Lightened flywheel

[DieselBalz]

I didnt want to completely hijack the short shifter thread, so I figured I post some preliminary impressions on the Eurospec lw flywheel that comes in the BFI kit with the clutch and pressure plate. (91 1.6 Eco)

I also threw in an ASF coded transmission as the AVX was just not highway friendly. This gearbox only had 112k on it and no glitter in the fluid. Changed the throw out bearing and input shaft seal, and put new gear oil in it.

Got everything put back together today and took it for a spin. Aside from first being a little tricky (gonna need to do the shifter alignment) the tranny is sweet. Instead of 4800 rpm 5th gear 60 mph, I now roll 75 mph at 4800. It still bothers me though cause I have read so many of you running similar setups and @ 2800 rpm.

Its not the tach, as thats been verified with a timing light. Tires are 185/60/14, timing was done less than three thousand miles. All the driveline components are in good shape ( I know this cause I just had them all out and inspected everything.) Feel free to throw some suggestions at me.

The lightened flywheel made a difference. I notice it in acceleration. The motor feels more peppy. The clutch grabs awesome and I finally know precisely where the sweetspot is versus figuring out what it is for that day. As for the rough idle you all had mentioned, it does not. In fact I think it idles smoother. That just may be from all the motor mounts being tightened down with the install.

In all fairness though I have only driven it a few miles, and I may be experiencing that phenomena that one sometimes gets where they think there car drives better cause you put rain-x on your windshield and changed the air freshener. I will report more once I've had a little more wheel time.

[Quantum TD]

If that trans is an ASF, you should be running MUCH lower RPMs than 4800 at 75 MPH. That's redline.

It should be more along the lines of 3000 at 75. The tire size doesn't affect it much at all. It's about the same as having 175/70 R13 tires on there.

If the actual RPMS are 4800, you're fuct. Someone may have swapped the internals.

When you say: verified with a timing light: How?

[DieselBalz]

I took it to a friend who races dubs (SCCA and some local short trackin). His dad owns a SnapOn route, so he snagged a new timing light out of the truck and pointed it at whatever you point it at, while I sat in the car and verified what he was seeing, on the VDO gauge. It idles at 1200 with the cold start advance on and than around 1050 once its warm.

[JerryGTD]

So, did you remember to swap out the gear on the end of the speedometer to the correct color one after you swapped the transmissions?

[R.O.R-2.0]

So, did you remember to swap out the gear on the end of the speedometer to the correct color one after you swapped the transmissions?

yea, the AVX (stock eco trans) has a 4.25:1 ring and pinion.. thats the only VW trans that uses those gears.. believe it uses a GREEN gear on the cable?

3.67 gears use red, and 3.89/3.94 uses white/grey gear..

[DieselBalz]

Indeed I did. Love how easy that was to swap. I heart German engineering. Now if I could just figure out why my RPMs are so high in contrast to what I have read around here.

A little bit of a smoke tale, went to put fuel in it and since first is still a little tricky, at a light I was first in line and fumbled a little with the engagement. This apparently aggravated a semi that was bobtailing behind me, so he goes to go around me and I figure lets test the new clutch and go to keep him from passing, grab first and jump on the go pedal, boost screams into life and we are off, he was starting to pull away as i topped out second and than grabbed third, whoosh goes the garden snail and I'm back even with his front bumper. Shift to fourth and than jump on the breaks and turn into the gas station. He hits me with a double blast from the horns and changes into the lane I was occupying. Meanwhile the crotch rocket rider behind me got the full brunt of the smoke screen.

I also realized I put the anti rattle springs on the break caliper front driverside upside down as they went bouncing under me. Damn it.

[DieselBalz]

So an update with this fw and clutch kit now that I have a solid week on it. In a word, awesome. It doesn't idle any rougher than before, and the engine is definitely more responsive than before. The kit was cheaper than having it taken somewhere, and cause I did it myself, I saved cash and got an ugrade.

[R.O.R-2.0]

its more responsive, but it has less torque. trust me. ive been down this road a time or 12. 

[745 turbogreasel]

^Torque, or Inertia?

so...how much weight  did you save?

[DieselBalz]

^Torque, or Inertia?

so...how much weight  did you save?

I dont know how much the stock diesel FW weighs, but if you do than math can be our friend. The new FW weighs 8.75 lbs.

I am curious as to how it well effect torque? Is it just a gasser way of thinking that by freeing up any mass the engine doesnt have to spin, push, pull, its a help? I was also wondering about lightweight pulleys? Does anyone even make em?

[R.O.R-2.0]

^Torque, or Inertia?

so...how much weight  did you save?

I dont know how much the stock diesel FW weighs, but if you do than math can be our friend. The new FW weighs 8.75 lbs.

I am curious as to how it well effect torque? Is it just a gasser way of thinking that by freeing up any mass the engine doesnt have to spin, push, pull, its a help? I was also wondering about lightweight pulleys? Does anyone even make em?

light weight pullies are a waste of time. have you actually felt how heavy the stock pullies are? not that heavy.

most of the time, people put light weight stuff in/on their engine to make it turn more RPMs quicker.. our engines dont turn lots of rpms.. and were turbo powered, so we never rev that fast.. not explosively fast like a gasser engine revs.

[burn_your_money]

That's an AAZ flywheel though

[8v-of-fury]

whats an aaz 210mm??

[burn_your_money]

whats an aaz 210mm??

Yes, and a 1.6 is 200mm

I may as well add that I think this is a great mod. I did a whole pile of things all at once so I have no idea how much effect a lightened flywheel alone had. I have driven 2 AAZs (1 turbo [Giles], 1 NA [my brother]) both decently modified and I would do this again in any performance build. I do find my brothers 1.9NA shakes a good bit, but I can't say that the flywheel is or isn't the cause. Giles AAZ was very smooth. His is also a 02A though.

[R.O.R-2.0]

im still not sold on the light flywheel..

i will run gasser flywheels, but not lightened gasser flywheels, because thats what you are being sold..

a gasser flywheel is light compared to a diesel flywheel, and a lightened flywheel is lighter than a gasser flywheel..