Mean Green Biodiesel Machine build

loudspl

Veteran Member
Joined
Apr 22, 2005
Location
Osakis, Minnesota
TDI
02 ASV w/ 02J
Also, curious about how much more mass do the BHWs have over the .5 over ASV pistons? Could that extra mass offset the gains?

I ran the +.5 ASVs and now have the BHWs. As far as I can tell there is no loss due to slight piston mass increase. Mine were machined for clearance so weight difference is even less.
You will build revs & spool quick with minimal exhaust restriction, like using exhaust cutouts...or just large diameter all the way back
Revs will still build quick even with 22lb. FW
 

runonbeer

Maintenance EnthusiastVendor
Joined
Apr 15, 2002
Location
Austin, TX/Chapel Hill, NC
TDI
'00 Golf 02M, '10 Golf 02E, '02 UTE 02M
I have the reinforced fork if that is what you mean by selector. Otherwise, please elaborate so I understand .


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that's what I was suggesting. Glad it's done. One less worry. Looks a lot nicer than my green 2 door golf.:D
 

brnsgrbr

Veteran Member
Joined
Oct 13, 2009
Location
Washington State
TDI
2002 GOLF GTI converted to GTD
Nice build plan. Should be a fun one.
I will mention another problem with the light weight FWs, sometimes the lack of rotational dampening will cause the car to hunt around specified idle speed and kind of lope. It doesn't happen often but is really annoying.

And no, I cannot see light FW having any positive influence on turbo spool-up.

My next FW will be in the 22-23# range, minimum.
Hmmm I wonder if the balancing of my rotating assembly would lessen the extra need for damping, as I read on a post that there can be a lot of mass variance in rods and pistons on some of these TDIs. I figured the heavy DMF countered/absorbed the harmonics to smooth it out. (I know a harmonic balancer has this job. )

On this note, why won't Fluidamper make one for us!!!

A colleague here had a problem with chugging and slow down shudder on his '99.5 Golf, regardless of IQ setting. He just replaced the 14 lb. flywheel with a 22 lb. one. I drove it this morning: problem is totally solved.
Wow, I had no idea that could make that much of a difference.


I ran the +.5 ASVs and now have the BHWs. As far as I can tell there is no loss due to slight piston mass increase. Mine were machined for clearance so weight difference is even less.
You will build revs & spool quick with minimal exhaust restriction, like using exhaust cutouts...or just large diameter all the way back
Revs will still build quick even with 22lb. FW
Thanks, I hope for more comments on this. I am investigating the justification for the pricey BHWs. I have already spent a mint. If they are worth double to triple the price of the ASVs. I just want know why is all. If justified I will spend it.

I have 3" from the turbo back.





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Whitbread

Vendor , w/Business number
Joined
Jan 21, 2007
Location
Johannesburg, MI
TDI
Several
Thanks, I hope for more comments on this. I am investigating the justification for the pricey BHWs. I have already spent a mint. If they are worth double to triple the price of the ASVs. I just want know why is all. If justified I will spend it.
Always get rotating parts balanced no matter what.


BHW's are the cheapest piston option out there right now :confused::confused::confused:. Both 1/2 and 3/4 are in stock at Rock Auto right now for $74 each. Order quick!
 

brnsgrbr

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Oct 13, 2009
Location
Washington State
TDI
2002 GOLF GTI converted to GTD
Not working!!! Damn Damn Damn why won't my cart add them! Damn
Animal!
Animal!
Animal!
(Muppets reference!)


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brnsgrbr

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Oct 13, 2009
Location
Washington State
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2002 GOLF GTI converted to GTD
They had the 3&4 pistons but not the 1&2.

I remember a thread about rock auto and completely forgot.

Thanks again.


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brnsgrbr

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Oct 13, 2009
Location
Washington State
TDI
2002 GOLF GTI converted to GTD
I received the 2.0 liter 3 & 4 BHW pistons today as the 1 & 2 were not in stock. I compared them with the .5 over ASV.

BHW on the left



The top of the ASV piston tapers in.



Above, you can see the tapering that I have heard so much about on the BHW piston. You can also see the difference between the oil cooling galleys. What is the benefit of those 2 differences?



Here is another angle



The tops side by side. Without measuring, I can't see the positioning differences in the bowl locations and valve relieve positioning if any. You can see the style differences. The ASV reliefs are a little deeper.



Here is an angled pic.



This angle reveals that the ASV reliefs are deeper.

You can also see the deep ridges above the top ring of the ASV on the right.

The BHW piston is a little taller too. Maybe not as the plank these are on are not perfectly level at all. However, the ring spacing is identical.

Seeing these two side by side for the 1st time, answers so many questions for me.

There is more meat at the top of the BHW. The start of the bowl is deeper in the BHW. Does this mean anything? Compression? I thought I read that the BHWs start at 18.5:1 compared to stock 19.5:1 for the ASVs. Is that why? More cc's at the top of the area of the bowl down to where it truly starts to taper to the in side I guess.

The bowl of the BHW is smooth where the ASV bowl has ridges. The ASV bowl agles down at a higher angle too.




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brnsgrbr

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Oct 13, 2009
Location
Washington State
TDI
2002 GOLF GTI converted to GTD
More piston porn:

BHW on right ASV on left.



Illustrating oil galley differences some more.

Below, BHW on left this time



ASV piston has an extra galley for some reason.



Common sense here. IE ALH Tuscan rod won't seat into the PD style BHW piston



However, it of course easily seats into the ASV piston.

Piston rod pins below. BHW on left





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brnsgrbr

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Washington State
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2002 GOLF GTI converted to GTD
Thanks. This is my 1st time performing an engine build. Some things I know and some thing I don't. I plan on heavily detailing things I am curious about.


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oldpoopie

Vendor
Joined
May 14, 2001
Location
Portland Oregon
TDI
2001 golf gl, 2006 jetta, 1981 ALH swapped rabbit pickup, 1998 beetle
IMO the sacrifice in driving smoothness and the really loud gear rattle isn't worth the minute benefits of a light flywheel on a low revving engine. While light flywheels rev up faster, they also rev down faster basically letting the engine return to idle the moment you push the clutch in. In the cars ive driven with a 14lb flywheel, you have to slam shifts to catch the rpms falling at the right time or blip the throttle if you were too slow. It totally ruins the perfect/smooth driving manners TDI's have.
Your tuner can and should be able to adjust the off throttle fueling maps to adjust this. Ive seen Jeff tweak tunes to the rpms drop in a millisecond to idle, or take 5 seconds.
 

brnsgrbr

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Joined
Oct 13, 2009
Location
Washington State
TDI
2002 GOLF GTI converted to GTD
Good to know.

On another front, Saturday, I was getting on it hard onto a highway onramp and sheared off one of the motor mount studs in the block and the threaded mount on the motor.

Timing couldn't be worse. I have to figure out what to do as money is tight after my company filed chapter 7 bankruptcy a couple months ago.


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brnsgrbr

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Oct 13, 2009
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Washington State
TDI
2002 GOLF GTI converted to GTD
Sweet thanks.

I accessed where the bolt sheered off in the block. My cordless is too long a d my air drill was seized up. Grrrr. Anyone know if some one sell a SS or other hardened steel kit?


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brnsgrbr

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Oct 13, 2009
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Washington State
TDI
2002 GOLF GTI converted to GTD
My mechanic, John Davis at Dub Autowerks in Pacific WA, introduced me to a race car engine builder that recently ventured out on his own. Mike Gipson. He is awesome. I feel very fortunate that he is doing the machine work on my build.

He was so happy to do something different and is going to fit me in after landing some big race car builds that I cannot disclose.

He couldn't believe how knowledgable I was. I just regurgitated what I have picked up on this forum.

Engine dropped off. Parts dropped off. Down payment made. I am soooooo stoked right now!

After 3 years of assembling parts. Finally, I am going to be able to check off a bucket list item. He said he will even photo document the build.

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Whitbread

Vendor , w/Business number
Joined
Jan 21, 2007
Location
Johannesburg, MI
TDI
Several
My mechanic introduced me to a race car engine builder that recently ventured out on his own. Mike Gipson. He is awesome. I feel berry fortunate that he is doing the machine work on my build.

He was so happy to do something different and is going to fit me in after landing some big race car builds that I cannot disclose.

He couldn't believe how knowledgable I was. I just regurgitated what I have picked up on this forum.

Engine dropped off. Parts dropped off. Down payment made. I am soooooo stoked right now!


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Just make sure he keeps P2W clearance factory (Shoot for .0015" to .00159" ). I had a race shop hone to .0035" without asking me/looking up a spec; they went off 50 years of gas engine building specs. Motor ran great, but burnt oil.

If you need to borrow a torque plate, let me know.
 
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brnsgrbr

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Washington State
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2002 GOLF GTI converted to GTD
Thanks Matt. I am going to send him a link to the this thread.


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brnsgrbr

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Oct 13, 2009
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Washington State
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2002 GOLF GTI converted to GTD
Dropped off the 1&2 pistons, front and rear crank seals, & miscellaneous gaskets and mounting hardware.


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brnsgrbr

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Oct 13, 2009
Location
Washington State
TDI
2002 GOLF GTI converted to GTD
subscribed. what color are you painting the motor?
I don't think that it will get painted since I am having the machine shop assemble the motor. I was thinking a black block, green head, black injectors. Something like that...

On another note, I was able to purchase and install the Van Gogh block mount repair device from DG (very time consuming). I am so happy to get my car back on the road.

I installed 2 of the 3 60 durometer mounts engine and dogbone. At first I thought the vibration was insane. Then I turned off the AC and vibration disappeared. Shifting is great now.


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brnsgrbr

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Oct 13, 2009
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Washington State
TDI
2002 GOLF GTI converted to GTD
I have a catch can that I will be hooking up. I have heard a few thoughts a long time ago. One was to drain into the exhaust.

I am asking what is the best way.


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brnsgrbr

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Oct 13, 2009
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Washington State
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2002 GOLF GTI converted to GTD
I have a catch can that I will be hooking up. I have heard a few thoughts a long time ago. One was to drain into the exhaust.

I am asking what is the best way.


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brnsgrbr

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Oct 13, 2009
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Washington State
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2002 GOLF GTI converted to GTD
I have a catch can that I will be hooking up. I have heard a few thoughts a long time ago. One was to drain into the exhaust.

I am asking what is the best way.


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brnsgrbr

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Washington State
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2002 GOLF GTI converted to GTD
I think you need to fix your phone ;)

I'm skipping the catch can and going directly from valve cover to downpipe.

http://vibrantperformance.com/catalog/product_info.php?cPath=1022_1070_1340&products_id=1243
Lol. My phone was saying that the sever wasn't accepting the post, so wait 10 seconds and try again.

My only concern is the potential loss of oil and addition emissions.

So my next question would be to catch can owners that manually drain. What volume/quantity per oil change is caught/lost.


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