Mk1 16v Project

[Preen59]

:O dude i just read your WHOLE thread start to finish. big cudos to you for doing all this work yourself. i feel silly now for my comment in sydney "oh yeh building a 16v aye, what've you done with it?". lots of inspiration in there...

Hahaha. The WHOLE thread? man, thats some reading! Yeah there's been some work done. Being sread out it doesn't feel like that much, but when you look back on it, i'd hate to tally up how many hours i've spent on it. But hey, its better than blowing it on alcohol and cheap thrills! Thanks for the complement man.

[Preen59]

Did a little more tonight. I went to fit the head studs to the block the other day and the threads had a little corrosion etc in them and the studs were binding on them. I tried blowing them out but that didn't seem to work.

So, this arvo i made my own TPR Gingerbeering patented thread cleaner outerer. I just got an old 1.6 head bolt and ground 2 opposing flutes on it on the offhand grinder. If you don't have access to one, you could just use an angle grinder and be careful.

I would have just used a tap for this, but the bolts are 11mm dia by 1.5mm pitch. Why didn't they just use 12mm?

Anyway time for pics.

Here's the block with all the studs in and the torque plate slipped over the top.

I just wanted to make sure i didn't screw up on the dimensions when i made it. Thankfully, i didn't.

And here's a shot of the bolt i modified. Its a little hard to see.

[GoLfMan]

what does the torque plate do again mate? nice piece of machining there

[Preen59]

what does the torque plate do again mate? nice piece of machining there

Its to extend the cylinders so i can run longer rods.. Nah just kidding, you torque it down when you bore and hone it to distort the block 'out of true' so that it is actually 'true' when the head is torqued onto it. If you measure the bore under no tension after it has been bored and honed torqued up, it will be all over the place.

By the way, did you notice the TPR Engineering logo? A guy i know has converted an old bridgeport mill into a CNC mill and does all kinds of stuff like that.

[GoLfMan]

thats awesome mate thats for the explanation

[Preen59]

thats awesome mate thats for the explanation

Anything for you, Josh. Anything.

[Oneofthegreats]

Very nice work & good to see more progress.

Good explanation on the torque plate too.

It's a big misconception about why they are used. You should also use one of these when your grout filling a block fo rthe same reason.

It's alway's nice to be alittle closer to driving it.

Wonder if the torque plate will suit a 20VT.

[Preen59]

Very nice work & good to see more progress.

Good explanation on the torque plate too.

It's a big misconception about why they are used. You should also use one of these when your grout filling a block fo rthe same reason.

It's alway's nice to be alittle closer to driving it.

Wonder if the torque plate will suit a 20VT.

Check the thread, Head and Block Drawings in tuning and performance i started. Download the PDF. check the dimensions against yours. I didn't know you had a 20vt?

[Oneofthegreats]

Check the thread, Head and Block Drawings in tuning and performance i started. Download the PDF. check the dimensions against yours. I didn't know you had a 20vt?

Yep. I've had one since 2000. I brought the engine basically brand new with only 30K on it. It's also the AGU big port one.

I had it fitted into my 83 GTI around 2001/02 which if I had it going would have been the first out here I think, but other stuff came up & it got put on the back burner.

Also have a GT3076R (.82 A/R exhaust housing), 38mm Tial wastegate, billet fuel rail, etc. Just need coin for some rod's, piston's, cams, 630cc injector's, fuel reg, ECU & exhaust.
Everything else is there.

I was originally chasing 240fwkw's, but have been advised with the setup it should easily make nearly 300fwkw's on about 26-28psi. My plan was if I could blow the tyres off at 80km/h, I'd be happy.
Well maybe alittle more than happy.

[GoLfMan]

Anything for you, Josh. Anything.

i like the sound of that

It should easily make nearly 300fwkw's on about 26-28psi. My plan was if I could blow the tyres off at 80km/h, I'd be happy.
Well maybe alittle more than happy.

Tim i'd be happy with that aswell