My 91 GTI 8 valve to B4 1Z TDI swap

clyde · Aug 8, 2013

Hey, Myke, how 'bout you show us some pictures of that great Mk2??

GTiTDi · Aug 8, 2013

myke_w said:
There's a small chance I'll make it.. If so it will be a whirlwind of a day trip as I have family in from far out of town for the holiday weekend..

Oh man hope you can make it!

myke_w said:
I did finally get my coupe mostly shook out.. sure is a lot of fun to go fast AND get 50 mpg

That is the best part for sure

Definitely hard to believe to the uninitiated...Converting many of my car buddies to TDI with high speed trips in the GTI....

One Japanese car enthusiast friend said.."How can you average 90mph and barely use any fuel?!?

myke_w · Aug 8, 2013

Chris, I hope I can make it too, just depends on the way that weekend plays out...

Hey Kent, I definitely don't want to threadjack so I'll refrain from doing a pic dump.. Hmm.. Maybe I'll start a retroactive build thread...

GTiTDi · Aug 8, 2013

myke_w said:
Hey Kent, I definitely don't want to threadjack so I'll refrain from doing a pic dump.. Hmm.. Maybe I'll start a retroactive build thread...

Do it you won't!

myke_w · Aug 8, 2013

Ok Ok.. you made me do it!
pic 1 - In context at least

pic 2 - things that make me go vroom

pic 3 - best one I could dig up in 5 min.. Clearly I need more glamor shots!

GTiTDi · Aug 8, 2013

I Love Coupes

Nice pics Myke! Dustoff this year had four mk2 TDIs in total..I was the only last year! The secret is out they are catching on.....

Frankencar · Aug 9, 2013

GTiTDi said:
I Love Coupes Nice pics Myke! Dustoff this year had four mk2 TDIs in total..I was the only last year! The secret is out they are catching on.....

Sounds like the west coast has some catching up to do!

clyde · Aug 9, 2013

Nice looking car, Myke! Was it repainted? Mirror covers that match the body—gooood!

Thanks for giving us a target or goal.

Looks as if you use a Corrado PS reservoir, too…

Kristofk · Aug 11, 2013

myke_w said:
pic 2 - things that make me go vroom

You changed your intercooler again?

For the second one, is there enough room to slide in an AC condenser?
How about for the one above?

For the Saab one, it definitely seemed like you can slide one in there, what was the dimensions for that intercooler?

How much HP are you generating?

Im thinking of buying an eBay intercooler kit, but dont know if I need to install special fittings for sensors on the "HOT" side of the intake piping (after the turbo).

GTiTDi · Aug 12, 2013

Uh that's not my car.....
With my newer FMIC set up, there is absolutely no room for a condenser. I don't particularly care for air conditioning as I like to cruise with the windows down.

Here is a pic of my bay before I recently changed my air box to one I am experimenting with...

I had to clearance the lock carrier to fit the FMIC...which is made by Spearco. It barely fits, the radiator had to be moved back quite a bit more than with the SAAB intercooler, which for anymore than 20 PSI is not worth the effort as mine failed from constant beating and 28-30 psi..I took the end tanks off of it recently to strip it down for scrap and it does look restrictive. I also ditched the stock plastic boost pipe which had two 90* bends in a row for a less restrictive aluminum pipe which I TIG welded.

Kristofk said:
You changed your intercooler again?

For the second one, is there enough room to slide in an AC condenser?
How about for the one above?

For the Saab one, it definitely seemed like you can slide one in there, what was the dimensions for that intercooler?

How much HP are you generating?

Im thinking of buying an eBay intercooler kit, but dont know if I need to install special fittings for sensors on the "HOT" side of the intake piping (after the turbo).

GTiTDi · Aug 18, 2013

3' stainless side exit with resonator...

^above pic during finalizing adjustment of hangar before welding it...which is why it is offset...now nice and centered

AndyBees · Aug 18, 2013

How's the sound? I bet awesome at about 80 mph!

GTiTDi · Aug 18, 2013

AndyBees said:
How's the sound? I bet awesome at about 80 mph!

Deeper, much deeper, and the tone is much smoother...my previous exhaust was less than ideal..one spot in particular was probably causing back pressure...one of those "temporary test purposes only" parts that ended up being semi-permament!

JFettig · Aug 18, 2013

I couldn't imagine driving with that exhaust! I have 2 resonators in my Passat, piped straight out the back and it gets to me. I was planning on changing it but now that its not a daily, I'll leave it.

GTiTDi · Aug 18, 2013

JFettig said:
I couldn't imagine driving with that exhaust! I have 2 resonators in my Passat, piped straight out the back and it gets to me. I was planning on changing it but now that its not a daily, I'll leave it.

It isn't nearly as noisy and obnoxious as you would think it may be....May have a lot to do with the fact that it is a wastegate turbo rather than vnt, which sound like jet engines at low speed and idle when vanes are open...

clyde · Aug 18, 2013

Noise, VNT vs wastegate turbo

Interesting point!
Ever made a side-by-side comparison of exhaust sound levels?

JFettig · Aug 18, 2013

GTiTDi said:
It isn't nearly as noisy and obnoxious as you would think it may be....May have a lot to do with the fact that it is a wastegate turbo rather than vnt, which sound like jet engines at low speed and idle when vanes are open...

Next time you have a VNT TDI in your shop with aftermarket exhaust, pull the vacuum line, thats what mine sounds like at idle

GTiTDi · Aug 18, 2013

JFettig said:
Next time you have a VNT TDI in your shop with aftermarket exhaust, pull the vacuum line, thats what mine sounds like at idle

I have some customers with loud ALH's, and Pods mk4 Jetta is pretty loud....just took a fellow VW enthusiast for a ride and he thinks my car is actually quieter now

JFettig · Aug 18, 2013

Cool, well I'll let you know what I think in about 2 weeks

GTiTDi · Aug 19, 2013

JFettig said:
Cool, well I'll let you know what I think in about 2 weeks

I hope you are bringing your B5...other wise the deal is off! You might get a ride, but I will withold the test drive option ha ha!

JFettig · Aug 19, 2013

I still have to go pick up my B5 from my folks' place where I left it to go pick up the JSW
Clutch probably won't hold either

GTiTDi · Aug 19, 2013

JFettig said:
I still have to go pick up my B5 from my folks' place where I left it to go pick up the JSW
Clutch probably won't hold either

Its a FWD B5, wicked easy clutch to replace! Drive it by my shop on the way to Fest, I will hook you up with a killer deal!

GTiTDi · Aug 21, 2013

Love this pic, thought I would share

bassman5066 · Aug 24, 2013

Since were sharing car porn....

Removed huge pic

This is getting installed on the 2011 while I'm in ME and NH with the MK2.

Sent from my Bosch Motronic ECM via VCDS Version 1.9LVE

bassman5066 · Aug 24, 2013

Sorry bout that. I wrapped it but its going to Diesel dubs in shippensburg pa. Its going in for a timing belt because I didn't wanna do that job so I figured id get the tune done and downpipe installed while its there. 250 for the downpipe install isn't too bad in my book.

Sent from my Bosch Motronic ECM via VCDS Version 1.9LVE

GTiTDi · Sep 6, 2013

Had a blast with the GTDI at Fest last weekend, the time goes by too fast...next year should be at least a week long!

Did some more driving on my way back, took a shortcut down the seasonal part of 113 in NH, waterfalls on the road and rivers of water crossing at the low points...was like a paved rally stage at 80

so fun!
Kind words from Lugnut who drove the GTDI back in July after 40's in a bag

Lug_Nut said:
That's GTiTDi's A2, the best all-around performing TDI I've driven. Great handling and comfortable ride manners, brutal amounts of power but velvety-smooth delivery, and biodiesel powered to boot!
Note the silly/stupid smile on the owner? There's a damned good reason for that!
<edit> Oh, that OTHER white car? 87homebuilt's one-off creation that was 12 years in the making? WOW!<end>

and a comment by Tim who took the pic and has driven the GTDI at last Fest...forgot to let him take a update run, oops!

TooRoundTDI said:
Yea its insanely powerful and smooth riding. I didn't even know I got Chris in the picture until I posted it, haha.

GTiTDi · Jan 27, 2014

Been a while since I updated my thread, the build continues! (slowly)

New goodies waiting to go in after my next dyno session

Growler · Jan 27, 2014

ooo is that a phenolic(sp) spacer for the intake? nice.

Houpty GT · Jan 28, 2014

Let us know how that turns out. Jon seems to think it will upset flow.

You got me thinking that I could build some type of cooling into the long runner SDI intake's EGR system.

GTiTDi · Jan 28, 2014

Houpty GT said:
Jon seems to think it will upset flow.

meh.

My 91 GTI 8 valve to B4 1Z TDI swap

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