1979 Rabbit 16v turbo build

[sam.83gti]

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.

[sam.83gti]

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

[kompressorgolf]

Looks like my exact starting point! Same car! search my name for motivation

[sam.83gti]

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.

[jettaIIIridinglow]

this looks like a promising build thread

[sam.83gti]

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

[VT-MKJett]

Interesting thread. The Black MK3 Jetta has been getting some love...

[sam.83gti]

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.

[sam.83gti]

Interesting thread. The Black MK3 Jetta has been getting some love...

Hey! glad to hear it. Stay tuned for updates.

[ABAinA1]

looking good

[jettaIIIridinglow]

can't wait for more pics!

[vincent-mk1]

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

[turbochachi]

well done sir excellent presentation!!

[sam.83gti]

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.

[sam.83gti]

Thanks again for all the support guys. Also any input/advice is much appreciated

[ABAinA1]

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

[vincent-mk1]

Thanks! Awesome info..!

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.

[sam.83gti]

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

[AircooledKevin]

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.

[sam.83gti]

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.

[jettaIIIridinglow]

[sam.83gti]

a bit more work on the driver's side mount/clutch cable mount today.

[sam.83gti]

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

[Scrubbs]

Put the bolts to good use.

[sam.83gti]

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.

[sam.83gti]

Come a long way from this:

[sam.83gti]

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...

[nbvwfan]

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

[sam.83gti]

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.

[nbvwfan]

Thanks, I appreciate the links.
I have some ideas and was looking into options for building my own.

[xtremevdub]

[Filthydubber]

more work!

[sam.83gti]

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.

[sam.83gti]

mmmm...manifold progress

[nbvwfan]

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.