Just another compound build....

fouckhest

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g'vegs, sc
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.:GTD, .:R32, DangerRanger
Not to copy Gus too much....but, after more emails than I can even remember, and a few phone calls later, this is where I landed...

I have an mk4 GTi that has been my project car for several years...it was a bit of a whore in the gasser scene....it was featured in S3 magazine back in 2009...then covered ET in spring of 2010....I really wanted to do something different and naturally a diesel swap was naturally a great option....the car has already been 300+whp...it has a haldex swap...so then next progression was to figure out what to do with the engine swap....

so a 1.9L PD was found...and then the sourcing of parts began...

first a huge thanks got Gus for all his help, and well, not caring that i used the same 2 turbos for basis of the compound setup (i figured this was a good baseline for getting the setup figured out)....

So on to the list...

1.9L PD
Rosten Rods
BHW pistons (machined by Kyle @ PDE to lower compression to 17:1)
-total seal gapless second rings
1/2" Crank girdle
BRM oil pump sprocket
balanced rotating assembly
Bosio R783 nozzles
Malone Tuning custom file
Mild P&P head by me
..oh and the snails...same as gus...
gtb2056vk & s247

I decided not to mess with a cam right now, there is not a great option for cam, or valve springs (yet, soon to come)...so I have my feelers out for a PD150 head, JFettig has valve springs soon to come, then hopefully there will be a viable option for a cam, as well maybe get ahold of a set of the +160% nozzles...

Big Thanks go to:
-Gus
-RyanP
-Matt Whitbread
-Mark Malone
-Lee & Jesse Broznya
-Jon Fettig
-Bill Gerwig and Protech Motorsports
-Johnny Durham @ Durhams Machine shop....

so on to the photos...this is turbo parts, and such waiting to mock up the manifold...did this mid Dec when Jesse from JDL Auto Design (http://www.facebook.com/JDLAutoDesign) was in town to visit his brother for xmas.....

p.s. - this could take a couple posts:eek:

oh to the manifold mock up...









 
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fouckhest

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next step was to get the down pipe made...special thanks to my buddy Lee (i call him the mad scientist...b/c he is...) we finished this up after his brother left...

p.s. - i might add that i had a very specific aesthetic look in mind when i set out on this...you will definitely begin to see that i like the "less is more" when it comes to my bay content.....





 

fouckhest

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g'vegs, sc
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at this point...lots had been going on with the rest of my car...my CAE shifter got installed...final engine run/shakedown had to be done...then engine out and off to the machine shop....local dirt track builder, who happens to build grudge and pro-mod motors seemed to be a good choice...so off to Durhams Auto Machine went the bottom end...during that time Jesse @ JDL also finished up the manifolds and got them coming back east for them to fall in place for the final push to get the car to SoWo 6....

p.s. - i am limited to 10 pics per post apparently(and smileys count..doh!)...so this will take a while....:p








 

jjordan11

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Jan 5, 2008
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Lehi, UT
TDI
1988 Audi 80 quattro PD130, 1982 Westfalia TDI
That is looking very nice, I love that exhaust manifold. Are the collector pieces something your fab guy has or did he order them. Do you have any pictures of the port job you did?
 

fouckhest

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g'vegs, sc
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so this pretty much brings me to within about a month of what i called my "push for sowo"...i planned to take the week before work off to get the car ready to debut at SoWo 6...see the car had a special kin ship with SoWo...that was its first real VW show, and the car too the H2O Tuning "Club Choice Award" that year (2009, i think?)...so this was my real push to get things done....

this is a little bit of getting the motor back from the Durhams Machine shop....then taking it to Protech Motorsports, where some Porsche/Audi Gurus I know helped me and allowed me to put it back together under their 50+ years experience....big thanks to Bill Gerwig and his brother Frank Gerwig @ Protech Motorsports!

so pulling apart the o2m tdi gearbox, getting it ready to go into my 02mq box...thanks to RyanP!



shortblock back from Durhams! so clean and smooth!...lost the oil pump spacers...so huge kudos to Matt Whitbread for making those on the fly and over nighting them to me!!!


due to above spacer debacle, next photos are of the long block bolted together...


well....then got it timed, and it was dead nuts on first go around...so had to throw the turbo on there for some motivations!!!
**huge thanks to my guys at Steve White VW (Mike Wingard and Chad Brown for the timing tools....not to mention, Bryan Mann in the Parts Department..i think we were dating after this! LOL)



and just b/c i love this shot!
 

fouckhest

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so after ^^those^^ were taken i was able to rent a spot at a local shop to try and get the car ready for SoWo....so the next string of photos all took place from last sunday thru last wednesday night....the last photos are thursday afternoon when i dropped the car off to get wrapped even though it wasnt running...

so this was sunday afternoon after i got the car down to the shop...i spend friday night powder coating all the engine accs, saturday was wiring in the garage, then marrying the engine & trans, then sunday move to the shop and....

block cleaned up for paint...



good coat of VHT high temp etch primer


and...a couple good coats of CAT Yellow with an Eastwood Detail gun...my first attempt at painting w/a gun...had a blast to be honest!




little bit of bay cleanup....

 

fouckhest

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so monday i worked during the day on lots of little things...bolting on ancillaries for the engine and some bay prep work...then my buddy Lee (the mad scientist) came over and we got to work on my FMIC....

little fitment with the same side in/out IC...oh, p.s., it is from "justintercoolers" on ebay, and shipped from the same address as all the straights and tube bends from CX Racing....the elbows are all from mcmaster..ouch, they are pricey...



engine looking like something....




here is the mocked up FMIC and piping...when you look down onto the engine/bay you done see any piping!


 

fouckhest

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so the following day i kept chugging along...im pretty sure its wednesday at this point...so again...didnt mention had been working 7am-2:30am the past 2 nights...set out on weds with a vengance, was at startbucks and oriely auto by 8am, all ready for my day of action...if all went as planned this was to be the day that would decide if it would go to sowo or not....

here is the motor with turbos, oil feeds and such mounted



here is the bay after working most of the day/night on getting it preped, all the holes welded up from the wire tuck...during this time Lee was making all sorts of progress on piping for the turbos...he did some amazing stuff welding v-bands to make things clean and fit in tight places!

bay ready for paint...


car prepped and read to paint the bay


bay painted...firewall is a simple undercoating....rest of the bay is VHT roll bar paint...




and as of 4am thursday morning the engine was in the bay....


 

fouckhest

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so this is what happens the first night after a show i dont get my car too...i am too tired to work on my car...not to mention my g/f would probably kill me if i set out to work on it....but it is a much needed relaxer...and well...much needed catch up to show my appreciation to all that have help me me get the car this far...

we did get the car to the shop to get it wrapped...that should be happening this week...then going to try and get it home this weekend at some point and work to get it finished.....

this is how i left the car last thursday...



 

fouckhest

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Looks nice! I really like how simple the manifold is but how amazing it looks.
thanks! there is much more detail to follow....but well, you had been on me as many others have to post up...so i did...plus i am pretty much back at it tomorrow night;)
 

NoJoke

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Apr 11, 2003
It's about time! Nice color scheme with the CAT yellow!

Can't wait till you're running, at this rate you should be within a week:D
 

ryanp

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Jun 22, 2008
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Arosa CR - 550hp - 9.7 @ 150mph 1/4 Mile, Citigo 4x4 CR TDi - 340hp, Caddy 2.0 CR 4x4 TDI - 300+hp, Golf Mk2 Van 1.9 TDI - was 290hp, Mk5 Ibiza 2.0 FR TDi - 270hp, BMW 135d - 360hp, BMW 330d - 335hp, BMW 335d - 380hp + a few more ........
Tunring out better than i could imagine, Show and Go!! MH, sent you a Email BTW
 

fouckhest

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It's about time! Nice color scheme with the CAT yellow!

Can't wait till you're running, at this rate you should be within a week:D
Thanks Gus! this week is not going to be anywhere as productive as the last couple...after that push and not getting it done, i need to catch up on some house/yard work...but still hoping to have it going in the next couple weeks...

Tunring out better than i could imagine, Show and Go!! MH, sent you a Email BTW
Thanks Ryan! really appreciate all the help!...but wait you had doubt? :eek:....j/k i know i am hard to follow sometimes...but i tend to have a vision in my mind that i think will work! :p lol! got your email and replied! ;)
 

Nash_TDI

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Louisville, ky
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2000 Silver Jetta TDI
This week is not going to be anywhere as productive as the last couple...after that push and not getting it done, i need to catch up on some house/yard work...but still hoping to have it going in the next couple weeks...
Same here.

Sorry we missed this beast at sowo. Saw a crew of 3 reflex silver TDIs rolling around a lot of the weekend.

I blew a CV, my amp, and my 17/22 starting howling on the way there. Time to upgrade.
 

fouckhest

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Same here.

Sorry we missed this beast at sowo.
im sorry i missed it..i was really hoping to get it there in hopes of snagging the best forced induction award so i could participate in the "best of sowo"....oh well....maybe next year....
 

NoJoke

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Apr 11, 2003
What power goals are we shooting for? Also will you custom EDM the nozzles? Don't forget about gauges, LP boost and total boost separate beside the rest of the standard ones. I'm very excited for you especially with PD fuel delivery.

Forgot to mention the F-Town Haldex controller DOES work, Matt had tested it out; to be honest I was worried. A good option since you have quite a bit invested:D I'm not keeping tabs either haha.
 

fouckhest

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What power goals are we shooting for? Also will you custom EDM the nozzles? Don't forget about gauges, LP boost and total boost separate beside the rest of the standard ones. I'm very excited for you especially with PD fuel delivery.

Forgot to mention the F-Town Haldex controller DOES work, Matt had tested it out; to be honest I was worried. A good option since you have quite a bit invested:D I'm not keeping tabs either haha.
well from talking to Mark, it seems that the R783s are going to run out of fuel a little shy of 300whp...so with that being said, i would like to get those nozzles maxed out, and the motor running well....then look into a set of the +160% nozzles...or whatever may be out there by that time...i am actually looking to get a PD150 head over here to start building, that way when i get the nozzles and such maxed out i will be able pretty much simply swap heads and start with new injectors, then look into cams, etc....

i do need to get some guages spec'd out...they have been on the back burner till i can get the engine up and running and thru the break in period...ugh...

oh, i have had the F-town controller for probably a year! LOL! but that is great new that it works! haha, nothing like blindly sending someone close to a grand for something that seems to be a mythical creature! :eek::p i acutally have it mounted beside my air ride controller in the center vent in the dash:cool:
 

NoJoke

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Apr 11, 2003
Don't bother wasting your money on +160's; doing some math I think you will need minimum +180% nozzles, I believe Ryan might of opened up some PD nozzles. These combination of turbo's seem to produce a good amount of air.


Not sure what to say about the cam situation, I thought Colt or Frank had it figured out. We're having great results with Meister's cam. Definitely double spring action and proper porting to get that pressure in and out. Keep sharing notes with John since he'll will be working full time on the Porsche(glad you're OK).
 

VWDAVID

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tdi land
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Damn between this thread and nojokes who needs porn. Beautiful work can wait to see what kind of numbers this thing puts down.
 

fouckhest

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Don't bother wasting your money on +160's; doing some math I think you will need minimum +180% nozzles, I believe Ryan might of opened up some PD nozzles. These combination of turbo's seem to produce a good amount of air.


Not sure what to say about the cam situation, I thought Colt or Frank had it figured out. We're having great results with Meister's cam. Definitely double spring action and proper porting to get that pressure in and out. Keep sharing notes with John since he'll will be working full time on the Porsche(glad you're OK).
wow, interesting! i thought the +160s were going to be the answer...oh well, i am in no hurry to max this thing out at this point...i just want to drive it! but that is good to hear/know about the amount of air these turbos are capable of!

yeah man, the cam things seems to be a bit of a debacle, i talked to Jeff at Colt a while back, and it seemed like things were in the works...but to the same point as above, i am in no hurry...i have my name in the bucket for a set of Jons upgraded springs, so building the head will just be another project to keep me satisfied...well till i decide the R needs turbos! :cool:
 

fouckhest

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what kind of power is this setup going to give you?
not to vortex out...but come on man....4 posts above...:rolleyes:...


well from talking to Mark, it seems that the R783s are going to run out of fuel a little shy of 300whp...so with that being said, i would like to get those nozzles maxed out, and the motor running well....then look into a set of the +160% nozzles...or whatever may be out there by that time...i am actually looking to get a PD150 head over here to start building, that way when i get the nozzles and such maxed out i will be able pretty much simply swap heads and start with new injectors, then look into cams, etc....
 
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