ranton

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...

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 .

I understand

But did it clear up the T comment/ask I made

The T section, looks like it's more of a Y crossed with a T. (superimpose Y over T) I just mean it doesn't look directional as many log manifolds do I need a drawing!

The red is what I think might happen a bit (at the same time as the green)

And the 2nd horrible drawing is with a couple of 90's turning down to the collector.

BEHOLD the power of MSPAINT!!!!

But for those power levels I guess it won't matter much, thought I saw those larger figures in your build thread and thought it may be a problem

And if you end up with spare time/monies later it's all gravy.

I love this build.

**Disclaimer

Any comments I make are not to be taken as critical or confrontational towards any certain individuals, and are simply to be considered as my personal opinion only**

I would have liked to do something more like the lower picture but the spacing is confined.. and i have attempted to radius corners where ever possible

Man it really looks like the gas can go where it likes in that exhaust manifold!

And a few hard bends and pulses hitting one another.

Was there a reason you couldn't make a collector style one? (go up then down. space?) It'd be helpful for you EGT's

What's the dilly'o with those "t"s flaring both directions?

And because this is 2016:

**Disclaimer

Any comments I make are not to be taken as critical or confrontational towards any certain individuals, and are simply to be considered as my personal opinion only**

Haha mostly because of space not much higher than the exhaust manifold is the raintray if i had a mk3 or newer the engine bay has a slightly taller space available in the engine bay. Mk2s are poky and small and while i probabky could have made a collector style and made it fit. I didnt really feel need to spend hours and hours and hours for this little hack haha

Im not that fixated on power out put the car weights under a tonne so anything over 180hp and 250nm will be fast enough for this nana

Both the log manifold and the gorgeous collector style manifolds sell for around 600+ GBP (i dont have that much spare tin)

I made my manifold for under 100 NZD plus 2 hours of me fucking around

The bends are all schedule 40 1 1/4 and where the log branches off to the turbo is enlarges to 1 1/2 to match the inlet size of the turbos exhaust housing.

the turbo will be underworked anyway so egts shouldnt be that much of an issue i dont think. I dont really know anythibf about diesels or tuning them.

Apparently if i bothered to do crank and pistons etc I could see 350 - 380 hp with this turbo..

Not sure what you ment by the flaring ts?

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...

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. 

Haha what an epic thread,

When I did up my MK2 Golf 16V a few years back the Digifizz cluster went up in smoke (oil pressure sender wire got introduced to the switched 12V on the Coil)

The old instrument cluster had 267,000kms registered on it with the original engine, (unfortunately these digital cluster stop counting at 300,000km 80's hardware limitation that and they probably never expected any mk2s to be on the road after that amount of Km)

So queue a brand new in box genuine cluster from VW,

2 years and 10,000km since that photo was taken and its still going strong. (hardly driven any more to much other shit on the go lol)

What happens to these funky digital clusters - MK 2 Golf DIGIFIZ 299999KM the end - YouTube

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)

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.

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

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)

Well she went pretty well at the Nightspeed drags on friday night.

Consistently ran 15.5's all afternoon and night, got to the Quarters of the DYO Category, which was a heap of fun, got knocked out when she uncharacteristically pulled a 15.3 out of no where. so close to the Semi finals yet so far haha oh well..

Quite a few of the Track staff had good comments and a little laugh about the car and the windscreen banner it was wearing.

I recorded one of the qualifying runs for a laugh here it is

Throw back to good old Gran Turismo music.

Mate of a mate did some pretty swaggy photos for me to.

Gonna whack this up on trade me in the next week or so a well..

This is soo sweet, will be able to give a fair few unsuspecting drivers a fright at the lights. Hear the diesel clatter then boom its gone

Bahaha it sounds more like a Mac truck at idle..

Am I missing something here?

I don't know vw's that well, but it seems a strange thing to do to put an ecm in a place called a rain tray

standard place to put the ECU on a VW. these units are water sealed quite heavily from factory.

Any footage of it hooning? I imagine it goes pretty well?

I'm hoping to get it to a track day or drag day soon. other wise will try too get some "filmed on a private road" action pretty soon.

Took a bit to dredge this thread back from the brink!

 

Love the new color, and a very cool project in general.

Cheers mate.

goes pretty well pretty happy 

Well this happened on the 29th

#allthefilters

new colour to be revealed once its re assembled.

I really should get round to organising a Certifier... :-/

got a refreshed look on the gauge faces drawn up. my tdi cluster went up in smoke first time i plugged it in. pissed me off as it cost me a bomb ex the UK Ebay.

so have made new faces for the gauges to make the redline reflect the diesel style rev counter

engine bay is about done. just need to mount steering bottle, airfilter and boost control valve

update time.

final stages and probably the most annoying part plumbing up the Cooling system and the intercooler setup.

Car is running driving pulling hella hard.. for a shoddy diesel

runs reallly nicely i have to say