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TDI Conversions Discussions on converting non TDIs into TDIS. More general items can be answered better in other sections. This is ideal for issues that don't have an overlap and are very special to swaping engines.

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Old October 23rd, 2012, 15:45   #1
bzeien
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Default BobZ's TDI Smyth G3F Beta #9 Build

I'm posting my build of Beta kit #9 for those interested in the Smyth Performance G3F mid-engine sports car conversion for the MkIV Jetta and 4-door MkIV Golf. My particular build began with a 2004 Jetta TDI (BEW, 5-spd) purchased specifically for this project.

I hope to help provide some small insight into the conversion process through the following time lapse videos and progress posts...



My Build Specifics:
BEW 1.9 TDI
Chrome journal replacement cam, slotted bearings and cap mods (Frank06)
Passat cast iron exhaust manifold ported to Darkside Developments GTB adapter (RyanP)
Garrett GTB2260VK (RyanP)
SDI Scroll intake (RyanP)
4-Bar MAP (RyanP)
Firad +80% (RyanP)
O2M EFF 6-Speed (RyanP)
Peloquin LSD (RyanP)
SB Stage II Silent Endurance clutch/pp
Audi TT front suspension/brakes in both front and rear
Type 20 long flow air/water intercooler (very low restriction, rated to 350HP)


General information for the Smyth Performance G3F is at:
https://www.facebook.com/SmythPerfor...06171216118819


Additional sites, posts and build info available at:
www.facebook.com/SmythPerformance
http://www.ffcars.com/forums/139-smyth-performance-g3f/

In the beginning...


What it will soon look like (ok, different wheels, color, etc., but you get the idea...). Re-purposed for some fun!:

Last edited by bzeien; June 11th, 2013 at 07:39. Reason: add content
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Old October 23rd, 2012, 15:53   #2
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Step 1: Initial tear down...

http://www.youtube.com/watch?v=uUAUn1Fqpfo

Last edited by bzeien; October 23rd, 2012 at 15:58. Reason: content
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Old October 23rd, 2012, 15:54   #3
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Step 2: Get out the SawzAll!

http://www.youtube.com/watch?v=7GGhGLfBW9I

Last edited by bzeien; October 23rd, 2012 at 16:03.
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Old October 23rd, 2012, 15:54   #4
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Step 3: Assembly begins!

http://www.youtube.com/watch?v=Hf82YozNDIg

Last edited by bzeien; October 23rd, 2012 at 16:04.
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Old October 23rd, 2012, 16:06   #5
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Saving this spot...

Last edited by bzeien; October 23rd, 2012 at 16:18.
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Old November 13th, 2012, 07:37   #6
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Working on my BEW upgrades: here are photos of the turbo/exhaust/intake setup. I'll need to mount it all to the engine to test fit and determine the placement of the support bracket for the AWIC. Firad +80% injectors have also been installed.

The gtb2260vk is mounted to a Passat manifold ported to a Darkside adapter plate, the AWIC will be supported with a fabricated bracket welded to the SDI intake. The total plumbing consisted of only two 180 degree elbows (2.25" and 2.5"). I'm keeping the SDI ASV; there's a thread with instructions to convert the wiring to my BEW harness.

Overall a fairly compact package.






I cut a mount in UHMWPE for the 4-bar MAP, here mounted on the SDI intake

Last edited by bzeien; December 25th, 2012 at 09:31. Reason: image content
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Old November 13th, 2012, 17:25   #7
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Looking forward to watching this unfold. Great build plan and choices so far.

Any plan for head porting? Heavier duty pistons/rods/girdle? The PD100 bottom end is pretty stout by old ALH standards but with that turbo and those nozzles you have the potential to make that bottom end cry for mercy.

Can't wait for this to be done, should be a total beast!
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Old November 14th, 2012, 15:10   #8
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Kinda a waste of a perfectly good TDI, no? There's so many wrecked ones that would work fine for this.
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Old November 14th, 2012, 18:25   #9
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I had that in mind too you could have paid less for a wrecked one it is sad for a perfectly good tdi a 2004 to add but otherwise it is a quite nice project
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Old November 15th, 2012, 07:37   #10
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Quote:
Originally Posted by A5INKY View Post
Looking forward to watching this unfold. Great build plan and choices so far.
Any plan for head porting? Heavier duty pistons/rods/girdle? The PD100 bottom end is pretty stout by old ALH standards but with that turbo and those nozzles you have the potential to make that bottom end cry for mercy.
Can't wait for this to be done, should be a total beast!
Thanks! Some porting may be in line next year, I'll see how the tune works out before deciding on lower end mods. Even with an LSD and the 275/35-18's I'll be running, maxing out the power with this turbo/injector combination will make it difficult to hook up.

Quote:
Originally Posted by turbocharged798 View Post
Kinda a waste of a perfectly good TDI, no? There's so many wrecked ones that would work fine for this.
Quote:
Originally Posted by LexDube View Post
I had that in mind too you could have paid less for a wrecked one it is sad for a perfectly good tdi a 2004 to add but otherwise it is a quite nice project
Not a waste at all! This car was purchased with a bad engine; next stop junk yard. I rebuilt it, spent 30k miles driving it while fixing all of the other systems and now recycling it into something that's fun and I want to drive! With a $20K budget there isn't much available new that's actually fun to drive. Building my own car from an eight year old sedan rather than buying something new also saved countless tons of CO2 to produce that shiny new one.

A 60+ mpg mid-engine TDI convertible with 250+hp, 400#ft torque and air conditioning that works, reborn from a tired old sedan, for $20K = my kind of fun car!

Go Green, Go Fast
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Old November 17th, 2012, 15:40   #11
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Here are the parts mounted on the BEW, in the chassis. Testing fit and mocking up mounting hardware. Viewed from the trunk area.
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Old November 20th, 2012, 17:24   #12
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Quote:
Originally Posted by bzeien View Post
Not a waste at all! This car was purchased with a bad engine; next stop junk yard. I rebuilt it, spent 30k miles driving it while fixing all of the other systems and now recycling it into something that's fun and I want to drive! With a $20K budget there isn't much available new that's actually fun to drive. Building my own car from an eight year old sedan rather than buying something new also saved countless tons of CO2 to produce that shiny new one.
A 60+ mpg mid-engine TDI convertible with 250+hp, 400#ft torque and air conditioning that works, reborn from a tired old sedan, for $20K = my kind of fun car!
Go Green, Go Fast
You rock, Bob!
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Old December 4th, 2012, 10:02   #13
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AWIC mounting position is set, now to weld up those mounts
(photos coming soon)
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Old December 8th, 2012, 08:01   #14
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That's going to be one screaming little ride when you get done with it. And around 60 mpg, to boot= win! win!

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Old December 25th, 2012, 09:14   #15
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To minimize the overall size of the intake/AWIC assembly I decided to eliminate mounts and weld the intercooler directly to the SDI scroll manifold (after shaving off the threaded mount on the manifold side of the AWIC). This gave some additional clearance between the AWIC and turbo hotside/exhaust piping. I'm fabricating a stainless heat shield to mount beneath the intercooler.



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