Project Build: sc2020 - MK3 G60 - By sdezego

9 minute(s) of a 278 minute read

Not much to report.

I was up in NC for a week for some R&R and just got back a little while ago.

also, been waiting for 2 weeks for ZDMAK to get me the correct Headbolt Triple square bit after they sent me an 8mm long Allen (AEB used 8MM TS and rest of the 20Vs use the poly bit). Early 8Vs use a 10mm Triple Square which I had, but was not help obviously.

i finally received it though as they stepped up and sent me the correct one at no charge.

I did decide on the color for the valve cover and hope to get it to the Powder Coater by end of the week Still deciding on the manifold and may do a 1/2 Polished 1/2 Powder Coat (i.e. the runners) the color of the valve cover.

Shawn

July 16, 2007

Never a dull moment.. Because of the deck height difference in the block, shaved head and IM gear combination, the Cam timing was off 1/2 tooth. So, I ordered a TT adj cam gear (because it has the factory steel hub).

..and of course nothing is easy and the factory cam bolt/washer would not fit, so I needed to cut the washer down on the lathe.

I didn't get the valve cover off yet, because of my indecisiveness on color. But, I did break balls finishing up the intake. The factory casting was so bad...

Everyone likes pics.

The only modification needed for the Euro AGU big port intake was to clearance the one boss over the charger.

July 27, 2007

I think my indecisiveness on the VC color paid off. I am thrilled at the results. It is a Candy Blue (silver Base).

September 10, 2007

Small Update:

I have been making slow progress just due to everything else going on, but will hopefully have a big surprise this weekend that will help get me in gear 

Do some checking on the ABA and you will see that the Engine is quite different (even in stock form) than the PG (despite its appearance).

- The Deck Height on the ABA is ~16mm Taller than the PG

- It is a 2 Liter Engine Stock with 82.5mm Bore and 92.8mm (i.e. 1984cc vs 1781cc on the PG) stock

- 159mm rod length (as opposed to 136mm PG rod length)

- Crank Triggered Ignition

- Piston Design (Wrist Pin, Skirt and Crown thickness)

The Rod Ratio or "Squareness" of the Engines are quite different due to the above.

I would rather not get into a whole discussion in this thread about the different engine(s) potentials, etc, but will end with one final thought:

Regardless of the above, the bottom end is somewhat irrelevant to the hp production but both are potentially capable of withstanding that much hp. It is the Head, cams, intake, exhaust, management and most importantly the forced induction system (how much Boost) that will dictate hp potential. The G60 charger is a major bottle neck above 250hp. It is an air pump of limited capacity (a matter of physics) and is restricted to a lot lower RPM than say a Turbo Motor. This is a major crux if your goal is all out hp (like it or not). But, I tend to like it as my goals are a bit different

S 

September 16, 2007

The reasons progress was slow because I was getting My other Silver G60 ready for the sale (among other things).

...and with the silver g60's departure brought this little gem. An O2m 6speed is what I wanted all along for this project and now I have it ...along with some extra parts like a whole AWP 

October 05, 2007

update:

1. I am now going with the 02m 6speed trans that I acquired (as mentioned). Since I have to make motor and trans mount brackets anyway, I decided to hunt down an Extra Kframe, so I can keep my running car "running" during the build, mock everything on the floor and when the swap is ready, it will go MUCH faster with much less last minute fabrication. I am picking up the Kframe and rear engine brkt from my buddy Jeff this weekend (which is from a Mk3). So, I will be switching to the Vr style Rear engine mount.

2. I will probably be using all of the Vr + suspension stuff for the front that I already have from the 93 Vr parting. I need to use Vr hubs regardless, so the splines from the 02m axles match up (still need to modify the length of the 02M axles regardless). The + suspension will eliminate my 10mm spacers in the front anyway and add a few mm to match my rear. I am a little concerned about scrubbing with the + though. I will have to re-drill 5Lug Hubs->4Lug unless I get new 5 Lug rims for the Ft. But this is all minor stuff that i am not worried about.

3. I also decided to pick up a Vr front Engine carrier to run a Vr style front engine mount. Again, I needed to fab up a new front engine bracket anyway and the Vr carrier is stronger.

4. 1.8t Fuel rail is now modified with -AN fittings on the rail (will post pics of the mod later)

5. In my endless quest to make things as complicated as possible, the Serpentine belt route is pretty much decided and rear mount alternator bracket is well underway. I am using the "clutched" 1.8t 120A alt that I picked up with the AWP (which I am happy about). This setup reduces stress on the crank bolt due to rapid deceleration which is a bonus. One thing to note here is that I will be running only one accessory belt (no Serp + V belt as stock). A Serp belt will run everything -> (H20 Pump, PSteering, G60 Charger, Alt and A/C)! This was a trick and a half Pics of this soon.

6. I am having to spend a lot of time trying to research what I consider the perfect clutch setup for the 02m. This has been very frustrating due to what is currently available. Going from a 240mm clutch to a 228mm setup (as most vendors try and persuade) makes about as much sense as a horse with a kickstand. Granted my power goals are meager when compared to a Big Turbo setup, but I can't break myself to do this. ...it's like swapping your big brakes for smaller ones . The stock Dual Mass 02m flywheel is extremely heavy, but the AL lightweight flywheels most people sell are a bad idea for reasons that I won't go into right now. Spec, makes a very nice steel Flywheel with what I am looking for in Weight (~14lbs), but I am not sure I trust their clutch setup from all of the bad raps in the past. I have no personal experience with them, but the problem is trying to find someone else with the 240mm Clutch disk and PP that is not for the Dual Mass and has a High Torque sprung hub. I am very close and I will post much more on this, but if anyone has any questions in the mean time, feel free to ask. Either way, it looks like I will be in for about a $G and close to 2Gs if I add a Peloquin.

This read was for the non-window shoppers

Shawn

November 07, 2007

Not after recently picking up the following:

- 02m Flywheel (SPEC 16lb Billet steel Single mass ) Thanks Scott - USRT

- ClutchNet Yellow PP and Kevlar Disc - Sorry Scott for not going with SPEC

- Genesis 550 injectors with adapters - Got a good deal on the package

- 02m Peloquin

- Complete VF mounts and all new front suspension joints/bearings (again). I think I mentioned I was going to the +suspension that I already had.

- misc 02m parts (lines, slave etc)

- Spare K frame and VR front Carrier so I can fab all mounts and such on my Bench/floor mock engine bay. I can also paint and have it ready to go with the engine. (remember, I am still driving my Corrado which is part of the reason for taking my time)

I will have some more progress pics coming soon. I have the rear Alt setup about 99% done and serpentine belt setup about 80% done. I do not want to show any pics until it is complete though. I think I mentioned that this is a single serp belt with no vbelt! Running ALL accessories including A/C and PS

Oh yea and 02m is apart and Peloquin is pretty much installed. ...just need to order the proper diff shim.