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    Thread: 1979 Rabbit 16v turbo build

    1. Member sam.83gti's Avatar
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      79 rabbit
      01-18-2012 12:25 PM #1
      So far I have mostly been cleaning, prepping and gathering parts but I figured I would start posting pictures and such and update as I go.

      The Car:










      wheels:



      Engine Bay Cleaning(work in progress):



      Cleaned and painted Block(9a 2.0):



      Transmission Cleaning (02a from Passat 16v(work in Progress):



      Rebuilt Head: 2.0L 16v





      Parts accumulation:

      wideband controller: http://www.vems.us/eaw52



      guages:



      ARP Headstuds and TT HD dual Valve Springs:



      Hydro to Cable Clutch Conversin for 02a:



      Engine Gasket Sets:



      BBM Headspacer(Lowers Compression By One point for Boost:



      Cast Exhaust manifold(T3 Flange+38MM Wastegate Flange) T3 Super 60, .48 Hotside .60 Cold



      034 External Crank Trigger wheel+sensor+distributor Block/Wastespark Coil Mount



      Vems V3 Ecu (built in MAP, Boost Control, Launch, Wideband, ETC.)



      Bosch 550cc Injectors:



      Bosch Motorsports Waste Spark Coil:



      Thats all for now, I will post more pictures as more parts arrive and I make more progress.

    2. Member sam.83gti's Avatar
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      79 rabbit
      02-15-2012 09:04 AM #2
      Spent all day yesterday out in the garage Soldering the connections for my CE2 fuseblock into my Rabbit. I've got a Plug and Play to CE2 wiring harness from Lugtronics which I did not want to cut up. Also started cutting up my stock 16v Intake manifold to piece together into my Short Runner Intake. Tax Refund should be here soon... Almost done buying parts

    3. 02-15-2012 07:29 PM #3
      Looks like my exact starting point! Same car! search my name for motivation

    4. Member sam.83gti's Avatar
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      79 rabbit
      02-24-2012 03:06 PM #4
      finished up soldering CE2 connections...


      more parts arrived today.
      New digifant injector cups for my short runner in progress. and new bolts for pressure plate to Flywheel.


      New waterpump


      New Timing Belt Tensioner Pulley


      VR6 OBD1 Throttle Body


      Also Got rid of the Battery tray to make room for Intercooler piping and just to tidy up the bay a bit.

    5. Member jettaIIIridinglow's Avatar
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      92 GLI 1.8T
      02-26-2012 11:01 PM #5
      this looks like a promising build thread
      Volkswagens get CEL's like girls get there periods
      1.8t Mk2 GLI project build

    6. Member sam.83gti's Avatar
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      79 rabbit
      02-29-2012 01:17 PM #6
      Thanks for the positive words, my clutch kit arrived today. I have been doing some research to find a budget clutch that will hold up and is rated for the power I am looking to put out. After searching around I found this one:
      http://www.clutchstar.com/product/f1...sat-sedan-2-0l

      I haven't found anything on vortex about them but the guys on the honda forums say they have used them with good results, for the price, its worth a shot.

      It arrived today and here is a shot of it, looks to be of good quality


    7. Banned VT-MKJett's Avatar
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      95 Jetta 2.0, LG7N Golf Sport, 98 Cab
      03-04-2012 11:32 PM #7
      Interesting thread. The Black MK3 Jetta has been getting some love...

    8. Member sam.83gti's Avatar
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      79 rabbit
      03-05-2012 03:54 PM #8
      More parts arrived. finally have everything to bolt the engine and transmission together permanently and start making some new engine/trans. mounts.

      Resurfaced g60 Flywheel:


      NOS Locking Gas cap:


      Cluster W/ Tach.( currently have a speedo only cluster)


      Fuel Filter:


      Oil Cap Seal


      Oil Pan Drain Plug & copper washer:


      Dipstick Funnel:


      Flywheel to crank bolts:


      Freeze Plugs:


      Thermostat:


      Timing Belt:


      Release bearing Guide tube/input shaft seal:


      Lastly, Some euro bumper end clips(no sagging euro bumps for me)


      Sorry to keep boring you with all of my new parts arriving but I am very close to being done buying parts. I will be building up the engine/trans in the next few weeks so stay tuned.

    9. Member sam.83gti's Avatar
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      79 rabbit
      03-05-2012 03:56 PM #9
      Quote Originally Posted by VT-MKJett View Post
      Interesting thread. The Black MK3 Jetta has been getting some love...
      Hey! glad to hear it. Stay tuned for updates.

    10. Member kevlar_vw's Avatar
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      mk1 Jetta, mkv rabbit
      03-05-2012 04:09 PM #10
      looking good
      www.wolfsgart.com

      B5 Passat part out - PM me

      My VW is a hybrid, it runs on hopes AND dreams...

    11. Member jettaIIIridinglow's Avatar
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      92 GLI 1.8T
      03-05-2012 07:51 PM #11
      can't wait for more pics!
      Volkswagens get CEL's like girls get there periods
      1.8t Mk2 GLI project build

    12. 03-10-2012 05:53 AM #12
      Hi

      is there any Dyno diagramms concerning the T3 Super 60, .48 Hotside .60 Cold ?

      i have the same (car) project; but still dubbing about the turbo which is should take.

      K24-7000
      t3 super 60 .48
      gt3071r .63
      TD05-16G

      (i want aprox 250 - 320 ps,..with a very smooth torque ...)

      regards!

      Vincent

    13. Member turbochachi's Avatar
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      Mk3 golf, b5 passat, 99 dodge 1500 83 ironhead
      03-10-2012 03:14 PM #13
      well done sir excellent presentation!!

    14. Member sam.83gti's Avatar
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      79 rabbit
      03-10-2012 04:09 PM #14
      Quote Originally Posted by vincent-mk1 View Post
      Hi

      is there any Dyno diagramms concerning the T3 Super 60, .48 Hotside .60 Cold ?

      i have the same (car) project; but still dubbing about the turbo which is should take.

      K24-7000
      t3 super 60 .48
      gt3071r .63
      TD05-16G

      (i want aprox 250 - 320 ps,..with a very smooth torque ...)

      regards!

      Vincent
      Well, i wanted to go with a T platform turbo in case i decided to swap out turbos later I would have better options without buying a new manifold...also I wanted fast spool up and i have read that the super 60 spools like a Mother F**ker. I read here(http://www.audizine.com/forum/showth...99-t3-super-60) that one of the guys was running a super sixty on his gti and was pushing 288 hp with a water meth setup. My main concern was fast spool for pulling in and out of the nice tight turns up here in the mountains and at the auto-x/hillclimb events. I wont be doing much racing in a straight line so top end isn't as much of a priority. Hope This helps

      search google using "t3 super sixty vwvortex" you can find some good stuff on it.

    15. Member sam.83gti's Avatar
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      79 rabbit
      03-10-2012 04:10 PM #15
      Thanks again for all the support guys. Also any input/advice is much appreciated

    16. Member kevlar_vw's Avatar
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      mk1 Jetta, mkv rabbit
      03-11-2012 12:30 PM #16
      how is the quality of the clutch? I know you havent used it, but does it look well made? I gotta get a vr6 clutch soon...thats one I'm looking at
      www.wolfsgart.com

      B5 Passat part out - PM me

      My VW is a hybrid, it runs on hopes AND dreams...

    17. 03-30-2012 01:22 PM #17
      Thanks! Awesome info..!


      Quote Originally Posted by sam.83gti View Post
      Well, i wanted to go with a T platform turbo in case i decided to swap out turbos later I would have better options without buying a new manifold...also I wanted fast spool up and i have read that the super 60 spools like a Mother F**ker. I read here(http://www.audizine.com/forum/showth...99-t3-super-60) that one of the guys was running a super sixty on his gti and was pushing 288 hp with a water meth setup. My main concern was fast spool for pulling in and out of the nice tight turns up here in the mountains and at the auto-x/hillclimb events. I wont be doing much racing in a straight line so top end isn't as much of a priority. Hope This helps

      search google using "t3 super sixty vwvortex" you can find some good stuff on it.

    18. Member sam.83gti's Avatar
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      79 rabbit
      03-30-2012 02:01 PM #18
      Everything looks to be of good quality as far as the clutch is concerned, we will have to wait and see how it holds up to boosted abuse

    19. Member AircooledKevin's Avatar
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      04-22-2012 12:09 AM #19
      White and blue here too! Looks like a fun build. Been debating doing a 16v swap to mine down the road, just don't know yet. I sent you a pm about the wheels btw! Good luck with build.

    20. Member sam.83gti's Avatar
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      79 rabbit
      05-01-2012 08:55 PM #20
      Ok, I have still been busting my ass in the garage just without much for updates on here. The progress I have been making was just body work in the engine bay and wheel wells, and I figure all that deserves is a before and after picture. before: ,
      And cleaned and primed: .
      Today I gave myself a break from the body work to play with my welder and make one of my trans. mounts for o2a into mk1. New Crank seal,
      then flywheel
      then Clutch,
      then input shaft seal and throwout bearing,
      and together
      then managed to get the block and trans in place by myself with my trolley jack :bam!:
      after alot of measuring and leveling I ended up with this.
      still need to finish welding and clean it up but I think it will work. Next up is the rear trans mount.

    21. Member jettaIIIridinglow's Avatar
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      92 GLI 1.8T
      05-01-2012 10:34 PM #21
      Volkswagens get CEL's like girls get there periods
      1.8t Mk2 GLI project build

    22. Member sam.83gti's Avatar
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      79 rabbit
      05-02-2012 06:38 PM #22
      a bit more work on the driver's side mount/clutch cable mount today.


    23. Member sam.83gti's Avatar
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      79 rabbit
      08-20-2012 04:51 PM #23
      the car has been on the back burner for far too long. I finally finished prepping and priming the fenders. they will be put on with some fresh seam sealer tomorrow.


      Hopefully I will be able to get a friend of mine to stop by this weekend. He is very handy with a paint sprayer and he will be spraying some much needed fresh alpine white on the fenders/core support. Once that is on I can finally stop test fitting and put it in there for good.

      I also bought some more parts...

      Volvo Thermostatic oil cooler sandwich/bsp to barbed fittings/empi oil cooler radiator


      Spa 16v turbo bottom mount turbo/top mount wastegate manifold.(ebay manifold posted earlier positioned the turbo in such a way it was touching the firewall with the engine at a still) also pictured is the turbosmart ultragate 38mm wastegate I bought used off of vortex.



      Bosch LSU4.2 Wideband 02 sensor (my vems setup was sold to me without one)


      Bosch F5DP0R Platinum Spark Plug (apparently good for turbo application)


      5 bolt downpipe flange with some 2.5" vband fittings and clamp to weld to flange/downpipe.


      Forge dual piston Bov


      Also bought some ARP Rod bolts for the hell of it, I figured one less thing to worry about in the bottom end.

      Thats all for now. debating on buying an LSD and a few other things. Stay tuned

    24. Member Scrubbs's Avatar
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      Mk2,s Mk3's
      08-21-2012 08:40 AM #24
      Put the bolts to good use.

    25. Member sam.83gti's Avatar
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      79 rabbit
      09-02-2012 03:47 PM #25
      Well finally got around to painting the front end. Pretty happy with it. its a bit brighter than the rest of the car but I think with a good cleaning and maybe buffing and a fresh coat of dust from the dirt road I live on, it will look pretty even. Now for I can finally start assembly.










    26. Member sam.83gti's Avatar
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      79 rabbit
      09-02-2012 03:51 PM #26
      Come a long way from this:


    27. Member sam.83gti's Avatar
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      79 rabbit
      09-19-2012 08:57 PM #27
      Spent some more money on go fast parts...
      Scat Rods...



      Weld els exhaust manifold kit from treadstone (tried two other manifolds and didnt like the turbo placement) and 16v flange from columbia river mandrel...



      Short runner Intake manifold parts...



      Autotech 16v sport cams intake 252 exhaust 264...


    28. Member
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      G60 on CIS-E and a bunch of other VW's
      10-10-2012 09:21 AM #28
      Looks good. Can you link where you got the manifold tube parts?
      I am interested in building my own header/turbo setup and need raw materials.
      Thanks

    29. Member sam.83gti's Avatar
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      79 rabbit
      10-10-2012 04:57 PM #29
      http://www.treadstoneperformance.com...o+Manifold+kit

      http://www.mandrel-bends.com/catalog...less-2363.html

      not cheap, but now i can put the turbo wherever i want. and its all stainless. just have to add a turbo brace to make sure she doesn't crack at the welds.

    30. Member
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      G60 on CIS-E and a bunch of other VW's
      10-11-2012 11:54 AM #30
      Thanks, I appreciate the links.
      I have some ideas and was looking into options for building my own.

    31. Member xtremevdub's Avatar
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      10-22-2012 03:31 AM #31

    32. Member Filthydubber's Avatar
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      11-24-2012 05:53 PM #32
      more work!

    33. Member sam.83gti's Avatar
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      79 rabbit
      12-20-2012 04:46 PM #33
      Back from the dead. I have been working a lot lately to build my new business coaching a group of young kids snowboarding. They are all competitors in a reigional amateur competition series. The car has taken a backseat as that has been my focus. I have been saving money for forged pistons and block overbore and cleaning. In the meantime I brought some of my intake manifold parts to the machine shop to have one of my end plates milled into a circle and one to be bored out and drilled and tapped for my throttle body. They also milled some nifty reliefs for the throttle plate adjustment screw and another spot for where the throttle position sensor mount protrudes from the mating surface. I also took my angle grinder to my 4" O.D. Plenum to rip a 2" wide section which the shortened runners from the stock intake will be welded into...














      Next is taking some of my scrap pieces down to Larson's shop and practicing with his aluminum spoolgun until I get confident enough to trim the Plenum to size and weld the whole thing together.

      Once the Intake is done then its time to mockup and tackweld the tubular exhaust manifold together and find someone to tig it together properly for me.

    34. Member sam.83gti's Avatar
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      79 rabbit
      01-16-2013 04:50 PM #34
      mmmm...manifold progress


    35. Member
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      G60 on CIS-E and a bunch of other VW's
      01-17-2013 01:28 PM #35
      Good to see the progress.
      It is looking good.
      Maybe consider TIG when you do the intake manifold if you have/know someone good at it.
      Though, Aluminum MIG is probably easier for you to do and would likely flow into the interior less than TIG.
      I have been doing more and more aluminum TIG and I am getting better at fit-up and fill of thinner materials.
      I once thought I would never be that good at aluminum, but have found the more seat time I apply, the better my work gets.
      Keep up the good work.
      Last edited by nbvwfan; 01-21-2013 at 04:49 PM.

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