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    Thread: Project Build: sc2020

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    1. Member sdezego's Avatar
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      '90 Corrado | '62 Harley Panhead
      09-03-2006 10:58 PM #1
      Assembly has finally begun.
      Since my Interior Project is now complete -> https://forums.vwvortex.com/zerothread?id=2772227, I finally had some time to start assembly of my Hybrid 2L-20v G60.
      Planning, parts gathering, prototyping and machine work has been going on for about the last 6 months, but Assembly finally started yesterday. And progress has been great with no snags thus far.
      Here is the plan for those who don't frequent the G60 Forum:
      - 2L ABA Bored to 83mm with Custom JE Forged Pistons (9.25:1)
      - ABA OBDI block with Forged Internals, ARP hardware, Resized and Shot peened rods
      - AEB 20v Head (Large Port)
      - Custom Modified SuperSprint SS Mk2 16v Header re-Flanged for 20V
      - Light PnP and gasket matching
      - Stage IV G60 , Pulley size TBD to match higer revs
      - MsnS-e
      - FMIC Precision Core under Dietrich RS
      - Euro AGU Intake
      - some other stuff
      1.) Before I begin, let's get some semantics out of the way. This project is not about "the biggest numbers on the tex" so please don't talk about Big Turbos "BTs" here.
      2.) If you have any basic questions on 20v Hybrids, please visit this thread -> https://forums.vwvortex.com/zerothread?id=1674618. Al ot of details on my research and specifics are in there.
      3.) Although I am not the first 2020 by far, my setup will definitely be unique and will be full trim with A/C.
      3.) pic centric thread as usual.

      DisAssembly of donors






      Since no machine shop around here had a Torque plate to bore my block with, I decided to make my own




      Painted Block


      Pinning the Crank Pulley



      ABA Intermediate Shaft Modification for distributer using AWP 52T Cam Gear (initially)





      Modified by sdezego at 6:24 PM 1-2-2007

    2. Member sdezego's Avatar
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      '90 Corrado | '62 Harley Panhead
      09-03-2006 11:12 PM #2




      After Checking the IM Shaft bearings, I realized that the machine shop honed them to big... I shoudl have just done them myself to begin with.




      Checking the Crank Shaft Axial Play




      Plastigage'ing the Mains. I always check..




      Modified by sdezego at 6:28 PM 1-2-2007

    3. Member sdezego's Avatar
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      '90 Corrado | '62 Harley Panhead
      09-03-2006 11:22 PM #3
      Click to Enlarge








      Checking the Rods with Plastigage








      Modified by sdezego at 6:14 PM 1-2-2007

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    5. Member RaraK69's Avatar
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      09-03-2006 11:30 PM #4
      Wow. thats intense.
      running dizzy in block i take it? or going coils?

    6. Member sdezego's Avatar
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      '90 Corrado | '62 Harley Panhead
      09-03-2006 11:34 PM #5
      Quote, originally posted by RaraK69 »
      Wow. thats intense.
      running dizzy in block i take it? or going coils?

      I am going to Run Dizzy Initially, but will then go to either Coil pack using the ABA 60-2 took trigger or may even go COP.

    7. Member Pigsdofly's Avatar
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      09-04-2006 12:33 AM #6
      Quote, originally posted by sdezego »
      I am going to Run Dizzy Initially, but will then go to either Coil pack using the ABA 60-2 took trigger or may even go COP.

      Why go through the extra work to fit the dizzy if your using the MSnSe, it's a thing of simplcity to run a missing tooth setup from the get go.

    8. 09-10-2007 02:51 PM #7
      Quote, originally posted by sdezego »
      Click to Enlarge








      Checking the Rods with Plastigage





      Modified by sdezego at 6:14 PM 1-2-2007


      It looks like a G60 bottom end that will hit above 300 - 350 whp. I told you so you amateurs. I don't see why they have to hang around.
      Megasquirt is a good call. [IMG]http://*****************.com/smile/emthup.gif[/IMG]

    9. Member sdezego's Avatar
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      '90 Corrado | '62 Harley Panhead
      09-10-2007 03:12 PM #8
      Quote, originally posted by G60Junky »
      It looks like a G60 bottom end that will hit above 300 - 350 whp.


      From the first post on page 1:

      Quote, originally posted by sdezego »
      ...
      I finally had some time to start assembly of my Hybrid 2L-20v G60.
      Here is the plan for those who don't frequent the G60 Forum:
      - 2L ABA Bored to 83mm with Custom JE Forged Pistons (9.25:1)
      - ABA OBDI block with Forged Internals, ARP hardware, Resized and Shot peened rods

      The only similarity the ABA has to the G60 (i.e. PG) bottom end is that they both had 8V heads. Other than that the ABA is is completely different animal.
      Quote, originally posted by G60Junky »
      ... I told you so you amateurs. I don't see why they have to hang around.

      Please do not bring that into my thread. Thanks.
      Shawn

    10. 09-10-2007 03:27 PM #9
      Quote, originally posted by sdezego »
      Please do not bring that into my thread. Thanks.

      seriously dude I thought you were aware by now that no one here likes you. maybe thats why you've been gone for so long. why don't you dissapear again **** smoke.
      Build looks awesome Shawn, nice work [IMG]http://*****************.com/smile/emthup.gif[/IMG]

    11. 09-10-2007 03:28 PM #10
      So you're upgrading the piston size from 81.48 mm to 83 mm, for a 1.52 mm difference.
      As far as the block goes, it's practically identical. no real difference in animals here.
      And, sorry about the trash talk pointed to the non-believers of custom 4 cylinder G60 bottom ends that produce above 300 - 350 whp. [IMG]http://*****************.com/smile/emthup.gif[/IMG]

    12. Member sdezego's Avatar
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      '90 Corrado | '62 Harley Panhead
      09-03-2006 11:33 PM #11
      Forgot to add my original Mock-up. Shown is the Euro Large Port Intake from the AGU Golf.
      Click to Enlarge



      Modified by sdezego at 6:43 PM 1-2-2007

    13. Member G60ING's Avatar
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      12-10-2006 09:49 AM #12
      Quote, originally posted by sdezego »
      Forgot to add my original Mock-up. Shown is the Euro Large Port Intake from the AGU Golf.

      You don't think that will cause routing problems for the IC and air filter?
      Have you thought about running an OBDI aba TB?


      Modified by G60ING at 9:50 AM 12-10-2006

    14. Member sdezego's Avatar
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      12-10-2006 12:09 PM #13
      Quote, originally posted by G60ING »
      You don't think that will cause routing problems for the IC and air filter?
      Have you thought about running an OBDI aba TB?

      Yea, that was the only one I had at the time from a spare motor. Since that pic I did get up an OBD1 ABA TB [IMG]http://*****************.com/smile/emthup.gif[/IMG]
      I really haven't finalized the routing design just yet, but I have a plan and a fall back plan.
      My Main Goal is to keep a nice compressed flow out of the charger down into the FMIC (Drivers side) and then from the FMIC P/S up into the TB.
      Having the air filter on the PS might be a bit tricky to route and probably impossible with the stock air box, but running the Eurosport Coolflow and a K&N looks doable.
      I really want to go back to the stock air box, so I may run the air box on the Driver's side where the battery is and trunkmount the batt.
      I also plan on making the charger bypass mechanical from the stock G60 butterfly/Bypass welded onto a pipe just before the TB.
      Shawn

    15. Member Darrsh's Avatar
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      09-03-2006 11:37 PM #14
      Let me be the first to tell you that even though there r a good number of 2020's out there, your car is gonna stand out from the crowd, newer style w/hvac swap is awesome, so is the interior renewal.
      but 20vG60, i cant wait to here a sound clip
      keep it up man [IMG]http://*****************.com/smile/emthup.gif[/IMG]
      Corrado VS. Rice Burner

      "Corrado Wins"

      I get a buzz out of the combination of design and sport.
      Adrian Newey

    16. 09-04-2006 12:08 AM #15
      I've seen the work in person...
      Ehhh... it's okay... if you are into that sort of thing [IMG]http://*****************.com/smile/emthup.gif[/IMG]

    17. Member G60ING's Avatar
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      12-15-2006 09:20 AM #16
      Quote, originally posted by Darrsh »
      but 20vG60, i cant wait to here a sound clip

      Thats what its all about reasonable power with an awesome sound [IMG]http://*****************.com/smile/emthup.gif[/IMG] [IMG]http://*****************.com/smile/emthup.gif[/IMG]

    18. Member Corradoman8's Avatar
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      12-15-2006 09:56 AM #17
      lookin good, i can't wait to see the final product [IMG]http://*****************.com/smile/emthup.gif[/IMG]

    19. Member sdezego's Avatar
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      12-15-2006 12:10 PM #18
      Quote, originally posted by G60ING »
      That's what its all about reasonable power with an awesome sound [IMG]http://*****************.com/smile/emthup.gif[/IMG] [IMG]http://*****************.com/smile/emthup.gif[/IMG]

      [IMG]http://*****************.com/smile/emthup.gif[/IMG] Most Definitely. And I think that SuperSprint Header with this setup is going to help things sound very healthy

      ----
      Progress is being made, just not at the pace that I would like. Many other distractions including installing Megasquirt on my current setup to get it tuned and any bugs worked out as well the recent acquisition of another G60-> https://forums.vwvortex.com/zerothread?id=2974793
      ...oh, yea and various things in life (all good). Kids are definite Time Burglars, but they're worth it

    20. Member G60ING's Avatar
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      2010 3.6 4-Motion CC, 1990 G60/TDI/R36 Corrado
      12-15-2006 12:52 PM #19
      I miss the sound of a G60 with the TT SS Borla. I picked up an NA 20V header manifold



      Modified by G60ING at 12:53 PM 12-15-2006

    21. Member sdezego's Avatar
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      12-15-2006 01:01 PM #20
      Quote, originally posted by G60ING »
      I picked up an NA 20V header manifold

      That was my first option, but at the time no one wanted to sell one at a decent price. Also, when I picked it up timing was right to drop coin on the SS header and it was aplenty. Still going to take fab work to Reflange it and make it fit too.

    22. Member UTdaneVW's Avatar
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      09-04-2006 11:50 AM #21
      Thats going to be such a sick motor. [IMG]http://*****************.com/smile/emthup.gif[/IMG]
      I want to see this car in person, all the work on the interior and now this. Def holding it down for the FL Rado scene.

    23. Member sdezego's Avatar
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      09-04-2006 05:48 PM #22
      Quote, originally posted by UTdaneVW »
      Thats going to be such a sick motor. [IMG]http://*****************.com/smile/emthup.gif[/IMG]
      I want to see this car in person, all the work on the interior and now this. Def holding it down for the FL Rado scene.

      Thanks! You will definitely see it. Been driving it alot lately and enjoying it. Realistically, the motor will not go in for a few months as I am not rushing it. LOTS of stuff to work out between now and then.
      Among other things, I am thinking about the gearbox as well. Peloquin at the bare min, but need to sell some more parts to pay for that. I have also been thinking about an 02M lately That is just a matter of money, not effort.
      Shawn

    24. Member
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      92GTi 16v sold; 01 mk3.5 cabby sold; 86 325es sold; 03 4.6is sold; 2012 JSW
      11-24-2006 02:09 AM #23
      nice stuff [IMG]http://*****************.com/smile/emthup.gif[/IMG]

    25. Member speediG60's Avatar
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      11-24-2006 04:30 AM #24
      Nice build but painting the block gloss black might not have been the best idea as potential oil leaks would be hard to see.

    26. 11-26-2006 05:07 PM #25
      cool

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