Beautiful conversion you got here. I plan on doing the same thing, but my project won't really get started for another year or two.

 

Thx, this is going to be my truck for the rest of my life, so I want it to be perfect.

_check this out, I just got the stage 2 cam i bought in the mail, and it has a nick in the journal. should I run it or return it?

 

I would return it. Also, this build is so smart that it's stupid.

 

thx, and I got a new one coming in the mail now.

 

I want to know how it does and mileage when your there I have a German import jetta with 155 hp 318 trq (so Im told I know all the guys around here with the American version love the way mine runs and what to get theirs to run like it lol)and 50 mpg at 75-90 mph but have thought about exactly this for a while

 

Well, I was getting about 35 mpg at 110 hp, but I am curious how this will turn out after Im done upgrading.. I should have around 180 hp- but all my upgrades are stage 2 and the only one that will not increase my mileage is the pump upgrade... it will push way more fuel. After I re-gear it for freeway speeds (3.54 or 3.90, I believe are available to me- would be nice to have a rear with limited slip too. I think the 3.54 would be a better match for freeway speeds right now, so I would probably try those first), chop off the rear, add on bumpers and a winch, get less aggressive AT style tires 33x10.5x15 vs the 33x12.5x15 I have now... there are just too many variables to say where it will be but I am hoping to keep it above 30 mpg.

 

Sent that nicked cam back, should get it in the mail today or tomarrow along with a brand new aluminum dbl pass aluminum radiator. Once i get the cam, this build will take off.. slap the cam in install new balanced injectors with upgrade nozzles, hybrid turbo upgrade, 11mm pump upgrade, then just need to come up with money for my ecu tune and hook up the harness.

 

My cam came in the mail! Heres a pic of me opening the box with a steak knife and consequently visiting the doc... Its bigger than it looks, about 3/4" deep hehe

 

what no pics of the cam?


Good luck with healing quickly

 

My top speed is about 70 mph- thats really workin it, im guestamating around 5000 rpm. I need to cruise at 70 mph with 2000-2500 rpm, I think thats where my torque tops out if I researched correctly. I am digging around for some 3.54 gears in an 8" axle but having a tough time finding any- there are some adds on google shopping popping up but when I call, they are all discontinued.

http://www.precisiongear.com/toy8.htm
These are the only ones I can find, but they are discontinued when I called- I wonder if they can still make them though... like a custom order. Ill have to call them back and dig around some more. Its either that or get some HUUUUGE tires hehe.

Wierd thing is, when I enter in my specs and calculate the RPM's, it says I should be running about 2500 RPM's.... so unless im slipping like crazy, which doesnt seem likely, something is off here.

calculated at this site:
http://www.csgnetwork.com/multirpmcalc.html
specs: 4.11 gears, .850 5th gear, 33" tires, 70mph.
Use the portion at the bottom where you can manually enter the transmission 5th gear ratio.

 

If you dont already know the two places to check out for your computer upgrade is
http://rocketchip.com/ and
http://malonetuning.com/
both are great with the TDI 1.9 and some serious power can be had cheap considering

 

I have allready done my ecu, I chose kerma- they have a ecu wizard over there.

 

Malone has

FlashZilla is a very popular device that allows you to receive engine tunes via e-mail and upload them to your vehicle anywhere. It can also be rented for $50 plus a deposit.

Tunes are sold separately. We will send you an invoice for tune(s) after you purchase the FlashZilla.
Features

Supports most 2000-2008 model year vehicles.
3 Slots for storing ECU files:
1 Slot to securely store your stock tune.
2 Slots for modified tunes. You can swap in more modified tunes from your computer.
OBD2 cable for connecting the device to your vehicle.
USB cable for connecting the device to your Windows computer if you want to transfer tunes to FlashZilla.
Read and erase ECU fault codes.
ECU recovery for reliable flashes.
Ability to sell FlashZilla to a new owner. Restoring the stock tune in your vehicle will unlock it for use in another vehicle.

FlashZilla owners can download the software and guide here.

I am considering the 1.9 swap to my 93 4ruuner with sas so I am very interested in how this works out for you

 

my thread isnt a billboard- I bought mine from KERMA because they were highly recommended and are well respected within the VW community. Please stop peddling, I am not in the market.

 

Haha, hey man how's the build coming along?

 

soooo........... been slacking off a little. Took so long between working on it Im sure Ive lost bolts, and I cant remember where some of these things go haha. I just started the diesel & heavy equipment mechanic 2 yr course at the local college, and my instructor gave me permission to bring this engine in as a project- I am going to tear it down and put it back together starting this monday! sooooo should be some cool updates, we get to see what this thing looks like on the inside.

 

Well it is a good thing I decided to reman this engine! Took off the valve cover, and everything looked shiney and new as expected (new cam and buckets), then removed the head-
looks like the guy I paid to do my head gasket set up my timing incorrectly, the valves have made contact with the pistons. I cant wait to see what the valves look like when I take apart the head, but the pistons look fine at this point. I did however notice some carbon buildup on the cylindar wall that worried me a bit.




Pulled out the pistons, here you can clearly see the carbon


For the most part the pistons passed the initial visual inspection except three of them had a stuck lower compression ring! heh I wonder how long this engine would have lasted like that....





Had enough time to clean up one piston before school got out- looks perdy. I am pricing out a set of rings... better start a parts list!

 

lots of updates coming- Ive been tinking away at this engine on lunch break for a few weeks now- I bought some goodies, but I wont spoil it- Ill post some pics up soon. Head went on today, should be together by next week, then I just have to figure out the wiring harness.

 

Oh man, can't wait to see what you've got brewing.