My 1992 Ecodiesel is done

[larry104]

First, I’d like to thank the people on this board for making it all possible. Through here I hooked up with Giles for the modded pump, Daryl at AA Transaxle for the trans rebuild, and Jack at VW Diesel Parts. This is a great resource and I’ve learned a lot.

Details:
Neuspeed Softsport springs
Koni adjustable shocks
Snowflake rims
GTI grille w/Hella E-code lamps
2.25-in. stainless steel mandrel-bend down pipe and exhaust
Giles pump
GTD nozzles
GTD intercooler with thermostatically controlled fan, handmade air inlet and ducting. (the vice-grip trick I learned here works great for making lips on the tubing!)
Combo EGT/Boost gage
Boost controller -- 15 psi
3.67 ring/pinion, 0.71 5th
Audiovox cruise control

When I bought this car two years ago, it was, in my estimation, dangerously underpowered. Granted, this is my first diesel, and I was used to gassers. But I was determined to make it run better. All I can say is, I am totally impressed with the performance now. Giles trick pump made a HUGE difference. Thank you! The intercooler makes surprising, seat-of-the-pants gains in both torque and top end (I never would have believed it). No doubt the high-flow exhaust is a big factor as well. The added power easily handles the taller gearing. The car is a blast to drive. Thanks again all.

http://www.geocities.com/waloo321/P1010400.JPG
http://www.geocities.com/waloo321/P1010395.JPG
http://www.geocities.com/waloo321/P1010393.JPG
http://www.geocities.com/waloo321/P1010390.JPG

[Black Smokin' Diesel]

Beautiful car, digging the GTD intercooler setup. Must be a blast to drive.

[burn_your_money]

Very nice

Can you explain the vise grip trick?

[rallydiesel]

Awesome. So do you have a TD pump? Stock turbo?

[larry104]

Can you explain the vise grip trick?

You'll need a pair of vice grips and a large spike, like 0.125 in. diameter. Grind a circumferential groove in the lower jaw near the end to hold the nail. Bend the nail around and into the groove. Cut off the excess. Grind a mating "die" in the upper jaw to match the nail diameter. Find a suitable stop to keep the depth consistent. I used a miniature hose clamp. Walk the tool around the pipe end with the nail side inside. Clamp, release, etc... Tighten the vice grip a little and do it again. It works well, at least on 0.049-in. 304 aluminum tubing.

[larry104]

Awesome. So do you have a TD pump? Stock turbo?

Yes, TD pump. Stock K14.

[jimfoo]

Very nice

Can you explain the vise grip trick?

I think there is a thread with pics. I think Named TinTin posted it. I made a pair also, and they work on steel exhaust pipe as well.

Nice job on your car, it looks very well done.

[yankeejim]

Love it, exactly what I'd like to do with mine some day.

[jackbombay]

Nice ride!

r with thermostatically controlled fan

  Where did you get the thermal switch? At what temps does it turn/turn off?

[jtanguay]

rainbow electronics sells a thermostat that opens at 0C - 120C pretty cheap too... I have one

http://vwdiesel.net/phpBB/viewtopic.php?t=1694&start=0

Jake was the one who had the vice grip trick nice pics too!

[jackbombay]

rainbow electronics sells a thermostat that opens at 0C - 120C pretty cheap too... I have one

   Cool, thanks for the tip, I'll call them tomorrow!

[larry104]

Nice ride!

r with thermostatically controlled fan

  Where did you get the thermal switch? At what temps does it turn/turn off?

Electronic Surplus. Normally open and closes at 120 deg F. It's attached to the surface of the intercooler at the inlet side.

[jackbombay]

 Where did you get the thermal switch? At what temps does it turn/turn off?

Electronic Surplus. Normally open and closes at 120 deg F. It's attached to the surface of the intercooler at the inlet side.

  I couldn't find such an item on their website, was it listed under "thermostat" or "thermistor"?

EDIT- Is this the one you used?

[larry104]

 Where did you get the thermal switch? At what temps does it turn/turn off?

Electronic Surplus. Normally open and closes at 120 deg F. It's attached to the surface of the intercooler at the inlet side.

  I couldn't find such an item on their website, was it listed under "thermostat" or "thermistor"?

EDIT- Is this the one you used?

Not everything in their store is on their Website. I'd suggest calling them. It's called a thermal switch. The one I have works either normally open or normally closed (three terminals).  I use it normally open.

[larry104]

 Where did you get the thermal switch? At what temps does it turn/turn off?

Electronic Surplus. Normally open and closes at 120 deg F. It's attached to the surface of the intercooler at the inlet side.

  I couldn't find such an item on their website, was it listed under "thermostat" or "thermistor"?

EDIT- Is this the one you used?

jackbombay,
sent you a pm.
larry