180hp 1.8t in Bug
 

Finally, its in. Next up the structural frame to handle the forces it'll be putting out.

Jason

http://www.geocities.com/volkdent/Engine_In.html

WOW!!! That is way cool looking. How did you solve the axle problem. How are you going to rig up shift linkage or is it automatic. What are you going to do with all that space behind the fire wall. :D

Very cool.
I'd be very interested in seeing how you are going to improve the structure
around the engine...might be 'borrowing' some ideas from you ;)

Rob.

oh great the link dosent work for me :(

Axle will be a shortened stock MkIII version. Eventually I'm thinking O2M six speed, then I'll need custom axles. I'm using Porsche Boxter linkage for the shifter, it still has some kinks to get worked out. For the extra space, can you say "trunk!" or Boot if your from over the pond. Some space will be taken up by the exhaust, but I'll have quite a bit left over. Kataplun, click on Volkdent in the corner then look at volkdents homepage, then 1.8tconversion.

Jason

that's pretty sick...and you may be too. :D

nice work!!!!!!! :agree:

Wow, that is a great installation. I will be curious how you will contain that beast with reinforcement. Looks nice, when do the rides start? You sure have a great place to start as far as turning up the wick also. 250hp is no problem for the engine. What are you doing to the chassis to take it?

Thanks,

Randy

I'm going to use 1.5" round, 2" square, and 1 x 2" rectangular tubing. One of the major tie-ins to the stock chassis will be two 5/8" U bolts that will go around the torsion bar housing. Other points for pickup to the chassis will be frame rails I've fabricated that extend the length of the pan just below where all the bolts hold the body and pan together. This is 1x2" rectangular tubing with holes drilled into it to allow the use of Allen head bolts in the standard body/pan bolt locations. There will also be a crossbrace between the two frame rails that will be just about where the front of the stock rear seat extends. I'm going to mock the whole thing up in ABS plastic pipe, I'll take some pics then to get feedback from anyone who has a mind for this sort of thing.

Jason

Got a 3" GHL downpipe in. It will ned plenty of modification, but should work really well. There is actually a factory cutout in the middle of the rear apron that will work perfectly for this monster.

http://www.geocities.com/volkdent/Engine_In.html

Got my fuel pump kit from EIP Tuning today. Should work out really well. It's Bosch, and it looks like the one on my MkII! Also got a 1.8t expansion tank. It's amazing that I can get these parts at my door for much less than driving down to the dealership. Also making some serious progress on the design of the superstructure, thanks to Bob in Aussieland.

Man, that is cool! :eek:

Did you get it out of a wrecked GLI, 337 or 20AE? They're the only ones I know of with the 1.8t and a 6-speed.

What are your plans for the exhaust? Any plans to mod the engine?

Looks like one heck of a project. Good luck with it :agree:

It's from a standard 2002 Jetta 1.8t. The tranny is 02A with a bolt kit, but I'll be upgrading to the 6 speed O2M you mentioned eventually. It will stay stock till all the kinks are worked out, then will slowly be built up to whatever feels comfortable, maybe in the 280-300hp range. As it sits, if I end up with an 1800lb car, with the stock motor this thing will do 0-60 under 5 seconds, so I'm not sure how much power will end up just being scary. I'm thinking APR Stage III setup, but we'll see. Exhaust will be a custom 3" based on a stainless GHL downpipe and cat. I'm thinking that 2 3" pipes sticking out of the stock location might be kind of sic.

Jason

Just when you think you have seen it all...this should be wicked and the weight distribution should be great too.

I've finally decided on a plan for the superstructure. It took many hours of head scratching, but I like it a lot. It will be composed of 2 major parts, one under the car, one inside the car, and then a roll cage and crossbraces will be bolted to it. AND I get to use my tubing bender, so that will be fun. I had a change of mind this weekend on the suspension. I decided awhile ago to go with the stock strut type setup, but was talking to KW Suspensions about building a shorty version so I wouldn't have to cut strut mounting holes through the inner fender well. It was a pain in the butt, so I decided just to go with the Variant III KWs and cut the hole. With the shorty version I was worried I wouldn't have enough travel, now I'll have plenty. So they are ordered up, got some of the high grade nuts I need, and soon I'll be warming up the MIG!

Jason

:eek: that **** is awsome!! we all need more pics of the progress man!! :bowdown: :cool:

Apparently I'll be recieving the complete engine harness this week. I was supposed have had it right from the get go, but getting these not-off-the-shelf parts from RPI has been a challenge. I did recieve all the grade 10.9 mounting bolt and nuts from Maryland Metric, some used half shafts I got for a song on Ebay, some tubing clamps for the superstructure, and the KW struts are supposed to show up in a couple of weeks.

Wiring harness STILL not here. They had started to pull apart one then realized it wasn't drive by wire, so they're searching again. I'm a long was away from starting it up anyway, so I'm not too worried. KWs arrived and they are as gorgeous as they say. They are in place now, but have yet to have the upper mounts fabbed. Not sure exactly how to do that. Currently I'm thinking of getting the ring piece of the top of a strut tower and welding it to plate. I had a thought about using the Mk II rear end strut plates, but I think they are smaller diameter. Double A-arm front end design is complete now too, so should be getting to work on that in a bit. New pics on my homepage.

Jason

I recieved the 3" widened fenders that'll fit the 235/45/17s on the H20 platform from Creative Car Craft. I've read a lot of peoples comments on their quality, and I was not disappointed. They are amazing, the quality is phenomenol, the finish was perfect, the strength and build quality was amazing. IF ANYONE IS IS CONSIDERING REPLACEMENT FENDERS, WIDENED OR NOT, PLEASE BE ASSURED THAT CREATIVE CAR CRAFT WILL DEFINATELY MAKE YOU HAPPY. They are lighter and stronger than the steel counterparts, and won't rust or get dented.

Jason

told you so. :D

congrats! get us some pics as you get them fitted.

Engine and tranny have met for the last time. Superstructure is complete. Working in getting (you are not going to believe this) the wiring harness STILL, getting the details squared away for the front engine mount(this is a hybrid engine/tranny combo and the mount is somewhere in between), put a Audi TT 225hp intake manifold on and am getting the bracketry around it squared away. There is now a nice straight shot from the turbo outlet to the TT intake, about the distance a good A/W intercooler(chargecooler for the guys on the other side of the pond) should fit nicely into. The clutch might be a hybrid as well for now, stock type I cable back to a bracket that moves the hydrolic master cylinder for the stock Jetta. Eventually I'm sure it will be hydrolic all the way, the trouble is getting the pedal assembly in there without too much cutting. I was not able to integrate the "pendulum" style mounts of VWs from 1998-present. There was not enough room for clearance on the passenger side of the engine without cutting out the inside of the passenger rear wheelwell. I think I can make the oldstyle low mounts work, I just don't like the amount of engine/tranny movement that they allow. I'll probably build some additional motor mounts to prevent unwanted movement later. The biggest hurdle currently is how to attach the upper strut plates for the Mac struts. If they are welded on, to remove the superstructure from the vehicle would require the removal of much of the C pillar. I'm trying to come up with a way to make those plates removable so they can be unbolted then the superstructure will slide right out. That's it for now!

Jason

that is cool. I hope you dont run into reliability problems with the new VW parts.

You are too funny! :laugh:

That's exactly why I'm doing this, to get reliability AND power!

Jason

Finished Superstructure
 

This is the final version but it needs final welding and the addition of the strut mount plates. Their may be one or two more triangulating bars, but this should suffice till the kinks are worked out...

http://www.thesamba.com/vw/gallery/pix/215077.jpg

I work in a similar proyect.

And I have a questions.

How you install the radiator?

Well, I have a plan. That isn't to say it will work, but I have a bunch of space behind the spare tire area. I have a guy who will make me an aluminum radiator that is 8" high, but 26" wide and I think 3 cores. With ducting from a lip under the front end, I hope to have enough airflow to keep things cool at speed. I'm also going to have a spring loaded section of the lip that pops down to gather more air as the air pressure builds up on it. And finally, I have 3 8" electric fans for stop and go traffic.

From the looks of it, you'll have some cooling issues to get squared away too! Great work.

Jason

Thanks.

I have in mind something similar but unfortunately here in mexico nobody make an aluminium radiator.

I have to import from USA but the taxes and shipping are killingme.


Dou you have pictures of your front end?

Yeah, go to

http://www.germanlook.com/Forums/sho...&page=10&pp=15

The thread is kinda interesting.

Jason

:eek: The front end looks great. :agree:


And for the engine air intake?

Thanks, it been a long time coming and a labour of love, just like yours! It is basically done, but we are probably going to raise the upper shock mount just slightly to get a little more travel in suspension bump.

I think just NACA ducts in Lexan pop-out side windows. One will flow directly to a K&N type filter for cool air in, the other side to flow cold air into the engine bay.

Jason

Ok.

and for the intercooler?

sorry for so many question.

You're too crazy. The only reason you'd be asking about an intercooler is if you were thinking of turbocharging you're rig! Go for it!

For me, just to get things rolling, I'm going to attach another 8" fan to the back of the stock IC.

But the long term idea is an air/water IC. I've installed the Audi TT 225hp intake manifold so there is a very short run from the turbo outlet to the manifold intake, and just in between there's enough room for the intercooler. There will be a couple of small motorcycle radiators up front. The other option is a small wing over the rear window with a small motorcycle radiator in it.

About the radiator, let me know if you need something specific. I'm thinking about going to WRC Rally Mexico, and I could send something after I fly it down there.

Jason

Ok, Thanks.

:laugh: Yes I think in the supercharger for the future but first y need to find a transmission can handle the torque, becose I think the actually transmission can't handle.

Hi

Love what your doing with your car. I bought a air/water IC from an early Subaru Libery RS. It was only $150 with pump and radiator, the beauty is that it will almost connect straight up to my STI motor.

Steve

http://www.clubvw.org.au/images/Subaru_intercooler.jpg

Hey Steve!

The problem is that there were never any Subaru Legacy RS's here! Maybe you can hook me up with an intercooler when I get there. I just don't know how much shipping is! I might be having Bob fab up some more of the suspensions over there, so if I do there may be a crate being shipped back this way.

Jason

Hio Jason

Are you coming out to Australia? Have to meet if we can. I bought my intercooler from SSS Automotive in Sydney http://www.sssautomotive.com.au/ , they will sell just the IC for $50.00 Au, thats cheap in your money, they are not heavy, so post would not be to much. A friend is using one on a big Type 4 motor and as its all alloy he was able to weld up unused holes and make new ones.

Steve

Actually yes! High on my list is a trip down under. I've only heard good things, and I'd like to meet Bob Frost-Stevenson, the designer of my front end as well. Where are you located anyway?

Jason

Hi Jason

Let me know when your coming. Im in Sydney.

Steve

Do you know anyone in the US who can get it made for you and then send it to you as a "gift" therefore bypassing the tax ?

Just a thought.

No, I don't have anybody. :bawling:

C'mon hugovw1976,

We're all family here :D

Care to let your big brother Kevin here drive your toy seeing as I sent you the radiator? ;)

Seriously though. What would be the easiest way to get this guy the custom unit he needs? I'll meet you at the Rio Grande! I'll just hand it over the 'border' to you :laugh: