Pretty new into this forum,and thought I could make myself a bulid thread in here too... The car is a early 84,sold new as a Rabbit version with a minimum of equipment So I thought some extra parts should do it,maybe a 16v with turbo++? From the starting point,a dirty and worn 16v PL engine: Cleaned block and cylinder head.. Painted,soon ready for assembling.. H-beam rods with ARP2000 bolts,JE pistons 82,5mm and Sputter bearings.. Upgrade Stage 1 finished,now over to the cylinder head..
ABF 2.ltr head,raceported but still with original valves & springs: Windage tray from TDI.. Also got made a SS316 echaust manifold,I made myself a jig here.. In production @ mr.Nedregaard Finished welded, and strapped with exhaust band..I later found a turbo without wastegate,so more piping was needed.. A new and simple intake manifold had to be made,so I designed som drawings in my head a late saturday evening, and got it started.. Chop,chop!Later I glassblasted it to make a clean and good welding.. Rolled some pipes into the exact dimensions of the intake flange,and spot welded.. Bottom plate made..
Thanks,more pics to come.. I dont have old pics of the car,the only things I have left of the rabbit parts is the side mirrors and the rear hatch badge heh But how come it takes many hours before I post a new reply to it appears on the thread? Does it pass the moderators before it get posted here?
You LHD boys sure do have the space for have equal length tubes and even a decent sized downpipe. What thickness are the manifold tubes?
Hi, I`ve never thought about that befre though...And there was more room when the 020 gear levers was cut away.. I think the tubes was 2mm thick, 42mmx2
Finished...Only needs some grinding inside the runners.. Now over to the gearbox.. The intention was to use a orginal Corrado 02A transmission,but I got hold of a AFF gearbox from Passat TD that I will use instead.This has shorter 1-3 gears than the Corrado trans,what is perfect for track use..The 4/5 gears are longer,and good for top speed I think this has rounded soon 400t.kms Dismantling.. Overhauled and reassembled gear mechanism..Made new bushings in nylon,but think i will make new ones in brass..Or do I get better ones for these? Cleaning and glassblasting.. Peloquin differential with VR6 ring/pinion 3,39:1 with final ratio.. Finito
Nice work man Love how the amount of work/fabrication that is needed to build a 16vT means that every project is different to the others. Keep us updated
Here you go,in comparison to the VR6 CCM trans AFF 02A(From 1991 Passat 1.6TD) 1st Z=34/9=3,77:1 2nd Z=40/19=2,105:1 3rd Z=39/29=1,344:1 4th Z=34/35=0,971:1 5th Z=35/44=0,795:1 CCM 02A(VR6) 1st Z=33/10=3,300:1 2nd Z=35/18=1,944:1 3rd Z=34/26=1,307:1 4th Z=30/29=1,034:1 5th Z=31/37=0,837:1
Also needed a clutch kit..Spec 3+ with alu.flywheel,carbon/kevlar disc and strengthened pressure plate Got the engine and trans back together and thrown it back into the car, but had sold my T3/T4 turbo so I was in need of a new one..GT3071 it is As for the engine management speaking,I am running a Haltech E6X on this one..The first plan was distributor ignition with MSD 6A and Blaster SS coils.But when I found out that I could use later 1.8T coils with some slight mods this was a factum.These coils also have built-in igniters. Some wiring pics.. I am using a 60-2 crank sensor from VAG,mods was also needed for this one So when I ordered a new turbo,I also needed a wastegate. Tial 38mm.. More piping... I am running a 3" all the way back to the rear beam axle, with Magnaflow resonator and Borla muffler in the back..
Now over to the car.I bought it two years ago and has a low mileage with only 88.000km on the meter.. Anyways,I had to tear it apart..And back in with a new original front plate.. Finish welded...But I have more work to be done.. Rusty spots.. 2-component primer.. Stopping power.. 305x28mm with Brembo 4-pots, these are from Cupra R..With custom caliper brackets.The rear brakes are original 16v discs.. New KW variant 3 suspension.. Compo MO 8x16 with 195/45 rubber..
I had to try it with the fenders and hood on..Looks like it needs some more spacing at the rear Mounted oil cooler and the custom IC.. Ohhh, I cant forget this one...