mTDI MK1 winter upgrades :)

[rabbitgtdguy]

Figured I better get started on this soon, and now that Todd has helped to make room in my garage...I can get moving all the sooner.

If you interested in checking out the motor build thread (motor was built during the winter-spring of last year), check it out here.

http://forums.tdiclub.com/showthread.php?t=129127

Lots of pics, info, etc. Originally the motor was to go into the 81 (that Todd now has and is reviving since he has the room :) ) but the 79 seemed to earn it more last winter as it was a very very very budget buy ($100, bought in Pembrooke, NY last fall...) and served me well all winter (replaced two brake lines, the water pump and thats it intially), plus it has that feel that only a German made MK1 has and is a bit unique in its own sense...

Here is a picture the last day I had it out since probably... only day we had a decent snow as well...but i had to get it inspected so...

http://i18.photobucket.com/albums/b109/joeallison_99/79%20Rabbit%20DD/100_2757.jpg
Go figure....no MK1 I've had of course hasn't had its finger lever on the door freeze in sub 20's
http://i18.photobucket.com/albums/b109/joeallison_99/79%20Rabbit%20DD/100_2759.jpg
The motor as it stands now...
http://i18.photobucket.com/albums/b109/joeallison_99/79%20Rabbit%20DD/100_2755.jpg
and another vanity shot :)
http://i18.photobucket.com/albums/b109/joeallison_99/79%20Rabbit%20DD/100_2754.jpg

This winter I was hoping to do ALOT!!! Like paint and bodywork...along with all the other engine upgrades I was doing. Well...somethings gotta give, so I'm working on the engine only stuff and saving the bodywork for next year...unless I find someone really willing to help me out with a few welding bits I need to do, etc. Plus, its kinda cool driving it as it is now...no one knows whats coming !

So...big things this winter engine wise...namely the installation of my AWIC that I've had since I had my Lysholm corrado a few years back. We had built it with the intentions of using it in a 16v Lysholm variation I wanted to build, but sold the car prior...
The cooler...and variations exchangers I was initially going to use...as well as a VR aux water pump...
http://i18.photobucket.com/albums/b109/joeallison_99/VW%20Stuff%20for%20sale/100_2708.jpg
but now...have this for a pump to mount in the rear with a 5 gal tank...
http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_2752.jpg
and a VR aux radiator for an exchanger... was trying to find a decent one from an early audi 20v...but never found one that was in good shape...
http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_2748-1.jpg

Thats the big thing. I have some mandrels for the plumbing of it, but imagine I'll use aluminum instead as all I have are steel ones.
I'm also going to be installing a different style intake manifold on the car, a non-turbo AAZ TD unit that has D ports from the factory, but looks like a 8v gasser intake manifold so I can keep the volume. Currently I'm running a modified G60 one that I ported "WAY" out to D ports and just don't know if I'm satisfied with how much material is there to seal it up top...

I've also got some internal injection pump upgrades I'll be doing as well such as installing the complete TDI lower timing mech from a TDI pump and possibly modding my gov. for a few more RPM's even though I have to be careful running the 12mm head on the pump (vs. 10mm stock) past 4200rpm or so...

Lets see....remove and modify the downpipe with a larger flange and some really nice 2.5-3" piping I have...as initially, I built a good portion of it out of weld'els.
Rear bilsteins need to be installed on the car, as the fronts already has the GC/Bilstein coilover setup on it...but the last time I had the car out the front was soooo stiff and the rear running OEM that laying on the pedal just slightly with all the torque and "squat" that came from that action I think has toasted the rears!
Some items will also be relocated... for instance, the lift pump I installed to help pull fuel for the car I'm hoping to stuff in the p side wheel well, along with the filter if I can get it to fit. Planning on redoing the centras...maybe without polishing them if they stay on the MK1 (i'm looking for something interesting in the 14x7 variety if anyone knows of something...)
A turbo change...could be possible...but we'll see... I'd really like to get the cash up for the nozzles that I want R520's (.260+) because I'm only running .216's right now and the motor has the potential for SOOOO much more. Thats alot of cash in a wedding year, etc. though. Unless I'm able to off load some of the parts I'm selling.

Anyways...alot for one thread. Just thought I'd post what was going on and where things are headed. I think my old post on the car(s) got deleted...so here we go again.

Better not make the others jealous...the other cars here...
My '72 Westy... 2.0 TypIV w/ 36mm Dells
http://i18.photobucket.com/albums/b109/joeallison_99/79%20Rabbit%20DD/100_2765.jpg
The wagon...undergoing some new things as well..
http://i18.photobucket.com/albums/b109/joeallison_99/Passat%20Wagon/100_2800.jpg
and our Jetta...
http://i18.photobucket.com/albums/b109/joeallison_99/100_1696.jpg

Joe

[orion2.0]

nice rabbit! I actually saw that thread on TDIclub a while back...i bet that rabbit is snappy!

[rabbitgtdguy]

:) Neck snapping...

I forgot to mention.... I'm also trying to get together funds to get an actual TDI tranny for it. As bulletproof as I think I could build a 020...I just like the idea of having that much more meat there... So...I'm hoping to get the TDI tranny Ryan has here in the near future....

Joe

[BUNNYLOVE]

Cool, hopefully i'll get to see it sometime. Are the .216s OEM nozzles?

[meatwad!!]

you can powder coat pistons? can u give me a little more info on that ive never heard of that being done.

sick motor man. project is lookin good

[rabbitgtdguy]

Ryan, yeah... .216's are OEM nozzles...however, they are OEM on the 5cyl 2.5 Transporter....so not here in the states. Its supposedly the largest OEM nozzle out there. I got them through Kerma TDI, he sells bosio...

As for the pistons...thats not powder coating. Its thermal coating done by Swaintech up in the Rochester area. Its a thermal barrier coating (TBC) on the tops to keep the heat where it should be and help elminate dissapation through the piston... It all helps protect the pistons from cracking, melting, etc. I also had machined the lips off the combusion chamber bowls on my motor setup to lower compression safely without effecting squish in the chamber. They greatly remsemble PD style pistons now. The coating on the sides is PC-9 basically an anti-seize, dry lube for the skirts.

Joe

[rabbitgtdguy]

Ok, so...I've had quite a few requests here in the last month to "update" my thread. I've done alot of random PM'in, etc. to those interested in where the project is...but I thought I'd do an update.

The mTDI is up and running again for spring here...bigger and better thanks to some pump mods that Named Tin Tin did additionally to my custom 4bt injection pump setup. He is a great guy and really awesome to work with! Can't say enough good things...

I'm still chasing a little bit of a weird starting problem, very intermitent, def. with the pump solenoid I think I tested the solenoid, and it doesn't seem to stick ,etc. out of the pump...however, I have a theory that maybe when the key is intially turned on that there is too much of a draw on the battery (at start I'm pulling the starter, my holley "red" fuel pump which is pulling power right off the solenoid location). Flick the key a few times...instant start, sometimes go out in the morning, turn over without glows INSTANT start...then, shut down, and its a bit of a pain again. Def. am getting power to the solenoid as the pump is going as well (the fuel pump), but I'm wondering on crank whether the solenoid doesn't get enough power. Just a theory...kinda like my thoughts on the solenoid when I mentioned it in the "Troubleshooting" section if you are interested in reading with my first attempt to test it with a battery charger...

Another though is possibly something with the fuel pump and/or the fuel filter itself... working on that...tracking it down... its very intermitent.

Anyways...that was long winded...

So here is the car as it sat yesterday with the host of VWs here at the house!
http://i18.photobucket.com/albums/b109/joeallison_99/79%20Rabbit%20DD/100_3009.jpg

I traded off the Centra Typ 11's I was running for a set of pretty rare ATS Cup "White Edition" rims (15x7, ET28) which I really like better on the car and such. Trying to find center caps for them now and the tire shop buggered one of them when the tires were mounted too...so, they'll be paying for that... its not huge, but enough to piss me off...

The rims on the car...
http://i18.photobucket.com/albums/b109/joeallison_99/79%20Rabbit%20DD/100_3010.jpg

and a shameless plug of my baywindow westy since my driveway was all "oldschool" yesterday! Looked like a flash out of the 70's, early 80's with the cars there...
http://i18.photobucket.com/albums/b109/joeallison_99/79%20Rabbit%20DD/100_3012.jpg

So...what am I working on now? Where am I at... well, still no R520's! Did I mention I'm getting married this summer!!! So $$$ is in short supply and R520's are quite the dive at the moment. I'm working on it though... but currently the .216's in the stock 1z/AHU bodies (190bar?) which really need to be reshimmed, especially when going to the R520's here...
(so...if anyone knows of a good deal on injectors and reshim....let me know :) best price I've found around here is 35-40.00 /injector for reshim + the nozzles)
But...most immediately, I'm working on getting my AWIC installed.

so...my system...
http://i18.photobucket.com/albums/b109/joeallison_99/79%20Rabbit%20DD/100_3028.jpg

http://i18.photobucket.com/albums/b109/joeallison_99/79%20Rabbit%20DD/100_3027-1.jpg

Old Hamm's Brewing Company 2.5 gal aluminum keg (for resevoir)
http://i18.photobucket.com/albums/b109/joeallison_99/79%20Rabbit%20DD/100_3029.jpg
http://i18.photobucket.com/albums/b109/joeallison_99/79%20Rabbit%20DD/100_3030.jpg

The other parts of the setup consists of a intercooler that a friend and i had made back when I had my Lysholm Stg 4 Corrado...
A VR6 auxilary radiator for the heat exchanger (all aluminum)
Large electric water pump (RV/Hi flow/low amp draw)

I had to go "different" with the res on the AWIC as I didn't want the car to be too racey and I'm trying to do "original" and different things with it keeping to a time period sort of thing. Hard to explain, but its all right in my head :)

So, thats within the next two weeks here (and a fuel cooler i have to install too). The intercooler will be mounted in the battery location under the hood (battery relocation done last fall), and then in the trunk the battery will be moved from the spare tire well to the d side or p side area of the trunk on the flat portion right above where the bumper bolts are... on the opposite side, the keg will be mounted on its side to help balance the weight when full of water/methanol mix (gal of water weighs about 8.6 lbs from what I have found... so 2.5 gal, will weight close to 20 lbs) , the pump will also be mounted in this location as well.

Still need to put in the tach setup as well. Debating on whether to convert the stock vintage style "round" tach to work with the W terminal or use my optical setup. I'm leaning towards the W terminal setup because its one wire and "less" in the engine compartment. Also, since I run serp belt I feel there is less chance for slippage to worry about compared to if I was running the W setup on a V belt car...

Hmm...that'll be close to it before the wedding here. I have to install my autotech upper strut bar here after the intercooler install and I may relocate the fuel pump to the back of the car more instead of right up from...we'll see. May even go to a smaller pump (Facet) and use the Holley Red pump in the baywindow to feed the Dellorto carbs I have on that particular motor.

I'm still not completely sure what I want to do trans wise here this next winter, but it will either be a seriously built 020 or a 02a conversion... LSD, hardened gears, etc. etc. Something will have to happen. Hmm...that, bodywork and chassis reinforement too. And maybe even a Holset :)

The car is so much fun to drive though...its a bit on the crazy side and with the diesel trans it really you can tell could use some other gearing. First is useless as you end up shifting as soon as you push the go pedal...too much pedal and its just tires spinning....

Think thats enough for now...thats a long post...

Joe

[rabbitgtdguy]

FINALLY... no more trips to the welding shop...

Added this to the arsenal today thanks to Todd (Fuslit) and I poking around on Craigslist. Couldn't pass it up for the price, so I drove up to Rochester this afternoon to make sure it could be mine!

After that...found he also is selling a TIG machine (500.00) as well as a pretty nice portable plasma cutter too (800.00) and he only sold this because he upgraded to a 220v MIG unit.

Now just have to get some gas bottles and get to it.

http://i18.photobucket.com/albums/b109/joeallison_99/Misc/100_3034.jpg
http://i18.photobucket.com/albums/b109/joeallison_99/Misc/100_3037.jpg
http://i18.photobucket.com/albums/b109/joeallison_99/Misc/100_3035.jpg




Joe

[FusLit]

Nice welder man, wish it had been around when I was lookin. Glad you were able to snag it

:smile:

-Todd

[rabbitgtdguy]

Did some more work today on the car.
Namely... I was able to mount the AWIC finally, the "keg" res. and the pump in the back of the car. I'm pretty happy with the mounting of the intercooler and how I ended up doing it just in case I ever wanted to return the car to stock and/or run a battery up front again.

A few pics...
http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_3043.jpg
http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_3041.jpg
http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_3040.jpg

Tomorrow...may remount my aux. oil cooler slightly to make some more room up front for the AWIC radiator and the fuel cooler (though, may run that lower in the car, or up in the wheel well...haven't decided yet. Finding room in the MK1 body is getting harder to do.
http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_3044.jpg
Decided to cut costs and save a bit this summer by not going for full aluminum intercooler pipes at this moment. Plus, I have quite a few full mandrel aluminized steel piping downstairs that is just sitting and could be used...not to mention, good first practice for the welder as well. Have a variety of angles to use as well (one 135, several 90's and 45's). Going to order what silicone adaptors I need tomorrow online probably and if all goes well...maybe have this up, in and going sooner than I thought!

Going to work on the wiring/relay setup for the system tomorrow as well I think...

Anyone know "the best place" to buy the silicone couplers and elbows? I was looking at summit... and Ebay.


Joe

[rabbitgtdguy]

Well...more updates... A few of the pics are about a week old now as I went about installing the fuel cooler, relocating the oil cooler slightly and installing a few of the AWIC components...

The fuel cooler I'm using...

http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_3047-1.jpg

http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_3048.jpg

Also...the AWIC heat exchanger...
http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_3051.jpg


Some of the biggest good stuff came tonight though... my mocked up intercooler tubing/routing with the silicone connectors (that finally came today...after being a week late!)


http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_3060.jpg

http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_3061.jpg

http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_3063.jpg




Deburred, cleaned and flushed everything out of the intercooler system tonight. Drying now and I'll permenently install the intercooler tubes, etc. tomorrow. My autotech strut bar I believe is going to have issue clearing the tubing. Have to slightly "re route" the vac. pump line from the booster as well, but thats not a big deal at all. I'm very happy with the routing of the piping and its length.
The bay also doesn't look too cluttered in my opinion either. Can't wait to see how nice it is once the paint/bodywork is done this fall/winter.

Good news on the drivetrain end as well. Will be getting a CTN trans this weekend for sure in trade for another 02a that I sourced for someone.

Very exciting

Joe

[BUNNYLOVE]

Looks really good Joe. Do you run the fuel cooler from the pump return line to the tank?

[rabbitgtdguy]

Ryan,

Thanks for the comments...and yes, the fuel cooler is plumbing inline with the return line coming off the pump and then to the tank. Fuel is the hottest (especially with my 12mm pump) coming from the return side of the pump. :)
How's the truck? How'd you rectify your turbo situation?

Joe

[BUNNYLOVE]

Gotcha, still pretty new to diesels..

My turbo situation is still pending unfortunately. I've been down over a month now. I cancelled my GT20 order this week.. it just took too long. I ordered a new stock turbo to get me running again with any luck it will be here by tomorrow.
In the meantime I bought 2 other GT2052 turbos brand new that I ran across as a package and couldn't turn them down. So I have a pile of turbos coming and one non running truck, LOL.

[rabbitgtdguy]

Doh... That stinks!

What are the A/R specs on the GT20's that you have? If your not keeping all of them...I could possibly be interested in one for the mTDI build for the b3 when it gets going here. Though...maybe you already have plans.

Joe

[BUNNYLOVE]

I have all the A/R and trim info at work. I will get it for you next week. The one I would sell is non wastegated so that could be an issue. You would need a new housing or external setup.

[rabbitgtdguy]

LOL...no wastegate issue for me Ryan. I'd actually like to elminate the current one. :) With the motor built the way it is I can support alot of boost without worries... :) So, I'd be interested....let me know


Joe

[BUNNYLOVE]

Well this might be the one for you :)

[rabbitgtdguy]

Some more progress...

boost tubes fully installed after some tight work, etc. No rubs, etc from what I can see and I really took it for a run today and it was holding 30psi without issue...could have gone more...but, no water system yet..

Going to work on that setup here tomorrow afternoon and Monday...electrical setup, etc. and maybe have the water all set up for Weds.

Only thing that didn't work was I was hoping to use a stock overflow tank for the "fill" point in the system...since the keg is in the trunk and the pump which are the lowest points... Having it up high would make filling and bleeding easy...so, think I might get a nice small aluminum overflow tank and call it a day. Doesn't have to be huge.
The system is going to be really efficient though...so far I'm calculating 5 gal of water or so..., very nicely sized res., good line and heat exchanger flow, etc. :)

Now...if only R520s were in the budget...

Will have another goodie to post tomorrow I'm sure, but for now...

Intercooler plumbing in and installed and I did it JUST right as the autotech strut bar I've been waiting to put in just clears things!!!!
http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_3064.jpg
http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_3065.jpghttp://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_3066.jpg
Big reason for the fit is having moved place where I am pulling the boost reading from, which was the inlet source on the intake manifold...but now is on the intercooler since I had it there ready to use!
http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_3067.jpg
going to get a nice stainless one down the road...hate the vinyl tubing, but want to be "happy" with "where" things are located before I invest money in more expensive "odds and ends".

By the way...if anyone wants a phantom series vac/boost gauge (reads 30Hg/30PSI split), let me know. I have no use for the vac. side and would love to get just a boost gauge instead of the split...don't know what I was thinking in the first place...

Thats the update for today!

Joe

[Nuksucow]

The intercooler setup looks great Joe, I love the Keg:laugh:

[FusLit]

Looks amazing man!!! Very clean install, very very nice :)

-Todd

[rabbitgtdguy]

Another goodie for the MK1 as of today which will be going in this fall/winter.

02a TDI tranny... Code "CTN"

http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_3069.jpg

http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_3068.jpg

and these goodies on the way from Finland...

http://www.kotinet.com/matti.farm/Myydaan/IMG_2564.jpg

http://www.kotinet.com/matti.farm/Myydaan/IMG_2563.jpg

The "white" ATS caps were hard to find but are the correct ones for the "White Editions" that are on the rabbit.

:)
Thanks to Warren for meeting up today and making the trans swap...
He got this nice 16v 02a out of the deal! and a shift box as well...
http://i18.photobucket.com/albums/b109/joeallison_99/VW%20Stuff%20for%20sale/100_3052.jpg
working on cleaning up the CTN trans now to hopefully make it look close to as nice. However, depending on $$$ I may do an LSD this winter for it, so I'd be taking the case apart...maybe powder coat. Def. will 'blast the case though and do some other work! Going to be great gearing for my particular setup though...

CTN
1st 3.778
2nd 2.118
3rd 1.360
4th 1.029
5th 0.755
R&P 3.157

Right now with the FN in there, its really interesting with the R&P. Can't wait to have this stuff in!!!

Thanks again Warren (and Ryan, since it sat around so long, but luckily didn't get sold off somewhere else around the country!)


Joe

[Nuksucow]

Thanks again Joe, I'm glad we could help each other out. I can't wait to see your rabbit some time.

[FusLit]

Nice, that should hold up a bit better to the torque your ripping through there. LSD would be a smart thing to do (when the money presents itself to do that)

I can't wait to see the rabbit as well! :laugh:

-Todd

[rabbitgtdguy]

Well...the AWIC is finally completely plumbed in, filled with water and working. I have a few refinements that I'll "make as I go" here, but the fact of the matter is that it is up and working, which I'm very happy with.
so... a few pics...

Here is when I first started plumbing in the lines for it... I used some really nice Ag sprayer hose made by Goodyear for the job...nicely sized as well at 3/4" ID throughout the entire system. All total, once filled today it topped off close to 5gal of water.
http://i18.photobucket.com/albums/b109/joeallison_99/100_3085.jpg

One thing that took a while was finding decent grommets to fit the body where I made the holes for the water lines to come up through...
ended up in the "HELP" section of the local auto store and pondered...finally, came across a HUGE GM grommet...but it fit PERFECTLY for the hose and the body!!!
http://i18.photobucket.com/albums/b109/joeallison_99/100_3087.jpg
Installed one compared to the other line/hole...
http://i18.photobucket.com/albums/b109/joeallison_99/100_3088.jpg
Here is what the keg that I used finally looked like after searching through McMaster for the aluminum bungs for it... and my homemade brackets which seem to work really well and keep the setup looking "clean" in the hatch...
http://i18.photobucket.com/albums/b109/joeallison_99/100_3089.jpg
So...the final product as it stands at the moment.
I ended up using a Ford lightening/VR6 style aux. water pump as the RV unit I had wasn't up to the task...it was a diaphrapm style and got to be loud once in use for quite a while...
Keg mounted, system filled/bled at this point...I've also made a "mount" for the pump if I want to make it stationary to the spare tire well if need be. I'll also eventually here in the next few weeks be mounting my battery on the opposite side from where the keg is and that'll leave the spare tire well open.
http://i18.photobucket.com/albums/b109/joeallison_99/100_3099.jpg
http://i18.photobucket.com/albums/b109/joeallison_99/100_3098.jpg
Here is what you can see of the plumbing of the intercooler from the outside of the car...its not much, and I didn't want to run them down the center of the car of course because of the exhaust...
http://i18.photobucket.com/albums/b109/joeallison_99/100_3100.jpg

I'm so glad that with all these additions to the car in the way of drilling, cutting, welding, etc. that I have not done the bodywork yet. Its nice because when i go to do it this winter, I'll have everything "set" the way I want to, be able to weld anything I don't want back up and have a nice clean "ready to install" setup for once I get the paint and bodywork done here. Its a good feeling. Do it once...do it right.
This winter the keg will get a good polishing, as well as the intercooler itself and I'd like to eventually replace the intercooler pipes with some nice aluminum or stainless if I can find something at a decent price...or someone with scrap in the size I need and long enough...
I also am working on figuring out how to make filling the system easier. Originally I wanted to keep the look of the keg "clean" to keep it "keg" looking...so I was going to install a small aluminum res. for filling that would be the highest point in the system either in the back hatch of the car (t'ing off the return line) or installing it up in the front of the car.
Well...as you can see...room in the engine bay is getting hard to find and the piece I got off of EbAY really sucks IMHO and I don't want to use it. I may install a radiator neck/filler neck on the intercooler instelf, or could do it on the keg as well. Still up in the air about it. We'll see.
It is working though and is a nice setup. took it out for a good run after I finished things up and after the run you could easily touch the pipes and tell a distinct difference in temp before and after the intercooler. :) :)

Anyways...so....R520's...please come soon :) and I need to find someone to rebar my injectors!!! Preferably while I'm on the honeymoon so they'll be here when I get back!

Think I might work on upgrading the filter system (fuel) and hiding it (don't like where it is in the engine bay there...) and may try to relocate the pump back closer to the tank if I can find room....its kinda "large" though...we'll see... I'd like to clean up the bay a bit


Joe

[Nuksucow]

Looks great Joe, did you do the welding on the keg?

[rabbitgtdguy]

No, I didn't. I fear that I had done the welding on it, it would have been alot cleaner! However, I just got my MIG and am just starting in on the welding adventure which will be AWESOME once I learn "how". I wanted to try to do the keg on my own, but didn't want my first welding project to be MIG'ing Al ...so I left it to a local shop. I'm not particularly pleased with the job, but will clean it up/grind it down, etc. this winter. He started to hot it looks like on the "front" inlet from what I can tell...the other doesn't look so bad. He also made multiple passes as well too which really "uglies" things up a bit...

I'll feel so much better once I'm able to weld on my own...I will start with mild steel scrap, then the first project (if I can find some templates) will be making the 02a mounts that I need for the CTN tranny swap...

But...no, not my work and luckily the fittings cost more than the welding, so I made out ok on the keg (each fitting was 15.00 +12.00 for the shipping since McMaster does overnight shipping and such...). I only paid about 15.00 for the welding on the keg.

Joe

[rabbitgtdguy]

Heh...Heh...

Well, the white stuff is starting to fly...so I guess its time to start looking towards "winter upgrades" again....

A few bits of new stuff....updates...


Day that I shot these nice pics of the mk1 ...here is one...
http://i18.photobucket.com/albums/b109/joeallison_99/79%20Rabbit%20DD/100_3202.jpg

I somehow managed to snap the dp right in half on the way home that night!!! Sounded like a MACK truck whining all the way home! Fun stuff...SUPER clean break!

http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_3214.jpg
http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_3213.jpg

So...today i managed to of course get the dp off so I can repair it just for right now to get the car inspected (DEC) and put it away. I'll be building a new DP this winter...probably a v band unit with another, shorter flex section closer to the discharge. It must have not been a great weld as the motor mounts in the car are fine and in great shape, very little rock. However, the Mk1 front mount...traditionally not the best may have not helped the situation...especially with the torque this beast puts out...

Additionally today....i put on the other "new" good door on the D side...
What once had a front d side and rear d side door that was badly dented in, etc.

Now looks like this!

http://i18.photobucket.com/albums/b109/joeallison_99/79%20Rabbit%20DD/100_3211.jpg
http://i18.photobucket.com/albums/b109/joeallison_99/79%20Rabbit%20DD/100_3212.jpg
I couldn't even find a picture of the "bad side" here on my photobucket...apparently I always shoot it from the p side...hmm...wonder why.

Now if I could only find a nice Inari Green hatch!

However, I do have some body work to do this winter...
These are pics of the D side rocker panel
http://i18.photobucket.com/albums/b109/joeallison_99/79%20Rabbit%20DD/100_3219.jpg
http://i18.photobucket.com/albums/b109/joeallison_99/79%20Rabbit%20DD/100_3220.jpg
Def. going to have to do the D side rocker....contemplating doing the P side as well though pushing on it is fairly "hard" on the p side, but I can hear some cracking....better safe than sorry possibly.

The pans on both sides of the car are great...nothing wrong on the pside.. One small hole, less than a dime on the D side...
Some little work to do around the fender wheels in the rear and one spot on the new rear door I installed today. Looks like that MIG i bought is going to come in handly. Though, I'm hoping rockers don't kill me to do.


Additionally this winter...here is a big part of it...
1 of the 2 of these CTN TDI trans will be going in the mk1 (the one on the left...Ryans/Warrens formerly)... the other is for the b3 when I do the mTDI swap for it...
http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/100_3215.jpg

Hopefully time and money will allow the b3 swap to occur in the spring. If not, it may be closer or during next summer...but we'll see. The focus is to get the 02a in the Mk1 at this point and some of the bodywork done. Afterall, I do rely on the b3 as the daily at the moment. The b3 mTDI build will be another thread.

Also have some good chrome bits to add to the Mk1 as well. Correct, complete set of 4 chrome handles (just need to find the black trim for them) as well as a set of new chrome flags too. Going to try it...see if i like it. Chrome euro bumpers would be nice....but a bit out of my $$$ flow at the moment. Maybe in the future.

Anyways....thats an update. If anyone wants to help with the rockers in the future...that as experience doing them...that'd be a GREAT help, I can pay with some parts and beer :) if so desired! I don't think it'll be too hard though.

Joe

[FusLit]

Looking good Joe, the doors look great!

Can't wait to see the progress made installing the next step of what you have in mind.

-Todd

[rabbitgtdguy]

LOL...yah...which is that? The rocker...ugh.... or the tranny... YEAH!

I'll be reinforcing the front core support and elminating the stock Rabbit front engine mount in favor of the "modified" mk2 front cross member made to bolt to the front bumper mounts and utilize the Mk2 solid front mount. I was going to go with the BFI unit, but would like to rid myself of the mk1 front mount altogether.
Also...allows me to make the core support "removable" if I decide to do so...haven't gone there yet though.


Joe

[lotar_6]

right on! I gotta check this beast out sometime...

[orion2.0]

this car is effin sick. This is exactly what I have been thinking for my next project. ALH + MK1.

[Shrives]

i wish i could source out a mTDI swap, i guess i just don't look hard enough!

beautiful car, i love it!

[rabbitgtdguy]

Thanks guys...appreciate the good comments :)
She is a bit more rusty than I would like her to be at the moment, but then...I think that comes with two things in this territory
1. MK1
2. New York State and our salty roads...

Also, the car is 28years old as well... so there is bound to be a little rust. Luckily, the floors are SOLID and most of the rust is just surface which is nice. I will need to replace the drivers side rocker though at some point. I had considered being able to do this, this winter, but that isn't going to happen.
Currently, I'm student teaching as part of finishing my grad. degree at Elmira College, which meant I had to leave my job for three months...no income on my end. My contribution to our income at the moment is only in the way of what I got for fianancial aid. Oye....kinda wears on ya...

So upgrades this winter will be mild and trivial. I am hoping to at least get the 02a CTN TDI trans in the car. With the help of another forum member, I think I'm going to be able to save myself the 300+ in buying mounts and we're going to fab them up. Then, its only buying the clutch (as I have all the other parts ready including the euro cable clutch parts). The swap itself once I have the mounts shouldn't take long :) . I may also try and fab up a new dowpipe as well and I'd like to be able to find another turbo and/or .48 exhaust side WITHOUT the wastegate and just elminate it altogether. I'm able to run well over what the internal wastegate is able to handle, so I have no need for it as it runs disabled all of the time. I've got my ideal size turbo in mind...but again, thats money I don' t have this year.
Other upgrades this winter will be finishing the rear suspension (need to get up to Todd's to take my bilsteins off the rear of the car) as one big issue is the fact that the front is nicely setup with my bilsteins/GC coilovers...while the rear is stock. There is so much torque on takeoff that I can easily squat the car in the rear with the stock suspension and make the tires rub (without trying hard) and the stock suspension itself has finally gone....

Going mTDI has been alot of fun and in my opinion, gives you alot more tuning for the buck when you consider the limitations of turbo selection with an ECU or the limitations of the ECU itself. There is a big debate over this on diehard TDI sites....but honestly, if the mpump is done right, you have alot more adjustbablity and tunability in a very "old school" fashion which makes things all the more fun. When I consider what custom maps costs, chips, reflash, etc. I think it adds up in price. This motor is just purely simple, which makes it so nice! Parts aren't too hard to find, just depends on where you are looking and what you are looking for. I think the last "swap" that Ryan and I were able to source was really decently price considering what it came with.
Its def. alot of fun! I'm looking forward to spring and what upgrades I'm able to do even though there isn't alot of extra cash this year.

Joe

[orion2.0]

So did you use a mk3 TDI to build the m-TDI? Is it possible to convert an ALH to a M-TDI? Do you use a special mechanical pump or is it an actual VW pump from a non-ecu diesel? How much do those cost?

[rabbitgtdguy]

So did you use a mk3 TDI to build the m-TDI? Is it possible to convert an ALH to a M-TDI? Do you use a special mechanical pump or is it an actual VW pump from a non-ecu diesel? How much do those cost?

The mTDI engine I have is based on a 1z/AHU motor...however, my motor has some internal modifcations, namely in the area to the pistons as well. It was a 1z/AHU base though *mk3 or b4 passat*

Yes, it is possible and just as easy to convert a ALH to an mTDI setup.

Either situation uses a pump that you can either buy ($400-1,000+ depending where you look) or have someone "convert" a couple pumps that you might have on hand. Its not as simple as "bolt in parts" to make the mTDI pump work properly. You'll see many instances where some claim that you can just take an older VW diesel pump (IDI-Indirect Injection) and convert it to a mTDI pump. This isn't true. There are other considerations in doing it. A IDI pump from an older vw with the 10mm TDI hydraulic head, plunger and camplate WILL allow the motor to run...but not to its full potential . You MIGHT get stock hp/tq with the pump turned all the way up.
Building a full on mTDI pump requires that you build the pump and take into consideration several factors including
-Timing advance (mTDI's love their timing...and its a limitation as far as an "eTDI" pump is concerned). A properly built mTDI pump will allow you to pull alot more advance from the pump itself...and therefore more fuel/power as long as your motor is built to handle it.
-IDI vs. DI engine injection pressures... TDI (or DI) engines require quite a bit more injection pressure than the old VW diesel motors... this needs to be taken into consideration in the building of a mTDI pump
- FULL LOAD feuling and fueling relative to RPM/Gov settings. THIS IS A BIG ONE...especially for those that think a IDI pump will just cut the bill...

That names a few of the considerations. I prefer starting with a DI based pump...in my case, a Cummins 4bt pump. However, you can use a IDI pump as long as you take in consideration the same above modifications. The 4bt pump requires "more" in the way of modifications, but the reason for this is because the motors they were commonly run on didn't see much of anything above 3k.
A 1.9 AAZ TD pump (CAN spec mkIII, b3) is a nice pump to start with as is a Fiat Croma pump, some FORD pumps and Peugeot pumps...

There are also some, and your lucky if you find them, DI specific pumps already setup up for DI motors that are mechanical from across the pond.
There are also more obscure "VW Industrial" 4 cyl pumps that were mechanically based for the TDI. Also hard to find.

In all honestly, building the pump isn't super complicated, but its not as easy as just bolting on parts. When considering the time involved doing wiring, etc. I'd say in building your own GOOD mTDI pump (assuming you have knowledge of how the pump works, etc) , you'd have about as much time into wiring as you would building a good pump in the end. The mechanical end of things leaves the performance potential of the motor quite spectacular (even though eTDI's have there reflash, multiple programs, etc.) and also defeats many of the shear "mechanical" limitations that the eTDI pump has on it (one big one is how much timing advance you can run). Turbo selection is opened up as well with the mTDI option. You can mechanically control VNT turbos of your choice and then there is the host of wastegated versions out there as well.

I personally am at the third revision of my 4bt pump at the moment and am building another "based on the 4bt pump" for the b3 project here in the future. To me, I like the idea of starting with a DI pump, the larger shaft size and the fueling potential it has. I'm making further GOV modifications this winter to extend my fueling window as well....one big reason I need the 02a/j in the car.

I can point you in the direction of some good pump builders...that I know they are selling a good product. There are some out there not doing it the right way that still ask a fortune. I myself could also build the pumps, but don't have a good lot of spare pumps, parts, etc. at my disposal at the moment nor the time to do so until April. MOST pump builders will require you to pay their fee... PLUS you have to have at least a TDI pump and a IDI TD pump to send to them for modification. BE WARNED of the guys that want the above, but only charge $100 to make the modifications....you'll get what you pay for which is essentially someone just swapping the TDI camplate/head/rotor onto your IDI pump and calling it a day.
Since some of us have had sucess with the mTDI motors, these kinds of things have been popping up everywhere. People taking very little bits of information disclosed in build threads, and using that information to make money off of it. Scary stuff, as I've made sure never to mention every detail that has gone into things. Its sad that I know a few of these people too and what their customers are getting.

That said....its alot of information....sorry if I rambled. I enjoy the mTDI and wouldn't have it any other way short of if a NEWER TDI fell into my lap. The mTDI setup really lends to the old school approach to things and opens performance way up as well...comparable to that mpg wise of the electronic versions.

Anyways... thats my blurb for now!

Joe

[orion2.0]

no problem..ramble on...the more info the better because i am trying to learn if this is something I want to do in the future...and if its possible on a low budget.

Mk1's are dirt cheap on vortex. I figure i would get an older high mileage TDI engine for less than an ALH...then spend the bulk of my budget on rebuilding/beefing up internals, pump, and turbo. I figure 80% of the budget would go toward engine needs. I'll spend nothing on the interior (strip it) and the exterior will be pretty raw...probably just a satin black rattle can jobby.

If you dont mind saying...roughly what did you spend on your engine...purchase, rebuild parts, pump etc? I'll go back and read your build thread a few more times so I dont ask already answered questions. Thanks for taking the time to write such a detailed reply.

[rabbitgtdguy]

WOW it has been a crazy long time since I updated this thread. Its been a busy summer though...

Some things that have happened...

Well....we moved is the biggest thing. Still in the Elmira, NY area...but bought our own house, with a newly built garage as well. PO only had one of those plug in flourescent lights in the garage and I had to improve on that....

Here is the Rabbit and Westy's new home....
http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/DSCF1134.jpg

My lighting improvements. I LOVE CRAIGSLIST!!! I got these fixtures (40-60.00 fixtures from Lowes/Home Depot) for 1.00 a piece! I managed to get all of them... 5 4-bulb fixtures and 9 2-bulb units for a whopping 14.00!!!
Anyways....6 of them ended up in the garage. The 4 bulb fixtures (x4) in the rear and middle of the garage and then (x2) 2-bulb fixtures above the garage door when the door is shut....PLENTY of light :) Finally!!! You can actually see the b3's mTDI build started there on the engine stand....working on that as we speak
http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/DSCF1133.jpg

So....I was thinking about having finally broken the engine in that I was comfortable to open it up just a bit more. The 02a is still sitting...waiting and ready to go in the mk1, but I just didn't get there this year. Here is a shot of that.
http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/DSCF0748.jpg

So...today. Governor mod...
http://i18.photobucket.com/albums/b109/joeallison_99/TDI%20ENGINE/DSCF1137.jpg

All I have to say is WOW!!!! I shimmed the int. spring 1/8 and the main spring by about 1/4". Once I got it all back together of course it took some fine tuning of the pump and such but I am super impressed with the result. I can probably shim the main more if I wanted too, but I am good with this until that 02a is in this winter (along with all paint/bodywork...wait til you see what I have planned there). I just can't wait to really be able to play with the car once the new tranny is in.


It is NUTS on the road :)

Joe

[lotar_6]

nice man! Garage space rocks. I never have enuff, tho.

[rabbitgtdguy]

Can't believe I'm still posting to a "Winter Upgrades" thread...but, the project has taken much longer than anticipated. Paint, bodywork, 02a CTN trans upgrade this winter, interior as well as other bits. Especially now, at the new place, new job...garage....etc.

Here are some things I'm working on at the moment. Just enjoying driving honestly right now befoe it has to go away for winter.

Bought the rack from Brianh here on the forums for the mk1. Its in pretty good shape. It was tweaked a bit when i set it on the car and the drivers side "posts" look like they have been bent before...or clamped for some reason. Anyways, the clamps that were with it after doing some searching were not the original clamps. One "worked", and the other wouldn't even pull to my roofline if I tried. So, I tried my hand crafting something using some aluminum bar stock I had around. I'll be refining them this winter I think, but road tests show they are working REALLY well and they are "super" clean looking and pretty damn close to what the OE clamp looked like...

http://i18.photobucket.com/albums/b109/joeallison_99/79%20Rabbit%20DD/DSCF1194.jpg

http://i18.photobucket.com/albums/b109/joeallison_99/79%20Rabbit%20DD/DSCF1192.jpg

http://i18.photobucket.com/albums/b109/joeallison_99/79%20Rabbit%20DD/DSCF1191.jpg

http://i18.photobucket.com/albums/b109/joeallison_99/79%20Rabbit%20DD/DSCF1193.jpg

Another thing I have been working on is a new CCV vent system for my mTDI setup. I originally was using a "OLD NAVY" CCV from an ALH engine. This setup had a single port on it which required installing a block off plate on the 1z/AHU motors and elminate the block vent. I didn't like the setup and went back to the factory 'elephant hose'. I have two of these units here and one is brand new, and continues to leak at the CCV puck. I think it has to do with the clamp used on it and since it does clamp "completely round" so it leaks a bit. I never was happy with it and have started working on a variation of the KC TDI mod for CCV found on TDI CLUB.com

I'm using reinforced high pressure hose
An Agricultural filter
Stainless steel scrubbing pad
a crankcase vent plate (from 1.6 NA engine)
various connections.

In doing so, I'll have an efficient CCV system that is not venting to the atmosphere but is keeping anything in the intake tract nice and clear!
Some pics...
http://i18.photobucket.com/albums/b109/joeallison_99/79%20Rabbit%20DD/DSCF1183.jpg
http://i18.photobucket.com/albums/b109/joeallison_99/79%20Rabbit%20DD/DSCF1187.jpg
Here it is sitting on the other mTDI motor I'm building for the b3...fits perfectly on the block (1z/AHU....ALH = no crankcase vent on block)
http://i18.photobucket.com/albums/b109/joeallison_99/79%20Rabbit%20DD/DSCF1188.jpg

More update to come. Need to update the b3 mTDI build too....bottom end is almost completely done.

Joe

[BUNNYLOVE]

Joe, did you get the ccv installed yet? Wondering what your impressions are so far?

[rabbitgtdguy]

Ryan,
I'm just now installing as I mentioned in the post that I made last night. :) Will be in this weekend. Just haven't had the time.

Joe

[orion2.0]

I was bummed I didnt get to see this rabbit at the drag day! Next time maybe. I'm sure it would have spanked my TDI's 15.2 1/4 mile.

[rabbitgtdguy]

yep...sorry, didn't make it into my agenda this year. Had something come up and honestly thought it was this next weekend. My bad.


Joe