Mk1 GTD build by Monomer

5 minute(s) of a 19 minute read

Had problems with the crank. The PO did not set the thrust bearing right, and it made a nice groove in the crank. The shop wanted to weld and recut, but I've found another stock ground crank.

Whats everyone use as far a gauge pods go?


Steering rack is coming out (new boots) and the vac pump is already rebuilt and painted.


I really would lke to paint this car sometime. I'm thinking Porsche flat yellow with black BBS honeycombs. New front lip and flat black side trim kit is also in the works, right along with new halogen euro lights (which I can install my HID kit in)

10-29-2008

Crank ordered (found through the samba)


also ordered a stock Turbo manifold.


Con rods still need to be sized, pistons needs tops coated. Bearings, windage tray and oil pump need to be ordered.


Bottom end should be in sometime mid Nov. I'm saving for the 1.9 head right now (bills to pay....) Pumps still needs to be sent out, as do injectors. Turbo was pulled off the 300d (t3, .42AR - 52 trim; so I'm told) needs to be rebuilt (ordered new center section and possibly new wheels)


so much to do yet....

11-8-2008

I need someone who's had a 8v or a diesel apart.


I got the wrong crank (snub ends wrong, from an auto...) The Trust bearing area looks THE EXACT SAME. Same "Groove" (which actually looks like it was turned into the crank) same degree of depth (about .030/inch) I'm thinking it's an oil groove



Anyone rebuild one of these and remember what it looks like? Need help ASAP!!!! UghSmack

12-1-2008

moved into the garage.


Found a turbo. Nice small t3 (52 trim) for cheap. Freshly rebuild by garrett, nonetheless.

Now, is the stock crank the same diesel to gasser?

CAN I stroke this thing out? The 1.9 head gives more valve clearance, and what about better rods then?




Yes, the FW sides are VERY different. I have two JUNK cranks here now.

12-2-2008

It's a 1.6 engine.



The 1.9 AAZ head is the upgrade. Larger ports, more flow. Hydro lifters.


it requires a metal 1.9 gasket, minimum of 3 notch, unless you shim the valves (they'll contact the piston) Which lower CR to 19:1 (roughly) A block heater will be needed in winter, but the lower CR is OK - since this will be a FI engine.

There are a couple of modifications that can be done to the block - holes for coolant. Easy enough to drill in. The gasket will also have to be modified due to an unused oil port.

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The hardest part - the part that I have not done th research on yet is getting a freggin tach in the car. W terminals, GTI dashes.....so confusing. (I have a gasser A1 cluster here which I hope will work)

The dash HAS to come out. I'm not looking forward to it. anyone thats wants to help that'll work for beer is welcome over.

(dash needs to come out because we sawed open the heaterbox to put a core in real quick) foam is toast in the box, blower motor's bruses are done for....

3-16-2009

Update:


Warm weather breaks, car's pulled out of the garage (garage has LITTLE room)

Just pulled the steering rack to replace boots and bushings (Wish I had cash for a high-rate rack, and wish I ordered poly mounts...) Some beers is needed after all that work, I'm glad I noticed the boot tore while the engine was out, or else this woulda been a real PITA.


Block/crank/rods/balance shaft is back from the machine shop. Need anything done on the cheap IDJ in roseville is nice and cheap; and the work looks nice (have yet to blueprint.) Block still needs the oil squirters drilled in - automotive machine is going to do it (alony with flywheel resurfacing and coating the pistons)

I noticed theirs a new LSD setup for these tran's. $650 for a "wavelock" - I think I will take the time to save for it and do it while the trans is out. (I will need help with this, anyone here ever install one?)

Intake manifold is fabbed up, just needs to be tack welded and finish welded (have to heat the casting so no cracks form) I'll be running the stock 1.6 mechanical head for now, as the manifolds I have are for an 8v setup; and I'm broke at this point.

Turbo is still undecided. The people of the VWgtd forums (www.vwdiesel.net) are trying to make a control system for a non-tdi engine. I'm going to hold off on the turbo until I'm far enough along to NEED it - if the vnt system works (hopefully by then) I'll be running one BIG vnt setup.





I'm still debating on the IC setup. I'm thinking of doing a top-mount (I have a spare STI intercooler here) with a hood scoop - but I dont wantto lose the sleeper look....