nine-deuce Jetta

[Rocambolesque]

TurBRO build started.

I still need to go to a shop tomorrow so they can get the snapring off the compressor, so this weekend I couldn't park the car and start tearing into it just yet. So I worked on some things that will allow me to still use the car tomorrow.

I started to make my boost gauge mount. It will be in my left air vent. So I disassembled the vent.


Then I cut the back part.


Make some cuts in the back so the gauge fits well.


Then I took that old 2.99$ plastic toolbox.


Cut it.


Fitted to the duct.


Plastic welded.

To be continued...

Today I moved on to fitting the intercooler. First I held it in place with zipties.


Of course it doesn't fit just yet.


Bust out the grinder, cut everything.


More room now, actually I think I could've bought a bigger cooler..


Top mounts made with 3/4 steel pipe and threaded rod.


Bottom mounts made with flatbar. Those were kinda easy, you just have to enlarge the holes that normally hold the filler piece on small bumper cars. They left the brackets when they switched to big bumpers in 1990.

I need to paint those now!

While under the car I checked if everything was cool. My bulletproof oilpan is still good.


Front motor mount will need new pucks soon.


But apparently EMPI axles only last one season.


That's it for today!

[Sir_Townsend]

top notch fine sir

[Rocambolesque]

Today it was time to disassemble everything to make room for the manifold/turbo install.


I finished the intercooler install! Here you can see the mounts:


And here you see the finished product:


After that I soaked the shit out of my manifold bolts in PB blaster to make sure that I don't break the studs while removing them. If I do I'll probably have to pull the head, which I don't want to do... Anyways, while the PB was doing his thang I installed the boost controller.


And yesterday I took my turbo to a garage where they were able to get the snapring off the compressor housing. So today I went to town with my DeWalt Impact gun on the oil and water fittings. I also found out this turbo uses oddball fittings, so I'll have to go to a hydro place to get some new ones. The ones I previously ordered were not good. Also the bolts that hold the CHRA to the turbine are also seized... One step forward, one step back?

[Rocambolesque]

I got the old manifold off, the planets must have been aligned or something because I didn't even break one stud. After that I put the turbo/manifold combo on the car for a test fit. I still need to gasket match the manifold because its a cheap 80$ ebay one. Looks like I have plenty of room for a bigger turbo :lol: T28 soon? We'll see...


I also found out the fittings to plumb this turbo with AN lines don't exist. Its a T25 but its nothing like the Nissan ones unfortunately. I went to a hydro shop, got 4 fittings and welded them together. It gave this:

Now I can run my AN lines!

Then I ran in 2 problems. The axle is in the way, and since the engine is slanted 8 degrees backwards, I'm scared the oil will pool in the fittings. I need to find a solution to this.. I think I'll get a male JIC -10 and weld it to the pan on an angle instead of a combination of 1000 adapters...


The boost gauge pod is taking shape slowly...

[stanceculture]

Clean as F

[Nuts]

I like how you transformed your car bud, Great work.

[Isuzupickup]

Just ran through the thread, me gusta! That job you did cleaning up the engine bay is inspirational, hahaha. I love the color on it, goes with the car very well.

[PhilipWOT]

Dude you should seriously consider mass-producing oil pans like that. I would damn sure buy one.

[kittenpuncher]

love this mkII always wanted one. tastefully done.

[Euroswoop]

Dude you should seriously consider mass-producing oil pans like that. I would damn sure buy one.

x2

[Rocambolesque]

I did some more work to the car and I got some more pics I need to post, but I'll do it tomorrow since I'm too tired and its late. It includes work to the pan hahaha

Thanks for the kind comments, it gives me motivation, I really appreciate!

[Rocambolesque]

Here's my solution to my oilpan fittings problem: -10 JIC fitting welded right to the pan.


I bolted that manifold for good with copper nuts


Then I installed my Ford/Bosch 440 cc/min injectors


I finished the gauge pod, but it was full of cracks, so I'm redoing it as we speak.


Then I temporarly put the turbo on the car to make the oil lines




I also worked a bit more on the intercooler piping.




The piping arrives where the charcoal canister once was


Other side is a bit tight on the crossmember though


Very good fitment with my bumper!

[Rocambolesque]

The turbo is now all re-assembled and bolted down! I had to make a custom flange on the inlet to accomodate a silicone coupler.


Then I just plugged everything I could.


The piping is almost done, I just need to have a couple of TIG welds done and I'm good to give it a test start!

[4g63lover]

Car looks dope dude. What did you apply the por-15 with? I'd love to use some for my Galant.

[Rocambolesque]

A paint brush. One time use only!