TDI RatRod (full thread)

[Kuma]

i love this.

[PRA4WX]

i love this.

Thanks, brother.

[Kuma]

i love this.

Thanks, brother.

:-)

[quattro87]

:stupid: Yea This is a sweet project. I commute 80 miles a day and would like something other than my motorcycle to get decent mileage. You have a Malone tune right? Did he tweak the ECU to control a variable vane turbo?

[PRA4WX]

:stupid: Yea This is a sweet project. I commute 80 miles a day and would like something other than my motorcycle to get decent mileage. You have a Malone tune right? Did he tweak the ECU to control a variable vane turbo?

I did go with Mark for my tune. I did convert the 1Z to vnt from a waste gated turbo. Also egr and maf delete. I've got to get some new software sometime soon for both a new map sensor and more boost, and an over write for the ability to left foot brake. To date, i'm averaging well over 50mpg. When i get anew things done i have left to accomplish, i expect to be able to return an easy and honest 60mpg.

[quattro87]

What did your 1Z come out of? Is it a PD injected TDI? So does Mark change it to speed density control and just look at a MAP sensor when deleting the MAF? Doesn't he also offer an option of on/off instead of the EGR delete so that on startup and when cold outside the exhaust recirculates and helps with keeping the engine warm enough for efficiency and a heater?

[PRA4WX]

What did your 1Z come out of? Is it a PD injected TDI? So does Mark change it to speed density control and just look at a MAP sensor when deleting the MAF? Doesn't he also offer an option of on/off instead of the EGR delete so that on startup and when cold outside the exhaust recirculates and helps with keeping the engine warm enough for efficiency and a heater?

My 1Z came out of a B4 Passat. It's a VE TDI, so not a PD.
Mark does what he calls a "dynamic egr" which allows it to operate much like you describe.
Yes, MAP w/o MAF, but these TDI's are drive by wire so it references throttle position as well as brake (which i'm seeking to have written out the next software write he does). You can see some images in my thread of the intake ports and the work of the egr in very clogged runners and swirl chambers. This was an impetus (as well as simplicity and a new intake mani i wanted to use) to make sure to do w/o the egr. To be honest i don't think it needs it. I drive a route consistently from my house and keep tabs on water temp. It took to the exact stop light, the same distance to warm to 160* today, as the hot running G60 used to. It definitely runs cooler over all though.

[Rallyfreak202]

Excellent project. I just read through the entire forum. Did you put the B4 1Z harness in or modify the G60 harness? The video/pics on Pikes Peak were great. Keep up the great work. I'll be following this and contemplating taking my 16v GTi to a 1Z rather than Lysholm status. Oh yeah, thumbs up for the Lemond too. Get a rack on the 'rado!

[quattro87]

The Egr delete must not be that big of a deal, because you sure see a bunch of them gone. I think if I ever get my planned TDI Project off the ground a EGR delete might be in order.......after all, how cold can it get in Las Vegas anyhow? Looking at some of the plugged, carboned up intakes that almost choke the engine to a no run condition, is a good reason to at least consider the delete. Did you ever run the TDI with a tune and the Maf, or did you go straight to the MAP based Malone tune? Is drivability still pretty good?

[quattro v1.0]

Funny how there is an Iroz sniffing around a diesel thread...

[PRA4WX]

The Egr delete must not be that big of a deal, because you sure see a bunch of them gone. I think if I ever get my planned TDI Project off the ground a EGR delete might be in order.......after all, how cold can it get in Las Vegas anyhow? Looking at some of the plugged, carboned up intakes that almost choke the engine to a no run condition, is a good reason to at least consider the delete. Did you ever run the TDI with a tune and the Maf, or did you go straight to the MAP based Malone tune? Is drivability still pretty good?

EGR delete is not a big deal at all.

I did not run it with tune and MAF. I talked my brother (aorsinger on here) into a Malone tune for two of his jettas both to retain the MAF. I've ridden in one of them to date and it is very nice, like factory except faster with further improved fuel economy. Malone initially recommended using the MAF but i didn't want to use it and he had no problems tuning without it. Function was my first concern and simplicity next. The car starts, idles, accelerates without stutter, hesitation, or flat spots. Boost builds boost by 2k rpm and is usable past 5k. With all the torque it makes for a lot of fun to drive! Did i mention i'm averaging well above 50mpg?!

[death 4kqt]

quattro v1.0 wrote:[/quote]

Funny how there is an Iroz sniffing around a diesel thread...[/quote]
diesels are where its at, i strive to be 100% diesel at some point.

[PRA4WX]

Excellent project. I just read through the entire forum. Did you put the B4 1Z harness in or modify the G60 harness? The video/pics on Pikes Peak were great. Keep up the great work. I'll be following this and contemplating taking my 16v GTi to a 1Z rather than Lysholm status. Oh yeah, thumbs up for the Lemond too. Get a rack on the 'rado!

Hey missed this. I utilized portions of the B4 harness integrated into the G60 corrado harness.
I have a rack for it....and for every vehicle i own. ;-)


Rear leather bench and center seat belt are in. Not finished the way i want yet but working on it.

[chaloux]

Nice build! Glad to hear you're liking the gtb. I was thinking of going the same route in my tdi s6 eventually. What manifold did you use?

[40v4kq]

Just read throught this thread and its awesome what you have done. Makes me want to put a TDI in one of my mk2's. Though I think I'll probably stick with the plan of using my GLI to make the Coupe into a GLI Coupe just because i already have the parts for the swap.

[PRA4WX]

Nice build! Glad to hear you're liking the gtb. I was thinking of going the same route in my tdi s6 eventually. What manifold did you use?

Thanks! I'm more happy with the GTB2260VK than i expected to be. It is more turbo (W/O a bottom end) than i need right now. I used an AFN EM.

[PRA4WX]

Oil feed line (stock 1Z hard line reshaped to work) worked w/o issue until the other night. Shut the car down with what ended up being about 1 quart remaining in the engine. 8-o
Really wanted to go with a stainless feed, now i have and also would recommend to anybody with one of the stock hard lines to do so. Simple failure of what ended up being about a $34 braided line replacement is a savings i won't afford in the future. This line was an off the shelf aftermarket part for the ALH that is currently working just great for my car.

[quattro87]

It looks like you dodged a bullit on that one. Did the smoke tip you off or what?

[PRA4WX]

It looks like you dodged a bullit on that one. Did the smoke tip you off or what?

You know it wasn't smoking at all. I just could smell something unidentifiable......stopped and noticed all the oil dripping from underneath the car.

This is the second time i've dodged a bullet with this car. :dur: (The first was the cam pulley "slip" incident)

[quattro87]

Like my old journeyman used to tell me, " when you're lucky, crap will do for brains " . It looks to me like you have a bit of both brains and luck......Nice combination. :wink: Glad to see that one of my favorite project cars didn't bleed to death.

[Twintowers]

Almost a Turbo fire... not good, be careful, I like the swap, you should tilt the engine forward for some more room near the firewall, that or you that or you need a big hammer, and some dollies to massage that firewall back some.......

[PRA4WX]

Like my old journeyman used to tell me, " when you're lucky, crap will do for brains " . It looks to me like you have a bit of both brains and luck......Nice combination. :wink: Glad to see that one of my favorite project cars didn't bleed to death.

Similarly i had an aircraft systems instructor who would say "Hope your bag of
luck doesn't run out before you fill your bag of experience......because know as a pilot in command, your always the first person on the scene of an accident!"

Thanks for the compliment, Mr Iroz, coming from someone with his and hers urq's that's quite the compliment. ;-) But i make no claims to brains. With the maneuvers i seem too frequently to pull off i often feel like the village idiot.

On other subjects, i was shopping rods and pistons. Rods, pistons, are all the engine needs to unleash the turbo.....well maybe a map sensor too.......then a 12mm cam plate........then there's the clutch and differential..... :slap:
-So i THINK ASV's for pistons
-Rods, most commonly recommended are the Rostens. Looked at Integrated Engineering options, seems like the Rostens are at least as good an option as the IE's, maybe better. But this is a RatRod, so then i came into these:

http://www.cxracing.com/mm5/merchant.mv ... _Code=ENGP

Price is right at about 1/2 the cost or so of the alternatives. (They need fastening hardware).........hmmmmm

[foxbat]

quattro v1.0 wrote:[/quote]

Funny how there is an Iroz sniffing around a diesel thread...[/quote]

[quattro87]

:wtf:

quattro v1.0 wrote:

Funny how there is an Iroz sniffing around a diesel thread...[/quote][/quote]


Hey, if I had a scorpion to be working on I wouldn't have the time to be reading the diesel threads, but well, I don't have one you know. :wink: Come to think of it a mid engined, 1.9 TDI powered scorpion would be sweet! It would probably get 60+ mpg and still squeal the tires down to cord.

Micah, I think those rods look like a great deal, but I'm pretty sure you just like them because they are made out of forged aircraft 4340 steel. :wink: It looks as if the slippery slope exists in the diesel world too. Yea I might have a His and a Hers, but the His looks pretty sad and broken, which is what all the above comments are about. :slap:



Gathering parts, but want to stay 5 banger.




And TDI gears

[PRA4WX]

:wtf:

quattro v1.0 wrote:

Funny how there is an Iroz sniffing around a diesel thread...

[/quote]


Hey, if I had a scorpion to be working on I wouldn't have the time to be reading the diesel threads, but well, I don't have one you know. :wink: Come to think of it a mid engined, 1.9 TDI powered scorpion would be sweet! It would probably get 60+ mpg and still squeal the tires down to cord.

Micah, I think those rods look like a great deal, but I'm pretty sure you just like them because they are made out of forged aircraft 4340 steel. :wink: It looks as if the slippery slope exists in the diesel world too. Yea I might have a His and a Hers, but the His looks pretty sad and broken, which is what all the above comments are about. :slap:




Gathering parts, but want to stay 5 banger.




And TDI gears
[/quote]

Oooohoohohoo! 8) Now why are we talking about my dumb boring tdi when you have this kinda stuff going!?! Details please! Recipient to be? Management? Etc etc. Where's your thread!? ;-)