Bills Scirocco 16v project

3bAudios · Post by **3bAudios** » Tue Jun 17, 2008 7:24 pm

thinking about the turbo situation today. I think im going to have the smaller housing from the t3 42 trim turbo i have machined out to fit the wheel from t04 P trim. pics:
the pair

the larger housing

the smaller one

3bAudios · Post by **3bAudios** » Wed Jun 18, 2008 5:00 pm

Today i mounted up the intercooler, it tilts a bit back which i dont really like, but i'll fix the tabs the next time its out to make it fit right

3bAudios · Post by **3bAudios** » Sun Jun 29, 2008 6:36 pm

another update. I got a t3 60 trim turbo, WG, exhaust manifold, and a down pipe from a friend of mine down in FL. the downpipe is for a MK2 so i dont think its going to fit in my scirocco. the turbo was hard to get the turbine housing off and when off i noticed some buildup on the exhaust wheel.

there also is a stud that is broken off

then i fitted a random peice i had from back when i lived in fl. I'm not sure what car it is off of but it was a tad to wide for the compressor housing so i had to do a bit of modifying to get it to fit, but it fits. next is finding a 2" peice of tube and get it welded on to the output or find a flange for the existing outpout

I also ordered some parts, rod and main bearings with a lower gasket kit as i'm going to try to use the block I have.

3bAudios · Post by **3bAudios** » Wed Jul 02, 2008 11:21 am

update from the past few days, i got the arp rodbolts and got them on the rods. Also started pulling the crank from the block so i can clean it and install the new bearings/seals. I also pulled the cams out of the cali head as well as the nh head. as soon as i get the valve puller tool set i ordered i'll pull an intake valve from the nh head, clean it up and put it into the ca head.....i also ordered a head gasket so once some of these parts arrive ill be able to put the motor together and get it in the car. i am debating on weather or not to use the dual friction disk i have that is a little to small or bite the bullet and get a stg 3 clutch that will probably hold the power i should be making once this is all done.....

3bAudios · Post by **3bAudios** » Sat Jul 05, 2008 11:25 am

quick one, been working on the block, have new bearings coming:
my 2 heads, front one is for a doner valve

turbo manifold and t3 60 trim

block awaiting cleaning

intercooler mounted

3bAudios · Post by **3bAudios** » Thu Jul 31, 2008 2:50 pm

spent a little time today on the car, did a quick cleaning of the block, basically poured gas over it and gave it a quick scrubbing.
then i dried it with compressed air, installed the new bearings in the block cleaned the crank real quick and got it back in and tq'd down with some ARP assembly lube. Then i switched gears real quick and started to put the oil return fitting into the oil pan. Couldnt find one out of mild steel so had to get a brass one. Planning on tapping the hold so it will thread in and then using JB weld. Not my ideal situation but i tried to source a mild steel fitting at a couple places and then gave up and just got the brass one. I read over on vortex that people have used it for this purpose before....keeping my fingers crossed....pics:

3bAudios · Post by **3bAudios** » Tue Aug 05, 2008 1:38 pm

working on the oil return today, still need to JB weld it in there.....

3bAudios · Post by **3bAudios** » Wed Aug 06, 2008 7:27 am

Last night i mixed up the JB weld for the oil return flange and slapped it on after cleaning and roughing it up a bit.....also picked up a new welder, its way bigger than it looked in the pics, should be able to weld most any of the orchard equipment we have.....

Post by **HT Motorsport** » Wed Aug 06, 2008 7:45 am

Nice welder Bill, yeah that should handle the big stuff for sure. I would recommend checking the gun, feed mechanism and feed sheath as they are really the only parts that wear out.

Now you can really do some fabricaiton

H

3bAudios · Post by **3bAudios** » Wed Aug 06, 2008 11:51 am

timmmy wrote:Nice welder Bill, yeah that should handle the big stuff for sure. I would recommend checking the gun, feed mechanism and feed sheath as they are really the only parts that wear out.

Now you can really do some fabricaiton

H

Yea I am going to have to do some stuff to get it to running 100% there is something wrong with the MIG leed i guess, I havent really had much of a chance to look at it much since i got it last night. But its a pretty nice, MIG and is able to be stick as well, i just need to find some leeds for the stick which it didnt come with.....all in all not a bad machine for 350 bucks, and the guy i got it from was a race car driver i guess, kenny white jr i guess?? i dont know what series he was in but it was def. a big left hand turn....he was working on the racecar when i went to pick it up last night, we talked about the car a bit and i told him about the sick project your building....

3bAudios · Post by **3bAudios** » Thu Aug 07, 2008 7:11 pm

Did some work today, got some of the block re assembeled and put the head back together.

This gasket was a real PITA to get off.

3bAudios · Post by **3bAudios** » Sat Aug 16, 2008 4:17 pm

I am in the market for another 1.8 bottom end as when i took out the intermediate shaft i found that the bearing was shot and even after honing the cylinder bores still had some markings on them from rust so I think im just going to try to find another one to use....

started the exhaust today.....got from the rear over the rear beam (had to noch it a bit to get the 3" over....

3bAudios · Post by **3bAudios** » Mon Aug 18, 2008 5:55 pm

got a bit more done on the exhaust...the end looks like crap because I dont have any money to get new 3" tubing so I am scraping together peices I have cut out of the exhaust from the old 90 project....it took a bit of massaging to get the 3" pipe over the rear beam, but i got it to fit

Longitudinal · Post by **Longitudinal** » Mon Aug 18, 2008 9:57 pm

Bill, that rear main seal is in farther than it should be. It should be flush with the outside lip of the housing. You may want to remove it and push it back out a bit before you get too far along. It may not mean anything, but it may be worth straightening up now while the oil pan is off and the engine is not in the car.

3bAudios · Post by **3bAudios** » Tue Aug 19, 2008 5:59 am

Thanks for in input, but i am actually looking for a new bottom end as the intermediate shaft bearings were toast as well as the cyl bores had some issues with rust that didn't hone out enough for my liking so I am just looking for a new bottom end....anyone have a good 1.8L bottom end kicking around?

3bAudios · Post by **3bAudios** » Mon Sep 08, 2008 6:24 pm

today I got my 2nd block torn down a bit....looks much better than the first one

3bAudios · Post by **3bAudios** » Thu Sep 11, 2008 2:41 pm

OK, today i went to the garage for about an hour or so.....I was going to try to swap my new used pistons/rods into my new used block which is a lot better than the old one that i decided to scrap...but i didnt get them in....first thing i had to do was swap the drive gear on the intermediate shaft, but of course they are different between the 8v and the 16v so i had to swap the whole shaft, the bearing was a little messed up but i dont have time to get it replaced so i just left it...its not under load anyway so i hope it will be fine...i lubed the 2 bearing points with ARP assembly lube and re-installed it and put the new gear on. Then i had to swap the crank pully but I had a hard time finding the 16v tbelt pully but i did end up finding it and getting it started, i'll tq it down later on in the build. I also re installed the crank shaft gasket + end cap with new gasket and a light coating of RTV....then i pulled the oil pump so it would be easier to pull the pistons next time i get into the garage....

3bAudios · Post by **3bAudios** » Mon Sep 15, 2008 6:20 pm

Worked on the rocco again today, mounted the battery in the trunk:

Pulled one piston from the new block to compare it to the 3B pistons:

it looks the the GTI had better rods than the 16v....I think i may use the stock rods as they have the cooling passage...what do you guys think?
The 3b is on the left:

Then i did a bit of grinding to get the 3" pipe over the rear beam:

the exhaust so far:

Chad T · Post by **Chad T** » Mon Sep 15, 2008 6:29 pm

That one on the right looks like a shortened 3b rod. Can't tell which one is better though. 3b rods aren't super strong.

3bAudios · Post by **3bAudios** » Tue Sep 16, 2008 8:39 am

I wasnt going to use the 3b rods, they are stock 16v rods....the 3b ones looked like they could use some machine work as when you put the caps on you could feel a little groove which you couldnt on the 16v ones....

3bAudios · Post by **3bAudios** » Tue Sep 16, 2008 8:58 pm

worked again for a few hours tonight....got the pistons and rods in...ended up having to use the 16v rods, i would have liked to use the ones that were in there, but i couldn't get the ARP rodbolts out so i just said screw it....I dont think they were that much stronger anyway.....
Here is the block with the rod journals all covered over, ready to Hone

When putting the last piston in it would not go in because it was not tight enough

so i broke a ring...im a dumb ass....

so i replaced the broken rings and got it all together

I also thew the oil pump back on

Mowgli · Post by **Mowgli** » Thu Sep 18, 2008 7:44 am

Excellent engine carnage with a respectable recovery :-)

Mowgli · Post by **Mowgli** » Thu Sep 18, 2008 7:44 am

Excellent engine carnage with a respectable recovery :-)

3bAudios · Post by **3bAudios** » Thu Sep 18, 2008 8:59 am

Mowgli wrote:Excellent engine carnage with a respectable recovery :-)

yea, the motor blew pretty good eh!!!! I hop this new one will last for a little longer!!

3bAudios · Post by **3bAudios** » Tue Nov 04, 2008 6:33 pm

More work today. installed the arp headbolts, had to clean up the threads in the head first, but then they went in fine with some arp assembly lube. then i put the headgasket on, one of the guide pins was in a different spot than the hole on the headgasket so i had to do some custom modification to get the headgasket on....but after the mod it went on fine and i lubed up the washers and bolts and tq'd the head down, 30,42,60,75 lbs in the correct order. then i put on the accessory pullys and the timing belt and tesnioner...
1/2 arp bolts in

head gasket mod

on the block

all installed