Orwell gets boosted (another 1.8t 20v swap) by mk1vDUBtec

8 minute(s) of a 91 minute read

back from a weeks vacation!
Took the oil pan off so that I could get my machine shop to weld in a bung for a return line from the turbo.
Also took off my intake manifold. I'm gonna have them weld a log onto the runners because I cant find a reasonably priced 225hp TT manifold.

Received my 034 motorsports catch can adapter as well as my catch can, sachs power clutch kit, lightweight flywheel, and hd motor mounts in the mail while I was gone! It's like Christmas!!

I also sanded down the engine bay today and primed it. Local paint store will have my paint for me tomorrow (I decided on going the stock color in the bay, LE7Y silver) so that'll be tomorrow's project.
Keep in mind this is just a quick paint job, I'm on a strict time line, I'm only doing this because I have a few days of slack at the moment. Engine is on schedule to be dropped in next Monday.

8-3-2010

Update:
Motor mounts are a complete pain in the a$$ to take out and put back in. *I only got the passenger side done tonight.
But I also painted the bay. *What do you think? *Turned out relatively well I think...

^^ and you can also see the new techtonics short shifter I isntalled tonight! *Man, half of my bushings were actually missing (that explains the super sloppy shifter). *I'm so glad it came with new ones.
Also, the screw holes for the passenger side motor mount weren't used in the Passat, so they were all rusty and the bolts wouldnt go through, so I re-tapped them and they work well now.

Also got a serpentine belt, but it's about an inch too short :-(
Also got catch can fittings, so that's complete!
Finishing swapping the new HD motor mounts and timing the motor is my agenda for tomorrow after work. *

8-4-2010

I got a lot of stuff done today!  
I bolted the passenger side engine mount on, with the new HD insert. Since the engine mount is off of the Rabbit, the timing cover isn't made to fit it, so I did some custom fab work:

Then I timed it with the new timing belt and the 16v tensioner (used in place of stock tensioner to clear side motor mount)

I also did some fab work to the top timing cover in order to make that fit around the new engine mount as well:

Progress! Finally starting to a little more like a motor and less like a hunk of metal.
I also returned the 38.5" 4 rib serp belt and got a 40" 5 rib belt (for $6 less? wtf?)
HALLELUJAH IT WORKS!!! (and quite well, might I add)  

everything lines up, I spun it around a couple times to make sure nothing would work its way off

Also stopped by Home Depot and got some fittings to adapt a catch can hose to the fitting I got from 034 motorsports to run a catch can off of the block (instead of all that PCV crap).

The problem I'm having now is running coolant lines. I've got to figure out exactly what goes where and how it's getting there. I muffed up and when installing the rabbit water pump, I also installed the rabbit waterpump housing, which has an extra port, hehe. Anybody got any ideas?
Here comes the engineer in me, I'll make it work to my advantage

8-8-2010

updates!

I switched to an 2.0 ABA oil pan. I had my machine shop drill and weld in a piece of pipe for an oil return line from the turbo. Also, the stock oil pan held the stock baffle in place, so I bought an ABA baffle/gasket combo and used that instead:

I got some goodies in the mail

Forge Splitter Valve (adjustable diverter and bov)
Sach's Power Clutch Kit and Eurospec Lightweight flywheel:

I also painted a few accents anodized blue to match the grille/wheels.

Pressure plate bolted on:

Then got the clutch centered and flywheel bolted onto the PP. Next came bolting the trans and starter on!

So I started rebuilding the k03 turbo and when I took the shaft out I found this:

NOT good.
But the guy I bought the car off of assured me the turbo was good and that if it wasn't for some reason, he'd give me some money back, so I'm going to talk to him and hopefully get $100 back. I'm so glad I decided to rebuild the turbo. I would have been pissed if I got the car running and the turbo blew right afterwards.
But it kind of worked out in my favor because I just picked up a k03-s today for $130. I know it's not too much better than the stock k03, but hey it's at least 10 hp for like $30 extra
I was kind of pissed about the turbo holding up progress, so I decided to drop the motor in yesterday. It only took 25 min and it fits like a glove!!!

with the evo 8 intercooler. I have to modify the radiator a little bit to make it fit:

I probably have to relocate the battery to the back too, unless i move the radiator some in order to run a charge pipe to the drivers side intercooler outlet.

So I made another error and forgot to check the clutch release before I dropped it in...
I can pull the clutch lever all the way up with my hand, which I shouldn't be able to do. the axles spin when the lever is up and down (disengaged and engaged), so something got screwed up...
Anyone have any ideas what I did wrong?? I'm going to take it out tomorrow and try to figure it out.