ranton Posted March 2, 2016 Author Share Posted March 2, 2016 M M gave me a hand to yank the engine back out this evening. 1 hour from start to finish wasnt too bad we thought. https://youtu.be/JVyQWR-C_vE made a silly timelapse to go with it engine is back out to sort a few niggles and improve the downpipe design, and paint the engine bay to match the rest of the car now! also looking at a Turbo and injector upgrade kit that would hopefully net around 280hp when tuned, (double the current 140hp the car is running right now. fingers crossed my new contact comes thru) 5 Quote Link to comment Share on other sites More sharing options...
ranton Posted March 19, 2016 Author Share Posted March 19, 2016 well i have ordered the Turbo and the injectors Will have to custom fabricate a new exhaust manifold and alter the layout of the engine bay slightly different intercooler, different exhaust layout today engine bay got painted again lol from silver to gloss black 2K 6 Quote Link to comment Share on other sites More sharing options...
ranton Posted April 16, 2016 Author Share Posted April 16, 2016 Well finally a bit more traction this week or soon to be lack-thereof Turbo & Injectors and miscellaneous other parts arrived from Europe. I need to fabricate a log manifold for the new turbo to bolt up to. Will also need to send the clutch off to beef it up All new intercooler and pipework to be done also. Will change it to a much larger front mount instead of the side mounted setup I am currently using. Should be good. 8 Quote Link to comment Share on other sites More sharing options...
ranton Posted April 17, 2016 Author Share Posted April 17, 2016 Did another hour on the setup today Just stiching it all together bit by bit hoping it doesnt warp to much! Heres the new Garret VNT turbo on the left Vs the old one peice teeny tiny little KKK turblow on the right... Just need to make sure i get the new turbo positioned close to where the stock one sat so I can avoid having to make new oil return. (Yes im being a tight ass) 2 Quote Link to comment Share on other sites More sharing options...
ranton Posted April 25, 2016 Author Share Posted April 25, 2016 Well the manifold is now all fully tig welded inside and out.. (where possible)  and has had the die grinder in most of the ports smoothing the internal walls...hopefully it works out alright   Clearance is tight between the engine mount and the actuator but it should be fine 5mm is stack of room.  Will make all new brake lines this week and hopefully slam the engine back in for a test fit and all the new boost pipes to be run.  7 Quote Link to comment Share on other sites More sharing options...
ranton Posted May 10, 2016 Author Share Posted May 10, 2016 Been slow going with work in the way as per usual. Turbo and manifold are all bolted up and support gusset made. Had to wait for new gaskets to arrive which now they have and a oil drainline needs to be plumbed up. All easy shit. New strengthened clutch from Autoclutch will handle up to 450hp. (I will be happy with 280 to 300hp) Injectors to get installed this week hopefully too.. if i actually get any free time fml... 2 Quote Link to comment Share on other sites More sharing options...
ranton Posted May 13, 2016 Author Share Posted May 13, 2016 Just pictures for attention  but the Support bracket for the bottom of the turbo to tie it to the Engine block and help the poor snail hang on from all the diesel torque.    Also got the injectors installed, the manual makes it sound a whole lot more scary and complicated then it actually is... setting the backlash etc too was simple as fuck.      Also ordered a sizable intercooler (compared to the last one i used)  All new brake lines tomorrow, and fingers crossed a engine test fit  Everything else is all bolted back up to the engine no ready to be dropped in . 2 Quote Link to comment Share on other sites More sharing options...
ranton Posted May 22, 2016 Author Share Posted May 22, 2016 Well engine went back in with ease. But soon discovered that the turbo actuator has about 1mm of clearance from the steering rack and rear engine mount hahaha Any who stoked that its mostly correct... and can easy remedy it but lifting the turbo higher by 15mm. It also looks like i need to get the compressor housing outlet port cut and re welded on a different angle... just so the intake tract can be simplified. Other then that minty fresh!! Ran all new brake lines front to rear and and installed a larger 23mm master cylinder. Looks like my old 22mm cylinder was funked... 6 Quote Link to comment Share on other sites More sharing options...
ranton Posted May 24, 2016 Author Share Posted May 24, 2016 on the plus side it looks like there was way more room than i thought behind the engine so, I will get creative with the turbo positioning.. churr bro 2 Quote Link to comment Share on other sites More sharing options...
ranton Posted June 9, 2016 Author Share Posted June 9, 2016 Well looks like there is enough room to orient the trubo upward so manifold has been modified and turbo clocked around to fit a little better (in some ways) Looks like it will be the go. Will do a final weldup this weekend and make a different mounting bracked for holding the turbo.. then hopefully then engine can then stay in more permanently Just need to shift it a little more towards the port side and it should have ample clearance of the clutch master.... 1 Quote Link to comment Share on other sites More sharing options...
ranton Posted June 11, 2016 Author Share Posted June 11, 2016 Well manifold Mk2 is complete... Now just trying to work out how to brace the fucker off the block... bit hard now its so far away from original position. Also started putting some heat sheilding around the place. Installed a external oil cooler too. The factory water type heat exchanger was messy and took up heaps of room from between the front of the engine and the radiator. 2 Quote Link to comment Share on other sites More sharing options...
ranton Posted June 11, 2016 Author Share Posted June 11, 2016 Need to get the flanges faced off on monday as im worried about them sealing properly. Quote Link to comment Share on other sites More sharing options...
ranton Posted June 19, 2016 Author Share Posted June 19, 2016 Factory as bro! 2 Quote Link to comment Share on other sites More sharing options...
ranton Posted July 23, 2016 Author Share Posted July 23, 2016 Finally got back on the tools for the first time in weeks. And still got fuck all done lmao But mocked up intercooler/turbo inlet pipe... Then got the sections welded together to cut down on the amount of silicon joiners etc... Unfortunately the turbo inlet and outlet both point the same direction...and have to squeeze between the cambelt cover and drivers side strut tower and under the brake master cylinder After a little bit of pipe bending and swaging the ends it started looking better.. I canned the idea of wrinkle black piping for now too and stripped that all back off... And scouring brushed the pipes back to bare ally Really hope to get this thing fired up soon and start tuning this... I miss driving the horrid little beast... 3 Quote Link to comment Share on other sites More sharing options...
ranton Posted July 23, 2016 Author Share Posted July 23, 2016 Still to go... - mount fuel filter - run fuel lines - mount intercooler - clamp piping down - mount radiator - plumb up coolong system - find and mount suitable external oil cooler - plumb up oil cooler Quote Link to comment Share on other sites More sharing options...
ranton Posted August 27, 2016 Author Share Posted August 27, 2016 Well after a shitty few months got back on the project yesterday, Making brackets, oil lines, coolers etc.  Re Mounted the Fuel Filter so its out of the way   Oil Cooler Mounted in place   Map Sensor   Made some room for inter-cooler piping   Fuel Lines and Piping in place.   Cooler Lines Shortened to correct length and installed    It all fits pretty well just need to make some Air direction shrouding...   Just need to make the radiator hoses fit nicely now.... 4 Quote Link to comment Share on other sites More sharing options...
ranton Posted August 30, 2016 Author Share Posted August 30, 2016 I know the pictures are looking the same and the changes looking minor but it is pulling together again. (after all this is for my record too...)  Rangi'd up some Coolant pipes. (the clearance is tight between the filter and radiator....    Hell even the Expansion bottle return was a little on the tight side... but it clears the intercooler pipe  I tightened up all the intercooler pipes and got them sitting nice..  The Pre-Intercooled charge air pipe runs super close to the tensioner like last time....  Looking more complete  Chucked the front grille on to make sure it didnt foul with any of the Coolers.  Started making 2.5 inch down-pipe will try finish the downpipe during my lunch break today.   4 Quote Link to comment Share on other sites More sharing options...
ranton Posted August 30, 2016 Author Share Posted August 30, 2016 Well good thing work was boring AF today, so i went and hid in the workshop for the last few hours and mocked up and Made the Turbo down pipe.. Â bought a new flexi joint. as the one on the first iteration of the TDI engine had started to collapse. Â 45 plus gst at Chase... a little steep but couldn't be bothered waiting a few days for a trade-me one to arrive. Â Â Â Â Â Hopefully the inside and outside welding of the triangle flange keep the stainless flange attatched to the steel pipe.. :-/ Â The Downpipe itself doesn't look overly extravagant but its a tight space between the turbo and the drive shaft and to get the right bends to poke it thru the tunnel at a semi respectable angle. Â Trying to get all this shit done before my hoist sells on trade me.... 2 Quote Link to comment Share on other sites More sharing options...
ranton Posted September 3, 2016 Author Share Posted September 3, 2016 Its alive... Its a touch rauccaus.... But its pretty quick judging by the use of quarter throttle and it surging its way to 100kmh in no time... I think ima need a muffler https://youtu.be/z2RI9rC1pUs No driving videos yet bit of shit to tidy up yet... 3 Quote Link to comment Share on other sites More sharing options...
ranton Posted September 5, 2016 Author Share Posted September 5, 2016 Made two exhaust setups yesterday. Interchangable at the last V Band. One with a Baffled Coby for when running the in "chill" mode the other a open 2.5inch that side exits for track and drag rape. Fixed the PCV crank case breather system. Going back to the 70s and just running a rubber hose to the ground. Also installed a touch of Bmw for the power steering reservoir. Thanks U Pick It just fit better then the vw options 3 Quote Link to comment Share on other sites More sharing options...
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