Mk2 Scirocco 16v Turbo Build...

[Thrasher]

Well, I haven't taken any pics but here is the info as it stands...

Parts on hand:
87 Scirocco 16v, retired since badly spun rod bearing...
Atomic Speedware 9.5:1 Flat Top Forged pistons
T403-57 trim compressor with a.48 T3 Hotside Fully Rebuilt with Stage 3 Turbine
Early Bahn Brenner stainless log manifold and downpipe, modifying to run Stock Scirocco Intake
38mm Tial Wastegate
Stock 1.8 16v bottom end, getting fully balanced in a couple weeks
ACN 020 Gearbox, super tall gears

I am waiting on getting my 1.8 head back, which will be fully rebuilt, gently ported and polished

Parts to come:
Frozen Boost 350hp Air to Water intercooler
Forge Motorsport Dual Piston BOV
Bahn Brenner Fuel Rail and properly sized FPR
32# Bosch Injectors
Megasquirt V2 ECU w/ Wideband O2

The initial tune will be at .7 Bar until I get all the bugs worked out, running right at the threshold of the 020 and stock rods, tranny is high mileage but SUPER solid

Trying to keep the car as 'Scirocco' as possible, retaining factory Intake, V-Belt setup, A/C the works... I want to keep this car as period correct as I can so it outwardly appears very stock aside from the snail in the back. I had a short runner intake, but realize the value is only there over 350+ HP which I don't ever plan to see in this car. Eventually I will do some IE Forged Rods, Water Meth and hopefully a 6 Speed gear box that can take the abuse of ~300 - 325hp.

I'm gonna clean out the garage this weekend and hopefully start cleaning up the engine bay, prepping for a short block install. I have a baby on the way, and the goal was to have this car running by then (Mid-April) but due to the 78 not selling yet and some repairs needed on the daily it looks like I'm a bit delayed.
Will update with pics in the next week, hopefully I can keep momentum and you folks can help keep me motivated!

[walle197871]

Helium! Just did a 9a block swap. Would love to go turbo. Maybe in a couple years...

[Rocco_julie]

#1 you dont want 350hp. A front wheel drive car gets really squirrely. Believe me.
Add power to a level that is fun, maintainable and driveable.

[Thrasher]

#1 you dont want 350hp. A front wheel drive car gets really squirrely. Believe me.
Add power to a level that is fun, maintainable and driveable.

When I get the 6-Speed and the Diff (a long ways off), I will be very happy with the squirreliness... it'll have R Compound tires, and I am well aware the thing will be petrifying haha.

[Thrasher]

I haven't been slacking on work... just updating :p


The first mockup... need to move the wastegate back about 1.75" and do some slight modification to the downpipe but it's not as bad as I'd thought. Going to route the inlet around the back, beneath the heater hoses into my air to water and kick it out the same side right into the throttle body.


Everything pulled out of the engine bay, I started degreasing heavily today will update before body work begins.


Scrubbed the crap outta these parts, some of them were so stained they are as good as they can be... not worth painting for stuff that is hard to see.


Did what I could, may be trying a de-yellowing technique soon. The P/S resevoir wasn't nearly as yellowed.


The intake manifold will get lots of attention though :p Cleaned up the T-Body and made a custom speedo-cable holder... I'm sure there is a factor one that would work but this actually keeps the cable situated in a very livable angle.


As will the valve cover


Brake booster, k-bar, and trans mount braketry are also pretty visible




Front Euro Bumper and Chin Spoiler freshened up


15x7 Et 27 Momo Quasars... going out for strip/powdercoating soon. Most recent purchase.




All rebuilt and cleaned up hotness.


Manifolds, yay. Tial 38mm Wastegate


Old School Empi oil cooling products, gonna give it a whack... confident they will keep great oil flow and still offer solid cooling.

I also have a brand new coolant bottle going in, and all the hoses are wrapped up and coated in rubber cleaner/conditioner... makes them like new. Did the same with my 16v Intake Elbow that I'm using to connect my charge piping with the Passat T-B.

[Rocco_julie]

I have both fuel maps (V2 and V3) set up for the 16v turbo.
Let me know if you want either.

Personally, I liked the V3 better and moved over to that this spring.

[Thrasher]

I have both fuel maps (V2 and V3) set up for the 16v turbo.
Let me know if you want either.

Personally, I liked the V3 better and moved over to that this spring.

I will let you know which version I end up with and would appreciate these for sure.

[Rocco_julie]

The V3 is set up to run spark direct to coil and the ISV was wired in yesterday. That certainly makes cold starts easier

[ziggirocco]

IMO, at the point you are I would do the ie rods now, even if it delayed the build.

[Rocco_julie]

The rods and crank are forged. Its the pistons that are cast.

[Thrasher]

IMO, at the point you are I would do the ie rods now, even if it delayed the build.

That's actually the plan... thanks for reminding me, I gotta call CTS and have them ship those. Already paid for... the bottom end will be set for life. True Seal Rings, Atomic Speedware Forged Pistons, and IE Forged Rods, Calico Coated Rod Bearings, and Factory 2 Piece Glyco mains... bombproof.

[ziggirocco]

The rods and crank are forged. Its the pistons that are cast.

On a factory 16v the rods and crank were forged?

[ziggirocco]

That's actually the plan... thanks for reminding me, I gotta call CTS and have them ship those. Already paid for... the bottom end will be set for life. True Seal Rings, Atomic Speedware Forged Pistons, and IE Forged Rods, Calico Coated Rod Bearings, and Factory 2 Piece Glyco mains... bombproof.

Should be awesome!

[868valver]

Good stuff! Nice choice on the Quazars, I love those wheels!

[Rocco_julie]

On a factory 16v the rods and crank were forged?

Thats what I was told. Usually people use lighter titanium rods as the force moment is reduced.

[Thrasher]

Did some work on the Rocco project this fine memorial day weekend...

Received these goodies on Friday... along with some Calico coated rod bearings.


Stripped the bottom end down of it's weak, wussy factory guts.


Clean bores, that's what I needed to find!


The crank looked marvelous apart from some burnt on oil... oh well.


Engine bay almost ready for paint... rust in the battery tray area freshly sealed


More cleaned parts.


I forgot to take before pics, but this trans came out of my 340k mile Golf... it was DISGUSTING. My old lady gets all the credit for cleaning this one up.


Painted intermediate shaft pulley.


Painted crank pulleys.


Forgot to take pics of the engine mount brackets I painted today too. Slowly but surely it's coming together. I think the next step is painting and assembling the bottom end.

[Rocco_julie]

I'd have the block tanked and honed. It cleans all the oil and water galleries.
Worth it IMO

[Thrasher]

I'd have the block tanked and honed. It cleans all the oil and water galleries.
Worth it IMO

That will be done on way another... no doubt.

[ziggirocco]

Looking great!

[polov8]

You own a Scirocco?

[Thrasher]

You own a Scirocco?

In theory

Looking great!

Thanks dude!

[markeysscirocco]

What is the brand and color of the paint you used on intake and pulley. I'm going to hot tank my current case and heads

[Thrasher]

I used the Rustoleum Cast Aluminum finish on the first round... I recommend the Duplicolor Engine Enamel though. Used that on the cam sprocket and the valve cover and it worked much better. Seems to hold up better for sure.

[oleblue]

And what mods are you going to do to get that kind of power to the ground?I think it is going to take more than R compound tires.
The torque steer is severe even with as little as 180 HP.

[Thrasher]

And what mods are you going to do to get that kind of power to the ground?I think it is going to take more than R compound tires.
The torque steer is severe even with as little as 180 HP.

Poly motor mount inserts, a solid trans mount, a race front mount, front and rear upper stress bars, and I'm planning to run a bolt kit and diff in the transmission. The torque steer will keep things interesting, haha.

[veetarded]

So the $64,000 question here is 'Are you actually gonna finish this?'.

ya Chad, but your track record is questionable....and what trans are you going to subject this punishment to?

[Thrasher]

So the $64,000 question here is 'Are you actually gonna finish this?'.

ya Chad, but your track record is questionable....and what trans are you going to subject this punishment to?

I'm so close I can't give up... plus I've got some more money comin' in so I should be able to actually see this through, I hope... haha. The old lady is supportive (and this one I've known for almost 10 years so she may actually stick around) which helps.
I'm using an 020 ACN that's got a ton of miles but NO abuse... rebuilding it, bolt kit and a diff hopefully. Should be running the threshold that the tires will break loose before the gears do.

[Road Boss]

I like this! Looking forward in seeing the finished product.

[Rocco_julie]

I'm so close I can't give up... plus I've got some more money comin' in so I should be able to actually see this through, I hope... haha. The old lady is supportive (and this one I've known for almost 10 years so she may actually stick around) which helps.
I'm using an 020 ACN that's got a ton of miles but NO abuse... rebuilding it, bolt kit and a diff hopefully. Should be running the threshold that the tires will break loose before the gears do.

Same as I used. 1st is really short but second is fun!

[Thrasher]

Also... if anyone has a grille for inner euro light deletion I'd love to buy it from you... must be well intact, but I'll restore the finish.

[Thrasher]

The engine block, mirrors, both spoilers and bumpers are now painted... need to take some pics.
Almost done stripping the 16v kit off, then straightening the seams I bent over the years of improper lifting procedures (oh to be 17 again).
All my sand paper and filler is purchased so body work should commence soon, then off to the booth to start shooting paint.
My manifolds got dropped off to a good friend for the needed modification, and my head should be ready soon as well. Once the head is together it'll be time for assembly!

[Black92EightValve]

alright Chad, I think it's time you post an update, I know you've had some time to work on this

[Thrasher]

alright Chad, I think it's time you post an update, I know you've had some time to work on this

The grill is on route from Germany compliments of BKS Tuning, can't wait for that to show up.
Body work has been coming along... get reacclimated to the processes.
Here is the work thus far...
From this...

To this...

[d-bot]

watching

[Thrasher]

The wheels are done.