There was a thread on the old forum I wanted to post a link to about when I redid my clutch with a 4-puck and lightned flywheel.  At the same time I also added A peloquin LSD and changed transmission ratios.  But I don't see the old forum being up right now!  :shock:

I don't know what the stock clutch was in your case... 200mm or 210mm?  Maybe a 210mm with stock friction surface and a heavy (16v) pressure plate would do the trick, but I dunno.  You'd also get a stiffer clutch pedal.  A lightened flywheel is very streetable and nice upgrade IMO - even for a daily driver by the way!

No, no increase in idle vibration at all!  Only downside is that you will have to re-train your clutching foot a bit (a little more gas / a little less clutch during launching.)  And in return, the engine response will be much more lively!  

But don't ask about how hard solid-center, 4-puck racing clutches are on motor mounts.  Or how bad engine vibrations get (both idle and cruising) with stiff motor mounts.    It's a great combo with a limited slip diff if you like 2-wheeled burnouts though!  :shock:  On the way to an autocross yesterday morning, it was damp out and I was on high-treadwear street tires (not much traction) but anyway I was doing 2-wheeled burnouts shifting into 4th gear!  I was amazed, and couldn't wipe an ear to ear grin off my face.  Doing 2-wheeled burnouts successively with every shift.  (Not that I usually drive like a maniac like that on the street... that is what autocross racing is for!  I just don't know what came over me.   :lol: )

Edit - by the way, I remember with a stock heavy 200mm flywheel, stock 1.6lTD clutch and taller transmission, I could barely manage it to make a 1-wheeled burnout!

For a street car, if you decide you don't want to spend a lot of money, and therefore go with a stock disc, I would recommend not worrying about shaving off max weight either, which makes finding an adequately lightened flywheel a lot easier.  8 pounds sounds like a reasonable target.  Focusing on lighter might not be worth spending the time/money/worry on.  I am running 7 pounds but I am racing my car and so I spend extra time fussing over little things like that.  I've only ever heard of a 6 pound VW 020 tranny flywheel being used by one other racer and his Rabbit is the most prepared autocross racing Rabbit that I know of, it's trailered only.  IE: if it were to fail, it wouldn't leave anyone stranded on the side of the road, etc.

I would say if you are willing to deal with a little stiffer clutch pedal, yeah the 16v 210mm pressure plate is also a good idea.  I would say despite the pound or so weight penalty (edit: 2 pounds) of the larger pressure plate, go with a 210mm clutch disc and flywheel on a street application to get more wear area.  It's just not worth sacrificing weight as much for a street application.  I think most would be plenty happy with a 8# 210mm flywheel, 16v pressure plate, and 210mm clutch disc for a TD street application!  If you want to make the clutch pedal stock-softness, only if you are not going to high-power engine mods and will take it easy on the launches, you could substitute in there the standard 8v 210mm pressure plate.  All these parts are readily available from a number of sources for pretty cheap too.  Good luck!

PS - now that the old forum is up and running again here is the link to the thread I was referring to previously: http://www.hostboard.com/cgi-bin/ultimatebb.cgi?ubb=get_topic&f=4037&t=40

By the way, I have a stock, brand new german made 210mm flywheel sitting in my garage here.  Ordered it but turned out I didn't need it...  it's the early style version with the 2 7mm dowel pins, not the later A3 style version that has only the 1 8mm dowel pin.  If it's of any use to one of you I would not refuse a reasonable offer!  The stock 210mm flywheel is a lot lighter than the stock 200mm flywheel coming on our diesel Rabbits by the way!  You could realize a significant rotating mass weight reduction by just bolting on the unmodified 210mm flywheel!  I could measure it's weight if anyone's interested.  I may have a stock 200mm flywheel I can get a comparative weight on too if there is any interest let me know.

I have a Sach Power Clutch and ligthen flywheel for my car. I paid big $$ for it when they first came out. If I was going to do it again I'd buy one from these guys..http://www.bsiracing.com/Products.asp?FormName=Search&FormAction=search&category_id=9
 They seem fairly cheap and have lots of options

where'd you get the light flywheel and kevlar disc doc? cost? availability? hop on msn some time soon