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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 April 13th, 2018, 04:51   #61
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no pics here either, as suggested above you can use tdiclub's picture server, a little clunky but the pics will be here with no fear of third party hosting ransom demands
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Old April 13th, 2018, 16:30   #62
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Sorry about this guys, I think I might have figured the pics out. Let me know. My first few pics are hosted on the tdiclub server but I realized quickly that because of the quality and amount of pictures that I wanted to post I would run out of room very quickly.
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Old April 13th, 2018, 17:53   #63
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I can see them all from the 2nd of April on..thanks and great job.
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Old April 13th, 2018, 18:53   #64
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Quote:
Originally Posted by Geobmx4life View Post
I can see them all from the 2nd of April on..thanks and great job.
Thank you, finally success with the pictures.
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Old April 15th, 2018, 14:55   #65
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Next up was some more exhaust work.

Here it is coming from the back of the truck on the driver's side.



Crossing under the front driveshaft.





And coming up on the passenger side of the transmission.



Removed the cross over section for some final welding.





Here it is bolted to the rest of the exhaust so you get a better idea of whats going on. This is as far as I could go with the exhaust until the engine mounts were made. Then I would be able to finish the downpipe.

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Old April 22nd, 2018, 16:16   #66
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Next issue to tackle was a reservoir for the air to water intercooler system. The main body of the tank is actually a section from an irrigation pipe that I cleaned up, and the pump is a Bosch unit I got online that is specifically for air to water circulation. I believe it was used as oem on the Ford Lightning and other supercharged vehicles that needed a good pump. I seen some people using cheap little bilge pumps, but those did not fill me with confidence like the Bosch one did.





I needed a cap for the tank and found this lying around.



Welded in a plug to turn the bicycle sprocket hub into a lid.



And attached it all to the tank with a bit of RTV under the gear and a lot of screws.





Made some ins and outs for the coolant. The lower one goes to the pump and the upper will receive coolant from the small radiator stuffed in the grille.





Mounted in the truck.




Last edited by J.Klassen; April 22nd, 2018 at 16:22.
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Old April 25th, 2018, 20:50   #67
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Scrap metal ftw!
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Old April 29th, 2018, 13:56   #68
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Scrap metal FTW indeed. Left over pieces come in handy all the time.

In this pic you can see that the jetta airbox is mounted in the corner and I started making the pipe that will lead to the turbo inlet.





A view from in the engine bay with the hood closed. Just trying to make sure that the intake pipe is going to have plenty of clearance.



Hooray, the adapter arrived. Randy delivered it himself and it was great to meet him. This was the first of the Nissan 4 cylinder trans adapters and I believe there are quite a few more out there now.



Test fitting on the trans.



Got my turbine housing and manifold back from ceramic coating. I wanted it done in white but their oven could not go hot enough to do white so I settled on gold. But then I decided I really still wanted white so I sprayed the parts with an aerosol ceramic paint.





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Old April 29th, 2018, 18:54   #69
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Quote:
Originally Posted by J.Klassen View Post
Hooray, the adapter arrived. Randy delivered it himself and it was great to meet him. This was the first of the Nissan 4 cylinder trans adapters and I believe there are quite a few more out there now.
Is that one of Randy's new "heavy" flywheels?
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Old May 6th, 2018, 18:26   #70
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The flywheel is just a stock Nissan unit that was re-drilled to match the vw pattern. I think I posted the weight somewhere earlier in the thread.
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Old May 6th, 2018, 18:33   #71
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Put the engine side of the adapter on and it lined up great.



Then started mocking things up to see what kind of room I had to play with.







This coolant hose going to the oil cooler was going to be a problem.



Good thing there was just enough room to shorten it up.



Here is the clutch I am using.



Making sure the splines fit the disk before I try jamming it on there.



And bolted it to the flywheel.

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Old May 8th, 2018, 04:24   #72
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Love the progress!!!!
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Old May 13th, 2018, 19:00   #73
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Thanks! I am glad I waited to post the pictures until after I had the truck on the road. It makes doing these updates easier and regular.

Here is my contraption for test fitting the engine. I used two old camper jacks so I could move the engine up and down easily and when I wanted to take the engine right out of the bay I just brought the tractor in with the forks and lifted it off the jacks. All without poking my windshield with the forks lol.





That big engine bay gets tight really fast when an engine gets stuffed in there!

This pic shows the clearance for the vacuum pump to the fire wall.



I think it would have fit but only just. So I decided to make a pocket in the firewall so that I could actually get at the pump if I had to later on.



There are two layers of metal in this firewall.



And then the sound deadening.





I use "CAD" for a lot of my parts. If any of you are following "Project Binky" on youtube you'll know what I mean lol.




Last edited by J.Klassen; May 13th, 2018 at 19:14.
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Old May 13th, 2018, 19:01   #74
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Old June 3rd, 2018, 09:59   #75
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Now that the engine was hanging in the right location it was time to make some engine mounts. I started with the passenger side because it was more complicated.

I bolted a stock nissan engine mount to the frame rail and then proceeded to make cardboard templates to go between the mount and the plate that I made earlier that bolts to the engine.



It was going to be interesting with all these things competing for the same space.









First cardboard piece turned into metal and tacked in place.



Second piece ready to be tacked in.



Ready for welding.



All welded up.



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