Common weight save items on tdi engines

bhodgkiss · Aug 22, 2012

I've gone from 60% front weight distribution to about 57%. 55% possible fairly easily with a few more tweaks with the car looking standard. Not that bad really, you can feel that sort of difference.
If i do achieve my 200 crank hp goal then 7% weight save is then an effective 14hp increase.
I understand people who say whats the point, but even if I had a 300bhp Audi S4 I'd be doing similar tweaks. This is cheap and fun! Just re-routing the battery in the boot was a good learning experience.
Its nice to surprise a few people with a 15 year old family diesel wagon.

GTiTDi · Aug 22, 2012

bhodgkiss said:
I've gone from 60% front weight distribution to about 57%. 55% possible fairly easily with a few more tweaks with the car looking standard. Not that bad really, you can feel that sort of difference.

I agree 100%.

I have done this with every VW I have owned since my first mk3 golf 2.0 way back in 2000!!!

devonutopia · Aug 22, 2012

bhodgkiss said:
You sure you got 20kg with a small fabia bonnet?
.

It's by no means a "small" bonnet. It is full size to me, similar to golf etc. I only just got it in the back of my car on the day I swapped to the plastic bonnet.

Carl2k7 · Aug 23, 2012

perspex windows would save a hell of alot of weight

bhodgkiss · Aug 24, 2012

I assuem perspex windows wouldn;t go up/down on the electrics? and curve to the right shape etc? Or are they flexi enough to bend to shape? And don't flap about in wind?
I guess they scratch easy and are expensive and for track cars only?

john.jackson9213 · Aug 24, 2012

Run cooling system two quarts low. Get two quarts of oil out of the oil Pam. Get rid of your intercooler and all that piping. Get rid of the front bumper.

bhodgkiss · Aug 24, 2012

ok......!

m1ketdi · Aug 24, 2012

bhodgkiss said:
I assuem perspex windows wouldn;t go up/down on the electrics? and curve to the right shape etc? Or are they flexi enough to bend to shape? And don't flap about in wind?
I guess they scratch easy and are expensive and for track cars only?

It's flexi enough to run on electrics if you really want I believe. But will scratch easily....

But you save more weight if you ditch the window mechanisms as well....

IndigoBlueWagon · Aug 24, 2012

Removing the bumper brace is a big improvement. Shifter counterweight. Get a smaller alternator. Delete the power steering. Make sure you have headlights with plastic lenses. You could probably get away with a smaller radiator and less coolant. Delete one of the cooling fans. And get the absolutely lightest wheels you can find. I have 16" Motegis that weigh 12 lbs. each.

TDIJetta99 · Aug 24, 2012

Does anyone make a manual steering rack that will fit in a MK4?

IndigoBlueWagon · Aug 24, 2012

Can't find one. Tried the latest manual rack I could find (think it was off a '91) and it wouldn't bolt to the subframe.

Also, the front bar is hollow. Doesn't weigh much.

joseluis.17g · Aug 24, 2012

the alarm horn

bhodgkiss · Aug 24, 2012

This is not a track car but a daily driver guys.....
I need horn and bumper bars

joseluis.17g · Aug 24, 2012

bhodgkiss said:
This is not a track car but a daily driver guys.....
I need horn and bumper bars

If I recall correctly the ¨steering wheel¨ horn and the alarm horn are two different horns so maybe you can take off the one with the alarm

GTiTDi · Aug 24, 2012

IndigoBlueWagon said:
Can't find one. Tried the latest manual rack I could find (think it was off a '91) and it wouldn't bolt to the subframe.

Also, the front bar is hollow. Doesn't weigh much.

The handling benefit of removing the front sway bar outweighs the weight saving factor..

IndigoBlueWagon · Aug 24, 2012

If you have the right springs the front bar is totally unnecessary, and removing it helps reduce wheelspin when exiting a corner. My point was it doesn't weigh that much, so removing it won't reap a significant weight saving benefit.

GTiTDi · Aug 24, 2012

IndigoBlueWagon said:
If you have the right springs the front bar is totally unnecessary, and removing it helps reduce wheelspin when exiting a corner. My point was it doesn't weigh that much, so removing it won't reap a significant weight saving benefit.

I know Peter, was just messing around!

Take off the front sway bar, just don't expect a huge weight savings (with a Mk4)!!

bhodgkiss · Sep 28, 2012

Some tdi's like agr and ahu had alloy cam covers but fitment is different to my afn.
There must be a lightweight bolt on cam cover I can use from another vw?
Mine weighs a kilo!

j29 · Sep 28, 2012

are you guys nuts this is a daily driver just enjoy it.
the cable to move the battery to the trunk would reduce any weight savings.

TDIJetta99 · Sep 29, 2012

since when does moving the battery to the rear make the car lighter? LOL...

Moving it to the rear is just for balancing the car a little better, not making it lighter..

bhodgkiss · Sep 29, 2012

Yes that is funny....

I started this thread for people who are interested in weight save items. Often its cheap/free and yes won't transform the car into a porsche but it all adds up with 10kg here and there.

I'm not after 'this is pointless' comments - as to me its not

I still think removing the front ARB is a slightly odd idea.
And yes on a track car you can run stiff enough springs to be able to remove the ARB, but this would be too bumpy on normal roads?

GTiTDi · Sep 29, 2012

bhodgkiss said:
Yes that is funny....

I started this thread for people who are interested in weight save items. Often its cheap/free and yes won't transform the car into a porsche but it all adds up with 10kg here and there.

I'm not after 'this is pointless' comments - as to me its not
I still think removing the front ARB is a slightly odd idea.
And yes on a track car you can run stiff enough springs to be able to remove the ARB, but this would be too bumpy on normal roads?

You don't have to do anything to the spring rate to run with out a front ARB...many put an ADDITIONAL rear ARB to stiffen the rear further...It dramatically reduces under steer and makes the FWD car prone to oversteer easier, not for the faint of heart (the choir lol)

Mikkijayne · Sep 30, 2012

bhodgkiss said:
Some tdi's like agr and ahu had alloy cam covers but fitment is different to my afn.
There must be a lightweight bolt on cam cover I can use from another vw?
Mine weighs a kilo!

I bet the alloy ones weigh the same or more than the steel ones - the alloy is pretty thick.

flee · Sep 30, 2012

There is at least 20 lbs of superfluous iron in the block casting, possibly more.
Get out your die grinder and go at it!
Sweep up the grindings and weigh 'em to see how you're doing!
Just stay away from internal passages and mounting bosses.

TDIJetta99 · Sep 30, 2012

If you really want to go all out, take out the interior (most of it will go back in), get out your drill with a 1" hole saw on it and cut a hole (or holes) in anything that's not structurally important.. Go around everywhere in/on/around the car where bolts protrude through whatever nuts they go through and cut off the excess.. Leave out the insulation under the carpet when you put the interior back in (that's 35-50lbs right there).. carpet trim in the trunk, spare tire cover, use an Avus wheel instead of the steelie for a spare.. put a bald tire on the spare too (less tread = less weight)..

I'm sure I can think of more ideas while keeping the car fully functional..

unclesfunnyonions · Oct 1, 2012

Take off the front wings and bonnet, take to your local friendly fiberglass specialist and ask him to recreate in 'glass.

Not be as bigger saving as carbon, will be cheaper tho.

H&R also do some light weight coilovers.

http://www.venommotorsport.com/manu...sion&product=MonotubeBlack&make=VW&model=Golf

Alex.

bhodgkiss · Oct 1, 2012

Thanks guys,

Insulation out will make the car too loud?
Fibre glass bits will be expensive
Just changed to KW coilovers which are already a fair bit lighter than the stock items, but those alloy HR bodies do look nice.

Yes if I had unlimited time and budget I could start machining away the block! Pretty extreme. Just after the easy stuff really.

TDIJetta99 · Oct 1, 2012

Mine doesn't have any insulation and it's not too bad.. There's some more road noise but no more than your average MK3.. My exhaust is far louder then the road noise though.. The main thing I notice is that I need to run the heat a little more in the cooler temperatures since the cabin cools off faster without the insulation..

I would never put coilovers in my car personally.. I drive it too much over rough roads and I like my suspension travel..

mlemorie · Oct 1, 2012

Aluminum exhaust? I know it wont be focused in the front, but it will save a decent amount of weight. My buddy made a few for some Evos he built.

bhodgkiss · Oct 1, 2012

Don't think aluminium is a good idea.....
Exhaust gases pretty aggressive so will not only corrode it but also give off harmful fumes.....
But Ti is a better idea.... but expensive

Common weight save items on tdi engines

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