Orwell gets boosted (another 1.8t 20v swap) by mk1vDUBtec

9 minute(s) of a 91 minute read

So there's nothing wrong with the lever arm or the throwout bearing. I took the new clutch stuff off and bolted the old/stock clutch PP, disc, and flywheel back on and it works perfect.
The new pressure plate compresses wayy too much. Then I tried the new PP with new disc and old flywheel, and it kind of works. The lever arm can be pulled up some to where the clutch starts to disengage, but is not fully disengaged.
I will be calling BFI about the Sach's Power clutch kit today and ask for a refund.
Anyone have any suggestions for a clutch kit/ setup?

The push rod length shouldn't change? I have an 020 4k trans (stock 84 gti). I've only come across 4sp and 5sp push rods, I obviously have the stock 5sp pushrod.
I ordered a Sach's power clutch kit for 8v, I called Bfi and made sure it would work for my trans and was assured it would. The flywheel came with the kit, it is Eurospec LW flywheel for an 8v. I have not mixed and matched anything I ordered exactly what should all work together.
I bolted the old clutch setup, with everything stock on and everything works perfectly.
I bolted the new clutch setup on and the pressure plate will not disengage because the 15 ft-lb torque setting basically bottoms the springs out already. If anything I'd think that the springs would be harder to compress rather than easier, since it's supposed to handle more power.

This is what I ordered and doesn't work.
I'll probably now either order this
or possibly this

Yeah, the clutch release plate? Yes, that came with the Power clutch kit. I compared it to the stock release plate and they look pretty identical. I used each plate with its designated PP. I didn't attempt to mix and match, but that might have been a good idea. I really think that there is a problem with the "power" pressure plate. I hardly consider a pressure plate with a lower spring rate to be "power" or any better than stock. I was screwing the flywheel bolts in by hand and the plate was bottoming out with the 15 ftlbs torque spec.
I called BFI today and they are refunding my money.

I just ordered the ACT Stg 2 kit . I've only heard good things about ACT. They seem to be really great quality (I'd hope so, because they're a lot more expensive). I don't want to have to pull the clutch out again for failing aver a few hundred miles, so I don't mind spending extra on a quality clutch.


Starting the Boost pipes today

8-14-2010

Started mocking up boost pipes. Those red connectors are not staying there. They're solely for purposes of mocking up how it'll be. They will be welded together after I have everything where i want it.

8-18-2010

yeah, but the guy @ BBM runs one and he said he loves it.. Mine is also a different kind than the ones I've heard breaking, so hopefully it'll be okay.

Does anyone have AEB into mk1 harness wiring help/ suggestions for me? I'm starting the wiring veryyy soon. I found boosted20v's wiring page, so I can try and use that, but it's into a ce2 fuseblock, so I know some things are going to be different.
It'd be awesome if someone had a list of what wires actually need to be spliced and into what. thanks.

8-20-2010

Great news!
I put the new stg 3+ SPEC clutch and PP on last night and it works!!!!!!

Also, my silicone connectors came in for my boost pipes and my K&N air filter came in too (kinda regretting I got a 7" one, shoulda went a little smaller). I've got a list of things to do this weekend (this is only the second weekend I'm working on this project. Everything else has been done after work Monday-Thursday):

1. mount radiator, trim shroud some to fit.
2. Finish running coolant lines
3. Mount Fuel Filter in place.
4. Mount catch can in place and run line
5. Mock up intake pipe with MAF and Air filter
6. Figure out where to weld in bungs for Diverter Valve
7. Buy 3" piping to start custom downpipe
8. Start wiring
9. drink some

Pm'd for sure!!
2.0TFSi in a rabbit??? I had no idea someone had already done that. That is truly insane!

Got some stuff done tonight. Catch can and fuel filter mounted. Axles bolted in. New trans fluid in. Modded the radiator fan shroud a little more to fit in.
Running coolant lines is gonna suck.

Pictures as promised.
My bentley = my best friend.

I made all of these boost pipes with 4 tubes that I got from my work for free because they were throwing them out. I don't think it could have worked any better if I actually bought piping. I still have to weld some 1" bungs on for the diverter valve, though.

8-22-2010

new Updatez!
Made brackets for the intercooler and radiator:

Drilled new holes for the radiator tits to sink down into. *I had to move my radiator, trim the shroud a lot, re-weld the fan bracket back onto the shroud, and use the Passat's "slimmer" electric fan in place of the rabbit's in order to fit it. Looks like it'll work pretty well tho! And there's plenty of room for the motor to rock back and forth too.

Fits pretty nicely *

Tacked the intake pipe for mark-up purposes.

Also had a nice trip to Autozone to find some coolant hoses. *That was fun. *
AZ: "Well, what car is it for?" *
me: "Trust me, this isn't in your computer, just let me look at the hoses you have."

I'm finally getting closer.

The coolant lines are finally complete. *Some stuff is rigged (kinda has to be). I'm praying that it doesn't leak, but I don't think it will.
Up next, the fun of wiring and making myself a downpipe. *Then I just have to figure out what vacuum lines need to be ran to the back of the intake manifold and which ones can be plugged, as well as putting my diverter valve in and then, hopefully (dare I say it?) it will run. *