GazzaG60 - new 16v t project -update with new post

[GazzaG60 0]

update 24 jan 06

 

new pics to be added on new post as currewnt one is full

 

 

update 12 jan 06 ****cant upload all pics-await supermods****

 

This week i have been waiing for my ARP conrod bolts to arrive. i already had a set but suddenly got the gitters on the standard parts so have splashed out on higher spec bolts. im now gagging to get it together so any further thoughts of lightening and balancing the bottom end are out of the window for now.

here are a few images of the bores, the newly painted block and the parts going in. ill add apicture of the old crank mains so that you can see what they may look like in your engine. the milage was unknown on this lump but you could spin the crank with your little finger when on the engine stand with the v.v.v.v heavy flywheel off.

 

anyway more pics added. cant say much more at the moment. a quick one of my mate Andrews engine in his subaru for thoses scooby fans out there. will shove a group picture up when they produce less offensive signs to the camera

 

 

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update 5 jan 06

 

quick test post update thingy update with a few pictures namely turbo, wastegate and injector rail and squirters

 

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After a few posts in other topics here is my first post about my car. main reson i havent done anything before is that i couldn't be arsed.

 

Im gonig to add some pictures of the current setup and of the engine in the build process and some of the other components i have chosen.

 

most of my post will be about the engine as thats what intersts me most. i will modify the first post for most of the stuff but may add a few others also at other times.

 

Before i start id like to say a big thanks to my 2 good friends Andy and Anthony the most infuential people behind Subaru specialists Jap-innovations. their experience with high powered turbo cars is useful as is the stockpile of parts and contacts they have. my engine is on a stand next to 2 600hp 2.3l impeza engines so its in good company. the guys have helped me with removing old engines from cars to having a word with a machine shop. Their next big help will be fitting it so thanks in advance. need any bits for a subaru or an engine build or somthing give me a shout, ill pass on details as Jap-innovations has closed. big shout over for now.

 

Currently i am runnning a G60 corrado on a J plate. i run a full ss system no cat, 65mm pulley stg 4 charger, golf u-bend, fmic red tops etc. the car has been reliable for the past 60k i have had it with a total of 138k so far.

 

on my new project im gonna use the following.

 

9a block bored to 83.020 approx

kr head p&p

forged piston 9:1 (Wiseco)

precison SC-61 turbo

external wastegate. (tial 38mm)

Home made full 3" system.

550cc injectors

megasquirt n spark extra

Home made short runner intake (half built)

 

Hoping for 300-400hp

 

i got a host of other goodies too but ill sort some pictures and hosting out this weekend and will progress from there.

 

BLOCK BORE AND CHANGES

 

The block, a 9a has to be bored to fit the new pistons. The bore size standard is 82.52 ish with the piston being 82.49 this needs to be upped roughly half a mm. as the new piston is 83mm and needs slightly more clearance the pistons were sent to the machine shop and measured. apparently pistons are still slightly different in size and better measured for a perfect fit. this is being done. the news on my engine is that there is a score on a bore so itll need sleeving. the crank is ok but some scratching so its been sent in to be polished or ground. the full assembly will be balanced when its complete.

 

An alloy flywheel will be fitted after to complete the lightening. i will be using the standard belt setup and oil pump so all usual 9a parts will be used. i may be using a subaru alternator as its the same style fitting as our 16v but the pulley is different. a quick mod..

 

The sump and windage tray were provided by Gavin (H100 VW) something built by himself and never used. this component im told is almost key to a good 16vt with good power. Its down to breathing. The 16v standard breather setup is quite poor. unlike the G60 it breaths from the block. with the higher pressures on a turbo engine the oil is forced out of the block under pressure as the engine cannot release the pressure. im told a catch can at 0.5l wil be filled on 1 quartermile run if i dont address this issue. What im gonna do is fit the breather/filler cap from a new beetle to enable the head to breathe as well as the block. i may also abapt the dizzy end of the rocker cover to fit a second one.

 

everything in the block apart from rods and crank will be new. full new seals, pistons. bearings etc. so far its cost me around 450 to build this block only. im not putting rods in as im planning a second block using proper rods and the ability to hit around 8500rpm

 

Cylinder head and cams

 

The cylinder head im currently looking to run is from a KR. it is in standard form at present but i plan on sending it to CNCheads for a full race spec FI port with hand finishing. this should get the flow of each port within 1% of each other. im gonna start with kr cams. there are a few opinions on 16v heads some say kr others say 9a and a few say ABF. the general i could get was that a kr flowed better on the inlet but had less material to take away cam wise the kr is a better option but i may step up to some proper cams once i have the overlap issues worked out. in all i dont think at this point i need to scrutinise my cam/head choice as this can be somewhere to work on after.

 

Manifolds

 

there are 2 main types of exhaust manifold available. tubular and cast log type. cast log is the design used by TT originally when they did the conversion and is of similar type to the standard manifold. its a cheap strong way to get the turbo to fit. some fit better than others. they will make good power but dont flow as good as a tubular manifold which as per description is a tube shape. some are equal length others not. equal length helps spool time and top end flow. tubular can be more suseptable to cracking than other types and will probably need wrapping to get the most from it. wrap is used to help the transfer of heat by holding it in the exhaust. it sounds strange that we hold heat in to get rid of it but thats what we do. heat causes propulsion meaning the gases leave the system quicker and also less heat soak to other components in the engine bay.

 

The inlet manifold is shown below in its early stages of production. what i have done is take a 50mm inlet and hack it up. weld on some bits of subaru manifolds which have a almost identical internal bore and get it ready for fitting a plenum. im still undecided as to whether or not to fit velocity stacks.

 

here are a few pics of the progress im having with it. i await some 4 inch ally tube to create the plenum.

 

lovely int it.

 

 

 

next update sooner than the last one :roll:

 

 

 

 

Edit: Huuuuuuge pics thumbnailed for people on smaller screens ;) -

dinkus

 

Thanks mate. more pics being added.

[cubed 0]

i,l be very interested to see how your project goes!!

i would like forced induction on my valver also,very tempted by the g60 rout and turbo also. was told that the turbo conversion for the 16v is no longer available,hence my great interest in your project.

really want to keep mine a 16v as thats how it started life.plus turboing it/charging it would be a little different to the 20v path

the best of luck with your build!i,l be watching attentivley!! :crazyeyes:

[h100vw 0]

You need to have this done for mid November or I'll not get to see it..... :cry:

Gavin

[GazzaG60 0]

post updated. some details added, pics next week when i start the build.

[veeDuB_Rado 0]

GazzaG60, I've read some of your posts on this forum and I can definately say you are a very clever man indeed, and this project is going to end up being perfect!

 

Be sure to keep us updated!

[Lippy 0]

gazza - fair play mate! be interested to see how it turns out!

 

fapping fast no doubt!

 

could you thumbnail the images? use the http://upload.the-corrado.net ;) :D

[GazzaG60 0]

ill have a go. been in IT for nearly 10 yrs and still cant sort images out.

[Lippy 0]

lol I graduated in IT last year!

 

may see you around Manchester!

[GazzaG60 0]

ive seen a car round here a lot like yours. im on the oldham/rochdale side of town.

 

mine is a jplate blue G60 with BBS RCs and its pretty noisy.

[Lippy 0]

hrmm not seen any blue j platers for a bit

 

I live just off the A34 in Wilmslow, but with a girlfriend who enjoys making me taxi around the place ;)

 

I'll keep an eye and ear out m8

[dannyc 0]

but with a girlfriend who enjoys making me taxi around the place ;)

 

i know how that feels mate :roll:

[Kevin Bacon 5]

Excellent work so far. Looking forward to seeing the finished result as I do have a particular fondness of the 16v T.

[aposegil 0]

mate good luck ;) thats looking really good

 

u going throttle bodes?? as with all ur putting in its the only way to go few turbo mates of mine going throttle bodies now

 

also great look exhaust manifold properly done all nice equal lenghts :D

 

well done upto now hope works out well and think about the throttle bodies its worth it

[Not_Aircooled_or_Taxfree 0]

That looks very interesting, will it all fit under the bonnet or will the shape have to b changed

[GazzaG60 0]

it should clear the bonnet. i got a bit more chopping to do but im on a late bonnet which im told is almost necessary for a short runner.

 

Im gonna run a subaru TB i think. thanks to the subaru guys for supplying again.

[GazzaG60 0]

update 23 jan 06

 

Well the bolts arrived. i got the wrong ones. ARP ford bolts are usable just get right ones. heres a picture of the slightly oversized ones.

 

The block is now ready to throw together i have everything other than the new smaller big rod bolts and 1 crank cap bolt that i lost. The manifold is progressing nicely. im getting ready to weld it all up now and fit some stacks to the runners. more pics soon.

 

anyway not a great deal as more bits are in transit from yankeeeeee doooodle.

[CaiosG60 PWR 0]

Gazza, why's there a Scuby engine in the post above?

[GIXXERUK 0]

nice scooby engine though:-)

[veeDuB_Rado 0]

Now this is a project!

[GazzaG60 0]

was supposed to be in the last post as some peeps have asked me about my mates scooby work. tuned by my good self for 350hp on the standard engine. its having a 2.4 with ported heads and custom cams in the next few weeks and some 720cc injectors to play with. cant wait. thats my scooby plugs done. anybody with scoobs interested in services that can be offered for jap crap let me know. as far as fitting one in a C. well it looks a bit wide and they are a pig to work on in the car. you never know for the future.

 

I am waiting for the correct rod bolts to be sent and a proper throttle body with a 75mm "flapper". ill update the post with VW stuff again arounf weekend time as i expect some drastic progress this week and next.

[Bally 0]

any updates mate???

[GazzaG60 0]

ok here goes.

 

ive been pretty busy of late with various none car and car stuff too so sorry for delay.

 

the manifold is nearly finished or at least the first stage.

 

its a bit of a mismatch but feels better than it looks at the moment. our welding aint to great but it seals.

 

more to come on the engine and tapping in the turbo hopefully in the next week or so.

[CaiosG60 PWR 0]

Cool, intresting stuff!

[mrbeige 0]

GazzaG60, how you getting on with this dude?

[GazzaG60 0]

hi

 

sorry no updates but i will soon. ive been a bit quiet over summer but heres what ive been up to.

 

scat rods - fitted now. waited 6 weeks for a arp ring compressor after swearing at the adjustable too many times.

 

the block is done. 83mm wiseco pistons, scat rods, balanced crank.

 

i got box, cvs shafts etc now. i plan to run g60 shafts, transporter inner cv's and mk4 shifter connected to the 02m from a cupra r.

i now got the clutch and flywheel too. i got a spec alloy flywheel 10lbs i think and a 6 paddle clutch. stage 3.

 

i need to pressure test the manifold i made. may make a vid of that as it may be destructive. i also got a vr throttle body to do my initial tuning on. the 75mm may be too big.

 

i have wrapped the exhaust manifold which took some doing. dont see many vw's wrapped but my experience with subaru's tells me its worth a few 100 rpm spool.

 

got a few msns mods to do yet.

 

cams are all modded. im gonna run the 2 exhaust cams first then may go solid lifter with some big shricks.

 

basically im a race spec head short of an engine. im gonna get that from cncheads. not sure if i will try and go oversize valves yet or uprated springs but expect i will. research tells me they may be a good idea over 7500rpm.

 

i am gonna be fitting my new brakes tonight hopefully. i got 4 pot wilwood superlites with 310x30 discs.

 

for reference a recent US 16vT with more or less the same spec as me made 410whp at 20 psi. so im optomistic.

 

i drove over my phone which is why i haven'y updated the post as i have to borrow a digi-cam. ill get onto it ASAP.