**16vt Cabriolet Classic Budget Build**

[Stangy]

The machining on the stress bar is finally done!



Cleeeeeeeean!

Now to weld some aluminium back into that hole to give the bar its regidity back!

[Sr. Karmann]

The machining on the stress bar is finally done!



Cleeeeeeeean!

Now to weld some aluminium back into that hole to give the bar its regidity back!

looks good

[Stangy]

Bar just came back from cnc + shop for welding. Fitting asap! Pics soon.

Xmas already?






Teaser of dp build:

[Stangy]

Downpipe Update:
Quick update for anyone interested. About 90% done the DP, just waiting on one more cut and the addition of a V Band flange. Updates will happen accordingly.

Materials:

• 2 90deg 304 stainless 2.5" pipes
• 4' of 304 ss straight pipe at 2.5"
• 1 4" flex pipe 304 stainless 2.5"
• 1 3.5" straight pipe in 2.5"
• 5 bolt ss flange
• TIG Welder
• Clamps
• Beer

Step by Step: (Applicable for 2.0 16v 9a with 034 manifold and t3/t4 60trim)
Note: I have already doen the calculations for you. This should be a direct fit for the application listed above.

• Cut your 1st 90deg albow down 1.75"- straight cut (yes this will now make your perfect 2.5" a slight oval)
  
  
• Tack your 4" flex pipe to your newly formed 90deg elbow
• Mount your 5 bolt flange to your existing turbo.
• Test fit your new piece by hand and insure this clears your WG and shift linkage(if running 020 tranny) and get a friend to mark the angle with a perm marker.

• Tack your peiace via TIG

Cut a 3.5" straight piece of your 2.5" piping and tack to to the end of your 4" flex pipe

• Grab your 2nd 90deg 2.5" elbow and run it in line at a 90deg angle to your outlet. Mark via perm marker and tig.

Note: When mounted this peice must run flat the rest of your pipeing moving toward the back of your vehical. Insure you test fit this peice and mark the angle you will need to cut. If you do not cut this angle your exist angle will be into your chassis.

Note: I will post this cut angle when it is complete. Should be done for monday and i will have pics fo the fitment + v band weld.

[Stangy]

All done. The cut angle was 80deg. Test fit it and was about 1/2" off (hitting ps shaft) so I have to rotate the entire pipe on the flange 1/2"clockwise and she should be ready to go!

[EdDzZzZz]

love the work

subscribed

[Stangy]

Finalized dp pics coming soon. Routed the dp over the lower tie bar. V band connections throughout. Pics and explanations coming soon!

[Stangy]

Update: Gauge wiring DIY to be up by this evening. Stay tuned.

[Vegeta Gti]

[Stangy]

Downpipe almost complete. Thsi is what it looks like so far.


Went over the tie bar- to many mk1-mk2 guys are touching or tapping the bar while driving.




Super Simple DIY:
Simple wiring for you guys/gals who want to wire up your guages but are to lazy/dont want to hastle with finding your wiring- especially with alot of you running custom wiring and so on. Use your fuse box dammit!

PS: Legend for VDO Gauges..
+: Positive 12v feed wire
-:Ground wire
G: Wire to sender

Start with wiring all your guages together and leave a lead for your power source. I did the same with my grounds and grounded it to the body using a screw.


Then attach to gauges.


This is your fuse power connection- can be bought at your local hardwear store. Simple connects to the fuse of your choice. I used fuse #20 (license plate lights). Pull your #20 fuse, fill the slot with your new clip and replace the 10amp fuse into the two open slots located on the new fuse power connector. Please a second 10amp fuse into the open slot. Tuck and zip your wiring. Test- done.







Enjoy.

[Jones84]

I have a question on you DP, Have you fit the shift arm in yet?? It looks from the pics that you might be hitting the DP once you install it. I could be wrong but it looks like its going to be very close..

[Stangy]

I have a question on you DP, Have you fit the shift arm in yet?? It looks from the pics that you might be hitting the DP once you install it. I could be wrong but it looks like its going to be very close..

Very close is right brother. About 1/4" clearance

[Stangy]

Full dp with v band. Not bad id say.

[Stangy]

What is everyone's opinion on downpipe wrap? Yay or na?

[Jones84]

I wrapped mine on my Jetta, I went back all the way the flex pipe. Witch is just past the sway bar. About where the cat would be, that is if I was running one. lol
It did cut down on the heat a bit..

[Stangy]

I wrapped mine on my Jetta, I went back all the way the flex pipe. Witch is just past the sway bar. About where the cat would be, that is if I was running one. lol
It did cut down on the heat a bit..

Is it worth it? Seems like thw work is not worh the reward.

[Jones84]

The Work?? Its not hard. Its not like you are redoing the down pipe. If it takes you more than a 1/2 hr i would be shocked.. Yes its worth it. At least I think think so. If your pipe runs close to anything like wires or brake lines you want to keep the heat off them.

[Gear_Dog]

I agree it's a quick fix to reduce under hood temps. Easy enough to switch back if you aren't happy.
FYI if you do it soak the wrap before it's more pliable.

[Stangy]

I agree it's a quick fix to reduce under hood temps. Easy enough to switch back if you aren't happy.
FYI if you do it soak the wrap before it's more pliable.

Note taken.

[Stangy]

Update! Well I FINISHED the car today. Worked on it for 7 hours today and added oil and coolant, primed the Turbo, checked for leaks and did some last min instals/maintenance. See below for proper (there are several different ways yes) Turbo priming. As it sits it has no exhaust just a 2.5 dp. Exhaust will be put on as soon as tune is complete. Gunna be loud until then!

Step 1:Add oil (4L w/filter change) +exhaust filter
Step 2: grab a beer
Step 3: check for leaks and inure oil feed and drain lines are tight and no kinks are found
Step 4: unplug coil connection to distributor + pull fuel pump fuse
Step 5:disconnect oil drain from oil pan and place catch can under line.
Step 6: turn engine for three 15sec intervals
Step 7: check line for oil drainage.
*repeat step 6-7 if needed until desired oil is found

Step 8-10 involve beer so I won't bother

Pics! She is awaiting tune on wed! Summer here we come!!







Comments are welcome. 5 months of work. Woot!

[Stangy]

Thanks!.

Did base tune on the car today with a friend of mine. Got it go idle nicely again around 14.5-15afr once warm. Starts at each turn of the key! Super loud without the exhaust (just has dp as of now).

Ended up grabbing a etx14 power sports battery from autoquest for $100. Same as the Dena ext14 just rebranded. Retrofitted the connectors and she works like a charm, even at 220cca.

Used some spare stainless to make a makeshift wastegate dump tube. It will work for now! Not bad actually. Made it in 5min literally. Its actually a spare header pipe from a old cbr600rr project-pis can be found earlier in this thread.







Street tune and video tomorro!

[Jones84]

If you have any issues with that battery, a full sive optima will fit turned 60*, the pos will sit just under the core support.. Just FYI

[Jones84]

Clean out your inbox, I cant give you the info that you wanted.

[Stangy]

Clean out your inbox, I cant give you the info that you wanted.

Cleaned. Had some trouble finding the right USB driver for my USB to serial connection. Should have the map for u to review tomoro!

[Stangy]

Here she is. 75% tuned. Just need a working VE table dammit!




Video of Idling after warm up + basic tune once I can find a way to load it!


I will post my Ms file later on. The car under acceleration sputters and looses power for some reason. Has terrible power across the board. Ve table or something must be way off. Any takers? I was using auto tune for ve as well. Made little difference..I must be way off?

I checked plugs. Bought new nkg iridium plugs gapped at .25. Check coil, distributor and wires...grrrr

[Stangy]

http://www.2shared.com/file/08mZADsw/CurrentTune.html

my full tune file as of today..ve looks wayyyyyyy off.

[Stangy]

Made some adjustments to the table. Look better now. Here is a screen shot. Removed the accell enrichment that was set way to high I think causing the hicupping or so says the Ms manual. So I put it too 2500 kpa/s so I won't ever kick in. They said to tune ve to near perfection before using the inrichments. Test number 3 tomoro!

[Stangy]

[Stangy]

75% tuned. Just need to tune in boost. Could not do so because it had the stock sachs clutch which dident hold squat in boost. Maybe 1spi..grr!

ACT HD 4 puck Ceramic clutching going in on wednesday! Pumped tp be able to finally drive it to its full potential!

[Jones84]

I hope you got the sprung hub? If not its going to be ruff for street driving. I have the same clutch in my Drag car, It holds nice. Its never let me down.

[Stangy]

I hope you got the sprung hub? If not its going to be ruff for street driving. I have the same clutch in my Drag car, It holds nice. Its never let me down.

Sprung indeed. Do u believe in the clutch break in mumbo jumbo? I'm driving it home for 45min softly..letting the clutch cool for a few hr. Then going to tune in boost. IV never broken in a clutch in for 500miles, I think its a joke. A 45min-1hr stop go drive and cool cycle should be fiiine to set the flywheel and disk surface. Plus its ceramic..Psh!

I hear these chatter a bit unless u rev them higher (3000rpm) out of first..?

[Jones84]

Yes break it in. You need to heat cycle it a few times. It wont slip in 1st or 2ct but it might in 4th or 5th. If it starts to slip just back off and hit it again. I did not have a issue with this one but i did a 200mile break in before i hit the strip. In my jetta i have a 6 Puck and it would slip in 3rd tell i went about 500miles. but after that its like a rock. You aren't pushing that much boost so I think you will be fine.

[Stangy]

Yes break it in. You need to heat cycle it a few times. It wont slip in 1st or 2ct but it might in 4th or 5th. If it starts to slip just back off and hit it again. I did not have a issue with this one but i did a 200mile break in before i hit the strip. In my jetta i have a 6 Puck and it would slip in 3rd tell i went about 500miles. but after that its like a rock. You aren't pushing that much boost so I think you will be fine.

I will be putting about 250km of stop and go on it before I go out and tune. Yea I wont even be close to the limit of this clutch. If it slips under 9psi there is issues!

[Jones84]

I run 20psi on a 12.1.1 comp 16v, with that clutch. I am sure it will hold. Plus its not like your car is heavy of anything.

[Stangy]

I run 20psi on a 12.1.1 comp 16v, with that clutch. I am sure it will hold. Plus its not like your car is heavy of anything.

Heavy on the wallet is what it is