-STI, 1993 Cabriolet Classic 2.0 16vt on MS1 v2.2, 2012 Civic Si, 2004 VW Golf GTI BT
      12-16-2011 08:54 AM #4
      My observations:

      ATP 16V Turbo Manifolds are terrible-see image below:


      Problems you will/may encounter especially if you are running a t3/t4 can be found below:
      • WG does not fit
      • Your turbo hits your shift linkage
      • You will have to run your turn cold side on drivers side-but even so thier is space issues.
      • Terrible and dated design


      Better alternatives:
      034 Motorsports:


      Note: With this manifold it places your t3/t4 intake extremely close to the side of the engine bay. You have 2.5" until the engine bay. your brake line and fuel line are also directly infront of your intake opening. Since this space is very tight your alternatives are to run a custom made mesh or find a VERY low profile intake cone-mushroom style. I will be tackling this on tuesday. I may rebend my brake line and relocate my fuel lines a few inches over- squeeze a 3" inch to 2.5" 90deg coupler if i can. See images below.


      BBM:


      Vacuum Source:
      Easiest way to pull a vacuume source is not your brake booster or tapping into your fpr line. Simple tap into the existing cnc machined (capped) manifold hole on the left hand side of the lower manifold. Simply punch the cap out with a flat head and use the existing 3/8 threads to mount a vacuum fitting. Also, vacuum logs are your friend. 42draftdesign has a great one- comes in cnc or black. See image below.




      More to come!
      Last edited by Stangy; 12-16-2011 at 01:04 PM.

    5. Member Stangy's Avatar
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      12-16-2011 01:05 PM #5
      Update!

      Found my way around my intake space problem.

      http://www.knfilters.com/search/prod...Prod=RX-4130-1


      I will need to modify the inlet size as this one is .8" to large. Win win!

    6. 12-17-2011 06:08 PM #6
      looks good mate! keep up the good work

    7. Member Gear_Dog's Avatar
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      12-17-2011 08:22 PM #7
      looks good in
      My Boosted 16VT Build


      FS/FT 83 GTI roller
      Make me an offer before I chop it up

    8. Member Stangy's Avatar
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      1999 Subaru R-STI, 1993 Cabriolet Classic 2.0 16vt on MS1 v2.2, 2012 Civic Si, 2004 VW Golf GTI BT
      12-18-2011 03:23 PM #8
      Catch can in and fpr on. UPDATED PICS!
      Bay:


      Fan assembly:


      Catch can:
      Can anyone see the problem?


      Completed my catcch can. I still need to make a vent though. Right now it feeds right into my aux air valve into my Vac Mani. When the engine is cold the valve is open but when warm it closes and essentially does not allow the trapped gases in the can to escape. I'm afraid this would cause backpressure into the crank case...hence the filter. What do u all think? My thought process is that when the aux valve closes it basically caps the Mani vacuum so I would need to release the pressure on the can side.

    9. Member Stangy's Avatar
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      12-20-2011 08:57 AM #9
      Update..


      Black hole represents filter which i will add. Will the valve be sufficent to hold boost? Will it seal enough to stop any vac leaks?

      Should i just unplug it and run the can to atmosphere dammit!


    10. Member Stangy's Avatar
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      01-03-2012 09:22 PM #10
      Update:

      Catch Can:
      Ended up running the catch can to atmosphere (filtered) and deleting the auxilary air valve- which was causing weird idle problems anyways.


      Turbo Filter Update:
      Also- the K&N filter did not fit so i went with a SS mesh and one of these ITG filters- modified of course to fit the small space. See below for details.



      Fueling:
      I will be switching to a stock CIS fuel pump/filter rather then my digi2 and keeping my 315 cc injectors. Since the CIS pumps still flow 200+ph it is more then enough for my needs- yes, no need for the famous walbro 255lph pumps that everyone pimps outs. I will use MS and try my hand at the fueling at 1 pulse rate and see if i can get my injector volumetric efficiency to around 80% by rising the fpr pressure-starting at 3bar until i get it right. If i cannot get it down i will raise the pulse rate to 1.1 and start again.
      Last edited by Stangy; 01-03-2012 at 09:33 PM.

    11. Member Stangy's Avatar
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      01-03-2012 09:23 PM #11
      PS- thanks to Vortex members for your ongoing help!

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      01-03-2012 10:10 PM #12
      Kinetic 16V manifold and 16G turbo fit awesome. They have and adaptor to T3 but I don't know how it all fits. I have an adapter unused if anyone is interested.

    13. Member Vegeta Gti's Avatar
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      01-03-2012 10:30 PM #13
      gonna need a bar to make 250whp, watermeth is your friend
      :HOMEGROWN MOTORSPORTS:1:4.9 SuaSponte #13Dead Rabbits. Ungluck on IG
      Quote Originally Posted by frechem View Post
      I like my women how I like my whiskey; aged 18 years and mixed up with coke.
      GTS Dealer.MK!forLife

    14. Member Vegeta Gti's Avatar
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      01-03-2012 10:32 PM #14
      oh and bigger injectors. those 30#'s arent gonna net much more than 300 with a bunch of boost, 630cc
      :HOMEGROWN MOTORSPORTS:1:4.9 SuaSponte #13Dead Rabbits. Ungluck on IG
      Quote Originally Posted by frechem View Post
      I like my women how I like my whiskey; aged 18 years and mixed up with coke.
      GTS Dealer.MK!forLife

    15. Member Stangy's Avatar
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      01-03-2012 10:34 PM #15
      Quote Originally Posted by antichristonwheels View Post
      Kinetic 16V manifold and 16G turbo fit awesome. They have and adaptor to T3 but I don't know how it all fits. I have an adapter unused if anyone is interested.
      True- a friend of mine has this same set up. Even with an adapter spacer there was still no room for a WG with a t3/t4 setup in my case.

    16. Member Vegeta Gti's Avatar
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      01-03-2012 10:44 PM #16
      you should see 270whp@15psi on 93 with 42# injectors

      did you check out any tubular mani's or such?
      :HOMEGROWN MOTORSPORTS:1:4.9 SuaSponte #13Dead Rabbits. Ungluck on IG
      Quote Originally Posted by frechem View Post
      I like my women how I like my whiskey; aged 18 years and mixed up with coke.
      GTS Dealer.MK!forLife

    17. Member Stangy's Avatar
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      01-03-2012 10:44 PM #17
      Quote Originally Posted by Vegeta Gti View Post
      gonna need a bar to make 250whp, watermeth is your friend
      Sadly you are right. My .6 bar (8.7psi) will only net me roughly 220whp if my calculations are correct. My calculations being that 5psi=roughly 40whp, giving me 69.6whp at 8.7psi. The car sits at 150whp (conservative)..so this would run me around 220whp. The #30 injectors will stay until i up my boost at the end of the summer/next season.


    18. Member Stangy's Avatar
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      01-03-2012 10:46 PM #18
      Quote Originally Posted by Vegeta Gti View Post
      you should see 270whp@15psi on 93 with 42# injectors

      did you check out any tubular mani's or such?
      The car will see 42# injectors and 1bar in the near future!

      Since this is a budget build i went away from the tubular, although i could have built one with m buddy, time did not permit this- as of now i have just reached my $2000 mark for all parts. Only thing i am in need of is a boost gauge and the build is ready for start up in april!
      Last edited by Stangy; 01-03-2012 at 10:50 PM.

    19. Member Vegeta Gti's Avatar
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      01-03-2012 11:32 PM #19
      makes sense!
      :HOMEGROWN MOTORSPORTS:1:4.9 SuaSponte #13Dead Rabbits. Ungluck on IG
      Quote Originally Posted by frechem View Post
      I like my women how I like my whiskey; aged 18 years and mixed up with coke.
      GTS Dealer.MK!forLife

    20. Member Stangy's Avatar
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      01-05-2012 12:18 AM #20
      Picking up some 46lb injectors. Might as well. Plus at 3 bar fuel pressure I won't have to worry about the 46lb injectors working above 80%+ efficiency zone where as the 30# injectors would have been working upwards of 100%the unless I changed pulse width to 1.1 on my Ms.

    21. Member Stangy's Avatar
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      01-06-2012 02:19 PM #21
      Stayed tuned for my CIS Bosch Fuel Pump DIY

    22. Member RalleyRabbit's Avatar
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      01-06-2012 02:31 PM #22

    23. Member Stangy's Avatar
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      01-10-2012 09:43 AM #23
      Warning: Brake Clean + Weld= Death

      Not to scare anyone but i read this article this monrning- and although i have never been in this situtation, i am hoping this might help some fabricators in the future!

      http://www.brewracingframes.com/id75.htm




      Fuel Pump DIY:
      So my camera crapped out and i lost all my pics . I will however post up a step by step within the next few hours.

      pss. Who knew a 20 year old car would have seized clamps and screws EVERYWHERE on the fuel system haha. Took me 3 times longer then it should have

    24. Member Stangy's Avatar
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      01-11-2012 10:36 PM #24
      Update Time!
      Sorry for the cell phone shots.

      Old 20yr old filter...ew

      ps. Lots of rust on it..but the car is 99% rust free. Solid everywhere! Has not seen winter in the last 10years. Ill prove it...see below

      Boom...not a drop of rust. Crotch shot.

      ps. The old exhaust is hanging..new will be 2.5" side exit.

      There has been a lot of questions regarding vac logs. 42draftdesign makes one which i am using and its a great item to have.


      Few questions about the SSQV-wanting closer pics.


      Waiting to start the DP! 2.5"


      My DIY Turbo Inlet Intake. Simply an ITG filter sock (rated for 300whp) over a mesh (Home Depot) and a 3" coupler w/clamp. Tested the mesh for flow and its great-tested the filter and it flowed fine as well. It literally was the ONLY thing that would fit.


      Interior Shots:
      Took me an hour to clean the parts out of it.... Threw the corrado seats back in for your viewing pleasure.


      Back Seats-Done right.


      Dash.


      Full Frontal
      Last edited by Stangy; 01-12-2012 at 03:57 PM.

    25. Member Stangy's Avatar
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      01-13-2012 02:30 PM #25
      Cut the 20yr old filter in half and you wouldent believe what i found....




      it was flipping spotless!. I dont even know how that is possible

    26. Member Stangy's Avatar
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      01-15-2012 01:50 PM #26
      Pic of the fixed catch can

    27. Member Stangy's Avatar
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      01-25-2012 02:27 PM #27
      These should help.

      62lb Siemens Deka EVI

    28. Member Stangy's Avatar
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      02-03-2012 10:26 AM #28
      So i received this yesterday-MK1 Raceland Upper Strut..flipping $45 new from thier website...did some test fitting and came up with this.

      Observations:
      It has terrible fitment, but i was aware that its not made for my intake- only scirocco. The mounting bars were not even the with of an mk1's mounting spots on the strut- i had to bend them with my hands!. Other then that its a very nice bar..simple and clean.

      Pics: (sorry for the cellphone pics)

      Sort of what ti will look like


      Rubbing


      Rubbing


      Gap due to rubbing



      Direction:
      As you can see below i will be cutting back the bar to clear the throttle wires and fitting the cut with additional aluminium to keep the bar as rigid as possible.

      Cut outline:
      This cut would clear the throttle wire and the actuator. It is a fairly large cut.


      The bar should still be super rigid after the weld. I will polish the welded area and possible paint the bar as well. I will post pics up monday as i should be done this weekend with the cut and weld.

    29. Member Stangy's Avatar
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      02-04-2012 01:04 PM #29
      My buddies supra 600hp+ project teaser..hand built in his shop. He has been great with helping me with fabrications!




      Drool..

    30. Member Stangy's Avatar
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      02-14-2012 11:43 AM #30
      Since i have not posted up anything lately..dont worry it will come! I have decided to post another cool project that myself and my supra buddy had put together for my 2007 cbr600rr race bike!

      I will be posting up my Strut and exhaust fabrications update soon.

      2007/2008 CBR600RR Exhaust Build:
      Take a look. Myself and another memeber put this bad boy together a while back for my 2007 cbr600rr race bike- thought i would post it up! My buddy is the welding master, i am simply the sherpa!

      Exhaust is SS steel with 4-1 header and 2.5" after collector with V-Band connection (yes on a bike haha). We also made CNC machined header clips (hold header to engine).This was matted to a 2.5" two borthers exhaust. Simply a for fun test go at an exahust build. Made less power down low and moved the power band way high- gained few WHP after 9000rpm. Ended up taking it off and running a two borthers header back as it yeilded better mid range which is what i needed. Never the less...and amazing build and learning experience.

      Custom 4-1 Collector:


      Jig:


      Sooo Fresh and Sooo Clean:


      Up Pipe:


      Done!:


      On Bike:


      Comments are welcome!

    31. Member vr6dubnut12's Avatar
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      02-17-2012 07:01 PM #31

    32. Member Jones84's Avatar
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      02-22-2012 01:13 PM #32
      Just one question, I see you have a welder as your Friend. Why not have him make you a Tubular exhaust Manifold? or a custom Intake for that matter?? Or ditch the stock TB and mod the Stock intake to fit a single TB say like 70mm?
      Sorry thats like 3 question..
      84 Rabbit GTI, 12.1.1 comp 16VT, 15psi 307whp 278wtq Winner 2012 bugRun Pro class
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    33. Member Stangy's Avatar
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      02-23-2012 12:03 PM #33
      Side projects and the fact that he is crazy busy does not help

      We are working ona 2.5" dp to full 2.5" 304ss exhaust with magnaflow muffler and techtonics race resonator. Just ordered all the parts i needed. Exhaust build to start next satruday hopefully!

    34. Member Stangy's Avatar
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      03-01-2012 10:54 AM #34
      Downpipe DIY coming this sunday! Upper stress bar is in the machine shop hopefully ready for sunday install. Then fluids and first start/tune coming soon!

      P.S Anyone form Ontario looking for a great exhaust/exhaust parts, i.c piping suppliers, tubing and much more..check out Tri Canada in Mississauga. Super cheap and great service- they are a manufacturign company who produces a massive amount of S.S fittings, piping, v-bands, flanges and such.

      http://www.tricanada.com/


      Last edited by Stangy; 03-01-2012 at 10:56 AM.

    35. Member Stangy's Avatar
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      03-01-2012 11:00 AM #35
      Custom exhaust hangers anyone?

      http://www.tricanada.com/Documents/N...2011657281.pdf

      Great product- i may test them out on my build and report.

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