Project Turbodiesel

[hiho]

This is the other golf diesel we picked up in a 2 for 1 deal. Its a bit tidier than the beige car, and has a much nicer tan interior.


Up on blocks for some work on the suspension. The plan is for king springs and new dampers, urethane rear beam and front control arm bushes, swaybars, upper and lower front braces


Wheels courtesy of Golfloon, cheers. We also have a spare set of Cabriolet 5 spoke "tiny teddys"



Sigma front sway bar going in the back



This is the project motor, its a 1983 1.6IDI motor from Canada. It arrived here in a caddy. It has been rebuilt by VW Canada but has vast amounts of blowby and oil consumption. Most likely it will receive new pistons. Fortunately oversize pistons are still available for the 1.6 diesel.


In the shed is a 5 speed box, GTI brakes, oil cooler, TD injector pump, turbo exhaust manifold and k14. The motor is going to the machine shop tomorrow where it will be cleaned and measured. Then all replacement parts will be ordered.

[Jarred]

I like where this is heading!

well be watching for sure!

[Water Boy]

Bro looking good! Where abouts in Melbourne you located? If ya get a chance should try and come to one of our meets

[hiho]

Im in Brunswick West. I'd love to catch up with some forum members, let me know when things are happening.

I will be living the diesel tachometer dream, first with a dedicated alternator driven tach, then by somehow driving a petrol tach with the alternator w terminal. Just gotta pull an alternator to bits to tap in a "w" terminal.

Also, as i am short a functional brake servo, what are the prevailing thoughts on larger booster/master cylinder combos. Do any just bolt on, bleed and your away?

[Water Boy]

Monthly meet:

http://www.vwwatercooled.org.au/newforum/upload/showthread.php?t=18969

[Jarred]

Im in Brunswick West. I'd love to catch up with some forum members, let me know when things are happening.

I will be living the diesel tachometer dream, first with a dedicated alternator driven tach, then by somehow driving a petrol tach with the alternator w terminal. Just gotta pull an alternator to bits to tap in a "w" terminal.

Also, as i am short a functional brake servo, what are the prevailing thoughts on larger booster/master cylinder combos. Do any just bolt on, bleed and your away?

Pete Jones did a fair bit on brake upgrade. Non are exactly 'bolt on' but with a few minor mods a mk 3 booster and MC can be put in place of the orig setup.

I believe mk 2 16V booster fits straight on, but well, good luck finding one.

link in a tic to Pete's write up.

here it is:

http://www.vwwatercooled.org.au/newforum/upload/showthread.php?t=11689&highlight=brake+booster

[GoLfMan]

cool! Im also liking where this is going

will be interesting to see how the 1.6 goes turboed

[raiden]

this thing is going to be a little power rocket!

[mollins]

Woohoo!

Im in Brunswick West. I'd love to catch up with some forum members, let me know when things are happening.

I will be living the diesel tachometer dream, first with a dedicated alternator driven tach, then by somehow driving a petrol tach with the alternator w terminal. Just gotta pull an alternator to bits to tap in a "w" terminal.

Also, as i am short a functional brake servo, what are the prevailing thoughts on larger booster/master cylinder combos. Do any just bolt on, bleed and your away?

Sounds like a great project mate! we need lots of these sorts of conversions! And much better to start with the 1.6 than the 1.5 for a turbo becasue the oil is fed onto the bottom of the pistons, which is important for cooling. But im sure you knew that!

I dunno if you saw my 1.9tdi mk1 conversion but i have done a fair bit of mucking around and reading, so if you have any questions then i hope i can help! http://www.vwdiesel.net/ is also a great resource

k14 is a great turbo for this too. Very fast spooling and boost all the way to the end of the rev range. The 1.9IDI mk3 runs this turbo as standard, and it is capable of running this at over 1.5 bar (22psi) without too much trouble.

Depending on your budget, consider ceramic coating the pistons (and maybe the head and valves). This keeps heat in the combustion chamber so it ends up through the turbo (producing boost) rather than the radiator. Intercooler is also a good idea, I am about to put one on my mk1 so i would be happy to share my setup ideas! (i will hopefully have it done this weekend).

Out of curiosity, Are you thinking about pointing the turbo manifold up or down?

For brakes, the easiest modification, which gives great results, is a SEAT cordoba booster and master cyl. Just requires some brake hose bending, and bleeding, and will easily handle bigger brakes (im running gti discs and mk3 drums). Make sure your vacuum pump is in good nick too.

hope this helps!

Now get to it!!
Cheers
Mike

[hiho]

Thanks Mike, im sure i'll need the assistance of forum members along the way.

The motor is at the machine shop, about to be hot tanked and crack tested. It doesnt have oil squirters. By accounts on vwdiesel.net and vortex this does not mean that it cant be turbocharged, but sense must prevail with regards to maximum output expectations. I will be using a TD pump which will help prevent overfueling off boost and will have a decent downpipe/exhaust, egt and boost gauges.

Does anyone know if intermediate shaft bearings are available for theses? (i assume its the same as the 1.5D)

Cheers

[gldgti]

yea you oughtnot have any trouble getting int shaft bearings - will be similar for all the diesel engines - 1.5/1.6/1.9...even 2.5..maybe.

cool project man! BTW -is yours solid lifter or hydraulic?

[hiho]

It has the mech head. This afternoon Im going to visit the machine shop for the measurements of the bores and crank. Then its a waiting game for the pistons and bearing to arrive. While im waiting i think i'll paint the block. Maybe mars red to match the car. Any thoughts on this very important decision?

[Jarred]

something other than black so you can see oil drips etc.

just imo anyways.

[hiho]

Are 200mm clutch/flywheels available in australia?

[Jarred]

I've never heard of 200mm clutch's. Heard of 210mm and 190mm though,.