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TDI Power Enhancements Discussions about increasing the power of your TDI engine. i.e. chips, injectors, powerboxes, clutches, etc. Handling, suspensions, wheels, type discussion should be put into the "Upgrades (non TDI Engine related)" forum. Non TDI vehicle related postings will be moved or removed. Please note the Performance Disclaimer.

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Old August 20th, 2012, 13:26   #1
bhodgkiss
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Default Common weight save items on tdi engines

HI guys

Not looking for expensive items like carbon bonnets and bucket seats.....

But cheap or free weight save off the front end of our tdi's
Any weight off the front end has to be good.

Items I have so far:

Engine cover remove 0.75kg
Egr valve delete 0.5kg
Air con remove (mine didn't work anyway) 20kg
Bonnet insulation remove 0.5kg
Battery in boot 18kg
washer bottle in boot 2kg
Decat pipe 2kg?
Ported head
Lightweight airbox heatshield 0.25kg

Things I thought might be good:

Smaller oil filter 0.5kg
Alloy cam cover. Do these exist? Surely they must? 0.3kg?
Alloy front uprights off audi a6 (for my PASSAT) 6kg lighter then steel
Alloy upper suspension mount plates " " 1kg

Sensible thoughts please!

I've probably done the biggest gains already but good to check I'm not missing anything obvious

Thanks
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Last edited by bhodgkiss; August 20th, 2012 at 13:29.
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Old August 20th, 2012, 13:33   #2
m1ketdi
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De-turbo must be a good weight save :P.
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Old August 20th, 2012, 13:43   #3
Lex4TDI4Life
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Rear seats weigh a ton. Ditch em.
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Old August 20th, 2012, 13:55   #4
bhodgkiss
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50kg is not to be sniffed at!
Looking at front weight save not rear!
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Old August 20th, 2012, 13:56   #5
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I've done almost all of what you have and I honestly didn't feel the difference until I drag race vs a friends tdi same year and everything.

You could also do a lightweight flywheel I don't think you'll mind the extra rattle and could save 10 pounds easy


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Old August 20th, 2012, 14:03   #6
bhodgkiss
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With rear mods like no back box and no spare wheel etc its easily 70kg lighter than stock so call it 5% or 7HP plus the weight distribution and braking improvements. All good fun and looks stock which is what I want
Oh roof rails gone too for a cheeky 4kg high up save!
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Last edited by bhodgkiss; August 20th, 2012 at 15:01.
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Old August 20th, 2012, 16:22   #7
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Maybe ditch the front swaybar,
Engine undertray


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Old August 20th, 2012, 16:50   #8
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Rear battery....



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Old August 21st, 2012, 04:26   #9
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How do you fit a smaller oil filter? and how can it save .5 kg when the stock filter doesn't weigh that much?
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Old August 21st, 2012, 05:09   #10
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Quote:
Originally Posted by VWBeamer View Post
How do you fit a smaller oil filter? and how can it save .5 kg when the stock filter doesn't weigh that much?
On the screw on type oil filters you can get shorter filters. Half the length of the filter saves some weight and you need less oil in your engine with less filter to fill...
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Old August 21st, 2012, 05:40   #11
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Ditch the front sway bar, It will only be more fun to drive with out it!
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Old August 21st, 2012, 05:45   #12
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Braile has a battery it is small. Indeglobulewagon had a thread going some time back on weight saving. might do a search for that.
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Old August 21st, 2012, 06:12   #13
bhodgkiss
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Thanks guys,

- Yes battery is already in the boot, I don't mind it being full size as I need more weight in the back.
- Rear sway bar will go on too to help reduce understeer and add weight in the back.
- Yes the oil fill can be less with a smaller filter
- Removing the front sway bar, is this a serious suggestion? surely the whole car becomes a rolling mess (albeit balanced) This can't be good??? Think I'd rather add a rear instead.
- Front undertray removal just allows the engine/ancilliaries to be covered in crap (salt etc) and reduces mpg as the undertray helps a lot with aerodynamics (and noise.)
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Old August 21st, 2012, 06:49   #14
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Carbon bonnet is worth having seen how heavy the original bonnet is - in my case it was about 25kg VS 5kg....

Lighter flywheel helps. Not sure what a dual mass weighs - I am guessing about 30lb, maybe 35lb? My flywheel weighs 16lb, so thats in theory over 8kg saved just in the transmission.

You could remove the front crash bar?
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Old August 21st, 2012, 07:32   #15
joseluis.17g
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Removing the front swaybar it is a serious suggestion.
I ran with the front disconnected, it balances the car, less understeer and the extra body roll is not that big
And about the front crash bar, well that seems a little bit to drastic for safety reasons but you could always drill some holes.
And if you end up with a light front maybe you could also ditch the power steering


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