My Official Build Thread! :) Updated!!!

[boosted_diesel_84]

Heres the MOD List

The Block- hot tanked, cleaned, bored and honed .0020, new   intermediate shaft bearings

Rotating assembly-
Crank- forged, polished, balanced,
Rods-forged, polished,balanced, weighed
Pistons-Forged, ceramic coated, dry film lube, balanced,
flywheel-lightened to 8lb. balanced
(all balancing within 1/10 of a gram) better than NASCAR Spec, which in under a gram)

Head-Cleaned, Port and Polished, New bronze valve guides, Stainless Steel valves, radius cut seats, blended, milled, lash adjusted, flow tested (see sheets on last page)

Other MODS

-36mm oil pump
-Windage Tray
-Spec Stage 2 Clutch
-APR Head Studs
-1.9 MLS HG
-Passenger Performance 2.5 downpipe, into 3 in. exhaust with 4 in. tip, no muffler
-Passenger Performance 3in. Intake Manifold
-GTD Nozzles
-Built and Modified Pump
-EGT gauge
-K24 turbo, rebuilt, ceramic coated in and out, port and polished, wastegate valve ground
-Stock exhaust manifold, ported and polished, and ceramic coated.
-SRT-4 FMIC
-2.5in intercooler piping
-german bearings
and for the nay sayers
-1 piece glyco thrust main bearings,
-New Alt, and Starter
-Relocated Battery to trunk
-New waterpump, timing belt, ac./ belts, inj lines, R32 blue Valve cover,
-NEUspeed 4 point strut tie bar.
And a crap load more i cant remember. hope u like





well finally, after tearing down my 1.6 TD almost a year ago, i am putting it back together, i have spent well over $6,000 on the motor alone, my goal for this project is to build a very reliable fuel efficient vehicle for daily duty, and still be fun to drive, but not sacrificing fuel mileage for power.

first i started by taking my block and head to Air Cooled Engines Plus, a local VW machine shop that is amazing, he hot tanked my block, bored and honed it 20 over, cleaned it, and put new intermediate shaft bearings in, polished and balanced the crank, rods, pistons, flywheel and lightened it, ceramic coated and dry film lubricated, my new Kolbenschmidt pistons, ported, polished and ceramic coated my exhaust manifold, Passenger Performance downpipe, turbo housing, which the turbo is being rebuilt by G Pop shop. I also just sent my intake manifold to Passenger so they can make the bad azz one they make.

he reworked the head, with new bronze valve guides, new stainless steel valves, radius cut valve seat, with a performance grind, ported and flow tested to flow 25% over stock without losing velocity, i will post the flow sheets showing stock to now in a few days. the head was then milled then cleaned.

 i have ARP hardware, a Spec stage 2 clutch, built injection pump, GTD injectors, windage tray, 36 mm oil pump, Good German bearings and gaskets,  srt-4 neon front mount intercooler, Egt gauge and probe from Aircraft spruce, all new belts, hoses, accessories, glow plugs,  relocated battery to trunk to have more room for intercooler piping, and anything else that is a wear item was replaced. here are some pics, i hope to have it running soon, let me know what you think.



























































:twisted:

[dillenger1]

Did you have the block decked?In the one picture it seems you can see the stone marks.

[boosted_diesel_84]

Did you have the block decked?In the one picture it seems you can see the stone marks.

no, clearances were close enough with just the head milled, its just marks from when it was machined from factory, and my camera picks up fine details like that,

[foxracer1]

Where in OH are you close to? I'm near dayton. Haven't heard of air cooled engines plus. I like what you have done. I've dreamed to do all that.

[theman53]

Me too. OHIO where?

[boosted_diesel_84]

Tiffin ohio, to be exact.

[foxracer1]

Not to jack your thread. I am up in Bowling green and perrysburg quite often. I'm moving there this fall. Haven't been in holmes county. Back to your engine looks good i'm very jealous. Can't wait for a start up vid!

[captainpartytime]

Really nice job! You have clearly built a VERY nice TD. I noticed your headstuds are ARP's but the mains and rod bolts look stock.

[boosted_diesel_84]

Really nice job! You have clearly built a VERY nice TD. I noticed your headstuds are ARP's but the mains and rod bolts look stock.

yea.. i had it in my original plan, but after i purchased everything and went way over my budget, i just cant afford to spend money on that, especially since the motor does not spin that high, the rod bolts are just kind of a bragging right, plus i need to be driving this thing asap. so i cannot wait any longer.

[JohnnyT]

Nice buildup i like the way u waited and put alot of pics and info all at once can't wait to see her get done

[riddleyo]

Awesome build up! I'm in ohio too, near dayton. A diesel g2g should happen...

[lord_verminaard]

Another Ohio dubber.  Good to know there is a machine shop that's at least in the same state that knows VW's.  I was wondering where to have the work done on my TDI engine.  Looks great!

Brendan

[boosted_diesel_84]

Awesome build up! I'm in ohio too, near dayton. A diesel g2g should happen...

deffinetly, lets put something together, like 2nd saturday in sept. or something, just far enough away everyone can make plans for it.

[boosted_diesel_84]

Another Ohio dubber.  Good to know there is a machine shop that's at least in the same state that knows VW's.  I was wondering where to have the work done on my TDI engine.  Looks great!

Brendan

yea, he is an awesome machinist, done it all, and great prices, he charged me $1,500 to hot tank the block, bore, hone, clean, install intermediate shaft bearings, redo the head, new stainless valves, port work, all the ceramic coating, balancing, lightening the flywheel, flow testing the head, and everything else mentioned in the first post.

if you want to talk to him heres his info

Air Cooled Engines Plus
John & Joanie
419-443-8987

[foxracer1]

Writing that number down now. Let me know on the date and place guys. I've got some MX races coming up around then.