Project: dz.day.c.rad.. by n0ftInc

12 minute(s) of a 25 minute read

Project: dz.day.c.rad.. 

Compliments of n0ftInc @ michiganvw.org

12/23/10

I went to crunching some numbers and outlined something I have been wanting to do for a while. I started to watch the classifieds for a few weeks and ended up making a trip..

I've never been to Canada before. It was quite the experience. Thanks to Jay, Andrew, & Tony for the help. In the end we made it back across the boarder (twice!) with this beauty.. hahano 

So, with the donor all set, it was time to search for a recipiant. I looked at a few Corrados around town, but nothing really tickled my fancy. I really wanted to have a VR since it already was 5x100 and had the larger fuel tank. I'm glad I passed on a few of the ones I checked out because shortly after this became available at a pretty decent price..

Previously owned by a fellow Miver, it wasn't too far away and met my search criteria.

The plan is to construct a nice realiable "plush" daily. I'm on some limited cash, so it will probably be a while till it's on the road. Both vehicles have running motors, so I will be selling the swap and any other parts I can to fund the project..so don't be shy to buy some parts!

Let the build begin!

12/25/10

Rabbit pickup to the rescue!

One motor..done.

12/29/10

Made some progress this afternoon. Pulled the transmission off and got it onto the engine stand, then proceeded to tear it down. I still have the intake and exhaust/turbo to pull, but not until a healthy dose of penetrant is applied..

So, the plan is to keep it nice and reliable. The block and head will go out to C-Tech for a refresh and most of everything that can be replaced will. As far as upgrades, it will be as deals come. About the only thing set in stone right now are clutch, nozzles, chip, and exhaust. The 10mm pump is staying, unless an auto pump surfaces for a good price. The turbo I have is in good shape, but I also might be replacing it if something else comes along. I'm not sure about converting to VNT, but maybe a K03/K04 hybrid. Intake will be refabricated and I might end up with a front mount instead of the stock side mount. Like I said, a lot of this is up in the air right now..we'll see. Oh well, time to wash up.

02/18/11

Damnit..my priorities have gone astray.

No secrets here..

Currently with the original 25mm adapters which fits better then I had originally thought, but for the love of my fenders/sidewalls 15mm seems like a better choice; especially now that I know I have the inner clearance for them.

03/16/11

Made some progress on the gauge setup I'll be using. I had an old center cluster from a '93+ that had fallen victim to a previous "custom" project that didn't end too well, so I decided to use what was still useable from it. Some minor trimming to make it fit an earlier style dash, some paint, and I came up with this.

OEM+..?

03/21/11

Today I made some progress on the front brakes. Upgraded to the later VR6 calipers and 11.3" rotors. They fill up the wheel a little better then the stock setup that was on there, yet still fit under 15" wheels for the winter.

The ABS is getting ditched for all of the Non-ABS parts out of the Passat. I've got some MK4 rear calipers coming for the back this week.

03/30/11

Was able to make some progress today. Ordered up a new heatercore that was scheduled to be delivered this afternoon..so why not get the job done?

The interior was a little torn apart already from the day the VR came out.. 

A little later, it was all out..

Still awaiting UPS, I got started on cleaning up the bay..

The toothbrush took a beating, but it did the job..

Also got in the South Bend Stg 2 Endurance..

If the weekend's weather stays nice, maybe it'll be the Passat's turn.

4/1/11

Oh, the heater core showed up! Time to bring on the business.

Still chippin' away. Tore down the heaterbox and replaced all the foam material on the flaps. Also got the new heater core installed. Don't have any pictures exept for this nice build-up shot..

Other then that, been working on wiring. Finally got all the bits out off the Passat yesterday and spent a good deal of time today weeding it out. Also weeded out some more on the Corrado.

Other updates? I got ahold of Frank's VW for a set of T4 Nozzels (~.216), but it looks like they are all sold out (he had limited supply). We started to talk about the conversion and the setup and he seems to think I would of been close to maxing them out anyways. He turned me onto some Titian P520v2 (~.260) Nozzels that would be ample for my setup. Some research shows good results with lower EGT readings, so it seems like a good call. Looking to shoot for 760ish whp and 1270ish wtq at the next C-Tech Dyno Day.. 

4/8/12

Couple more steps completed this afternoon.

Getting close to franken-harness time..

The Corrado got stripped out and I got rid of the auto-belts and wiring harness for that. Slowly it's thinning away..

4/14/11

Got a couple items going this week.

Heater box and Passat drive by wire pedal cluster are in..

Transmission got degreased and powerwashed..wish I would have taken a before picture - it was dir-tee.

The fuel system got some attention as well. Pulled the stock fuel pump out of the tank and drained out the rest of the gas. Waiting on a diesel fuel pump sender for the tank right now before I can button that up. Also received this little guy in the mail. It'll act as a lift pump to the main fuel pump. It's mounted to an aluminum plate and takes the place of the stock fuel filter mounting location under the car.

Was hoping to have the motor back this week, but it's looking slim. Maybe next week?

4/25/11

Some more pieces to the puzzle showed up this last week..

Engine is back home and coming together slowly. Hopefully a couple odds and ends will come in soon and I can get it mounted in the car. 

6/10/11

Found this nice little screen to put over my fuel pickup..

Got the MK4 rear calipers installed..

The PO had some steel cable holding the motor down; seriously..so new mounts were in order.

Engine finally made it's way together and was ready to go home..

Good fit all 'round..

Time for some piping..ZPA to the rescue!

3" Turbo-back..done.

Death to the EGR..

Life to the intercooler..

Props to Lans for helping me get this ALH Pump conversion completed. I really wish I took some more photos of the machine work..it was top notch!

Top off the goodies list with a fresh tune by Jeff @ Rocketchip..

Nozzels finally arrived yesterday and were installed last night after class. Worked well into the night trying to get everything buttoned up, but I threw in the towel today when the starter took a dive..just wasn't ment to be I guess. So this is where we sit as of this afternoon.

Thanks again to Joe, Kirk, and Lans for helping me out this past week

7/3/11

Been putting some miles on the beast..seems to be going well.

Last week, I got ahold of a Rieger Shift Knob..been looking for one of these for a while.

Kirk helped get me timed with the Vag-Com yesterday - thanks again! Today I added a MBC to help control boost spikes.

It also turned me into a smoke machine.

7/6/11

Put my leathers in last night.

Also got the keyless hardwired in.

2/9/12

The car got some KW V1s fitted a little while ago, but I don't have any pictures of the install. Thanks to Matt and Dane for help on that endeavor. Stainless bitch.

I installed a standard block heater instead..routed the plug for stealth-mode and easy access.

Around the same time, I decided to perform a "ventectomy" on my fuel tank. I did take some photos of that.

Here is the valve that gets removed:

Reinstalled and ready for maximum capacity.

I've gained about two gallons at the pump and my range has extended to 900 miles/tank; 52mpg average.