so some of you might have known i've been working on a project.

made a lot of progress in the past few weeks and thought i'd stick up a few pics.





pics here (more to come, i'm sure)
http://ncdubs.org/forum/album.php?albumid=48

1983 VW Jetta 2-door
2.0l 16v (9A) from a passat
megasquirt MS1 v 3.0
02A transmission (cable shift) from a passat
serpentine belt setup from a (94?) jetta
delrin suspension bushings (control arm, rear axle)
h&r sports with koni reds
new ball joints, new tie rods, new front wheel bearings, new front hubs, new driveshafts, etc, etc...

i still need to find a few pieces here and there. needs exhaust and wiring (hopefully wiring this weekend)

the current goal is to get it running as cheaply and quickly as possible. i have a spare 9A block and a ported head that i'm going to put together after it runs. JE low CR pistons/rings, scat rods, 1st overbore, ported head, tit reatiners, heavy duty valve springs.. basically building it as a turbo engine. the eventual goal is ~400whp at ~21-23 psi (based on similar setups). when the engine goes in the shell is getting a major overhaul.
currently no interior or seats or anything. going to be very minimal inside.


[Edited on September 5, 2008 at 12:58 AM. Reason : ..]

9/5/2008 12:48:42 AM

sweeet... makes me miss my '89 16V GTI just a bit

9/5/2008 12:57:37 AM

oh, and that's a mr. yuk on the side



was kinda drunk one night and trying to describe the color.. and it kinda stuck.. the paint will probably be changed up very soon.. i'm thinking about bringing the black down to the body line just below the door handle.

[Edited on September 5, 2008 at 1:03 AM. Reason : previous owner painted it and did the front grille. i bought a rolling shell.]

9/5/2008 1:01:59 AM

that bitch is SLAMMED

9/5/2008 7:28:25 AM

what's it weigh?

9/5/2008 1:32:50 PM

VW's never made a water-cooled car worth a da400whp?!!!! Nevermind, I'll shut up.

9/5/2008 1:53:51 PM

Quote :

"what's it weigh?"

its hard to find a spec online for the jetta, but the rabbits weighed around 2100# for this year and i can only imagine it is pretty close to that with full interior, a/c, etc..

this one should be around 1800-1900#

[Edited on September 5, 2008 at 5:10 PM. Reason : ..]

9/5/2008 5:09:27 PM

sweet

good luck with the build

9/5/2008 5:13:21 PM

^^damn, that's light. i was thinking more like ~2200 stripped. should move the fuck out with 400whp. what are you expecting with the initial setup? ~180whp?

make sure you post up some details on about the ms when you get it running and start tuning, i'm curious to hear more firsthand accounts of the latest version's functionality.

[Edited on September 5, 2008 at 5:47 PM. Reason : .]

9/5/2008 5:43:48 PM

I'll get my roommate to look at this thread when he can. He probably knows something

9/5/2008 6:54:40 PM

stock 2.0 16v was rated for 134bhp. right now i just want to get it running, but i should be able to squeeze a bit more than that out if it if i get the tune right.

i'll worry about making power later, i just want to be able to drive it and work the bugs out...

luckily there are a few places i can pull base maps so i should be able to find a pretty good starting point.

i got a good bit of the harness done tonight.. definitely making progress, but i wish there was a store open right now where i could get a spool of red 14awg wire

[Edited on September 6, 2008 at 5:25 AM. Reason : wire]

9/6/2008 5:22:51 AM

damn dude, i thought i was one of the few all nighters on here

9/6/2008 12:13:02 PM

yeah, well i've definitely put in a few all nighters..

earlier this year it was pretty regular, i some point in mid-late feb. was the first friday night i actually slept in my own bed this year. we were working on this car:
http://forums.vwvortex.com/zerothread?id=3592853
http://forums.vwvortex.com/zerothread?id=3905730

[Edited on September 6, 2008 at 3:37 PM. Reason : more pics]

9/6/2008 3:32:03 PM

good luck Kevin. still thinking of this color?

9/6/2008 3:33:25 PM

best thing in the world was when autozone off capitol was open 24 hours.

9/6/2008 3:33:46 PM

not sure about color yet. its gonna have the green for awhile until i pull the engine after the other one gets built.. then i'd like to redo all the paint, underbody, brake hard lines, etc... rotisserie style..

9/6/2008 3:37:17 PM

Quote :

"best thing in the world was when autozone off capitol was open 24 hours."

i'll never forget that meet where we ended up there and someone (was it you) that ran up to that car screaming "OMG SUBARU RACE CAR!!"

9/6/2008 3:40:05 PM

update that i put on ncdubs.org, basically a summary of where its at right now.

Quote :

"almost done with the engine side of the harness.. still have a little wiring to do, but its getting knocked out pretty steady. i just need to make an injector harness, get terminals for the coil, and wrap the harness. still a few other wires to sort out but all of those will be on the inside of the firewall. i still need to make a final decision on where to mount the ms box, relays, and the fuse block. i got a separate block for all of the ms wiring (coil, injectors, ecu, etc). i have a couple different places in mind, but it wont affect the harness because they are all within a foot or so of each other. once i figure that out decide if i want to keep the stock stuff in place for the fuel pump or rerun wires (i will probably re-run and use a new relay along with the main relay, coil relay, o2 sensor relay, which is part of the MS wiring). i also need to put ring terminals on all of the grounds (sensors and such) in the bay and connect those to the post on the end of the valve cover. i'm also going to run a few other grounds just to be sure (tranny to chassis for sure, maybe one or two in other places, there is one from the coil bracket to the cylinder head already) i think i have everything i need for the shift linkage on the parts passat and i have to order a cable clutch conversion (wrd). after that i need the exhaust (at least past the o2 sensor) and i could either buy a TT downpipe or just have one made. everything past that is just getting the settings right, loading a base map, and trying to fire it up. i need to sort out what i'm going to do about an intake, but that should be easy. pretty much just a pipe with a filter and a bung or two (isv & pcv) i've also been kicking around some ideas for the "until i get real paint" paint job. i'm pretty sure i'm going to re-do the black (its faded as hell) with some better stuff (what's on there was the $1/can shit) and bring the black down to the body line just below the door handle. i also need to get the seats and wheels (and order tires) from my house. i had a water leak into the car when it rained, but one of the sunroof drain tubes (which is supposed to just run through a hole in the front door jamb) was pulled through and was just draining into the driver side floorpan. so there is a little surface rust there that i need to take care of at some point. all of the glass seals are fucked, but luckily nate (for tww: he's a good friend of mine) works at an autoglass place "

[Edited on September 7, 2008 at 1:29 AM. Reason : tags]

9/7/2008 1:27:55 AM

i need to finish mounting the shift box, but the linkage is connected.

also, the engine side of the wiring harness is complete (including injector harness).. most of it will be fairly hidden. i've also started kicking around ideas about the in-car layout of the fuse block, relays, and ms box. i think i have one i like.

still need a wideband, downpipe, and wrd cable clutch conversion, but that is about all that is left.

9/13/2008 2:29:13 AM

just dickin around late nite.

stock one for reference. still needs work.


http://www.ncdubs.org/forum/picture.php?albumid=48&pictureid=502

[Edited on September 20, 2008 at 3:11 AM. Reason : tags]

9/20/2008 3:11:28 AM

made some more progress...

http://www.youtube.com/watch?v=Os9APERiwTU

vid sounds like shit..

[Edited on November 27, 2008 at 1:25 AM. Reason : still needs some tweaking obviously]

11/27/2008 1:24:51 AM

questions

1) was the 83 Jetta FWD, built off the Golf platform?

2) Maybe you haven't gotten this far, but are you making your own turbo manifold? What turbo are you going with? If you want really cheap you could put together a T3/60-1 hybrid, internally wastegated. should flow 400whp easy... or even cheaper, a holset hx35 internally wastegated

I don't know your experience level with megasquirt, but I have messed with it some (tuning, not assembly). if you need any help let me know. Are you using all GM sensors? I see you have an O2 sensor. The closed loop control on the Megasquirt is pretty tricky to get working decently. You should build the VE table open loop until you are close to where you need to be AFR wise. What are you doing for idle air control? Do you have a duty cycle controlled solenoid valve or just running without one? It's easier to get the car idling without the IAC first and then enable it later to stabilize idle with accessories/AC .

Your basemap-- is it designed for the cams you are running (do you even have aftermarket cams?) ? if it's not, there is a good chance you will have significant driveability issues. More aggressive cams = more overlap obviously = less vacuum under low load. They often require more timing under low load conditions especially for cold starts and smooth driving. If you find the car takes a long time to start and starts bucking randomly, try adding some low load timing. Slow cold starts are also helped by adding fuel for cranking. What are you using for your throttle position sensor? You should use TPS based accel enrichment for a turbo car as opposed to MAP based.

Also, MAKE SURE YOU HAVE GOOD SHIELDING. The megasquirt I ran (squirt and spark extra... I forgot which board, it was about 2.5 years ago) was sensitive to electrical noise.

[Edited on November 27, 2008 at 11:46 AM. Reason : .]

11/27/2008 11:32:00 AM

Quote :

"even cheaper, a holset hx35 internally wastegated"

I'll sell you one from adam8778's truck

just dont tell him

11/27/2008 11:53:27 AM

83 jetta is fwd, based on the "A1" vw platform, same as the old rabbit.

i had a t3/t4 50 trim that i sold. not sure what turbo i will go with, i am still not sure what the end goal is, i'm just glad it fired up as i've had the car (bought it as a bare shell) almost 3 years now.

i havent ever used megasquirt so it is all new to me. i'm using GM IAT and a OEM vw CTS with easytherm. o2 sensor is innovate LC-1, i havent turned on the AFR map stuff yet. IAC is the oem valve, a bosch unit (PWM). i had to modify the internals of the MS to use it (TIP 122). i dont know if i have it turned off or not, the car doesnt really idle for shit right now, but i had a problem with the FPR and it has a 3.5bar in it now where the required fuel is based off a 3-bar, i really just wanted to see if it would start because it was flooding the intake manifold due to the broken fpr. also, no accesories, no a/c. the engine drives the water pump and alternator. that is it.

base map is for a bone stock 2.0 16v, what i have in there right now.
not sure how the accel enrichment is set right now.

i really havent tweaked anything on the ecu. i put in the constants and loaded the base map. i worked out a few issues that came up when i plugged everything together (a few connections as well as the fpr). i'm just glad to see it start, now time to get to work.

11/27/2008 1:36:09 PM

Did you pressure test for boost/vacuum leaks? Does the car idle if you keep your foot on the throttle and raise the rpm pretty high? the tricky thing is that the engine isn't warmed up, which means you have the VE table, the water temp correction, and the air temp correction all coming in to play. If you can, see if you can keep the foot on the gas for a few minutes (or pull the throttle cable). Once it reaches operating temperature monitor the AFR and trim it so the car will idle.

The other issue is this. The throttlebody screws are set to make the car idle decently with the IAC valve at some given duty cycle, yet your IAC valve isn't running. It's kind of like how on a Honda they can sometimes/usually idle without the IAC valve but they will run at 400rpm or something. You may need to add idle air with the screws as well.

11/27/2008 4:12:29 PM

idle is fine when warm. i started tweaking a few things but got distracted. once it is to temp idle is smooth (a little high) and right at 14.7

11/30/2008 12:37:34 AM

good. then you will just have to adjust the cold start warmup map a couple times to get it right. it just takes some trial and error

11/30/2008 2:08:23 AM

i drove it last weekend. still needs some work before it is roadworthy but progress is being made...

12/23/2008 9:16:41 AM

pics are gone

12/23/2008 10:18:39 AM

starting and idling ok? no hesitations under low throttle?

12/23/2008 10:51:19 AM

http://forums.ncdubs.org/album.php?albumid=48

slight change in the address

starts up fine. warmup enrichment needs work. idles fine when warm. low rpms is still rough. it still needs work but i got the clutch stuff hooked up. havent had much time to try to get the tune right, especially when i couldnt put a load on the engine (since the clutch wasnt hooked up)

i'll have some time to mess around with it over the holidays.

i also had the wideband calibration wire hooked up wrong (i thought it was supposed to have a led and momentary switch in series, but they were supposed to be in parallel).. got that fixed last night. also, there is a seat in it now and i changed the oil a few days ago since the engine was flooding (bad fpr leaking into vacuum line). the oil was really thin and like 2 qts high and it smelled like gas


[Edited on December 23, 2008 at 11:37 AM. Reason : i'll try to get some more pics too...]

12/23/2008 11:33:50 AM

http://www.youtube.com/watch?v=VQSMtj_i0Po

12/28/2008 2:23:28 PM

IT'S ALIVE!!!

12/28/2008 4:47:03 PM

bttt per request

3/30/2009 8:10:36 PM

finally have time to make a post with some updates.

the base fuel map i was using had the wrong range for the map sensor, which is why i was having cold start and idle issues. it is better now, but the tune still needs some work (low rpms is still crappy). i'm lucky i've been able to find a few minutes to work on it.



recent stuff:
- installed front seats from a mk2 gti
- new battery
- put new wheels on
- bled brakes, front pads/rotors/SS lines
- fixed oil leak at valve cover
- replaced windshield seal (no more leaks!)
- other misc little shit

still need exhaust (open header at the moment) and tags, but it is coming along...

[Edited on March 31, 2009 at 12:33 AM. Reason : .]

3/31/2009 12:30:36 AM

shit looks pretty gangster, id like to see a bigger front air dam on it though

3/31/2009 9:30:16 AM

i like it. good job. i want to build an old skyline like that.

3/31/2009 10:20:50 AM

nice, i was wondering if this was in the skreetz yet. any plans to weight it? i'd be curious to see if it ended up at 2k or less.

[Edited on March 31, 2009 at 3:56 PM. Reason : and what the bias is]

3/31/2009 3:55:55 PM

i will probably weigh it eventually... not sure when, tho..

3/31/2009 5:51:54 PM

that car would have to be <2k lbs

3/31/2009 6:08:52 PM

and <$100

4/4/2009 6:17:57 PM

i have a non self adjusting clutch cable if you need one

4/4/2009 6:20:09 PM

and a bridge?

4/4/2009 7:19:49 PM

new rattle can finish over this past weekend...

^^ no offense, i doubt the one you have is the right one..

oh, it has tags now, but i still need exhaust...

[Edited on June 2, 2009 at 2:41 PM. Reason : ^^]

6/2/2009 2:38:33 PM

i approve of this thread

6/2/2009 4:18:21 PM

who gives a shit what you think, Squirt didnt approve of you trying stalking her and crying like a the little bitch that you are on the phone for hours

[Edited on June 2, 2009 at 8:04 PM. Reason : lmao]

6/2/2009 8:03:49 PM

old


new


[Edited on June 2, 2009 at 8:25 PM. Reason : ...]

6/2/2009 8:25:08 PM

damn i loved the mr yuck

my mom used to come to my school as a kid and hand them out (pharmacist). any chance they come back?



You and I have very similiar builds lol. We can have a FWD battle royal when you get it running.

[Edited on June 2, 2009 at 8:39 PM. Reason : .(bring back the greeen!!!!!!!)]

6/2/2009 8:33:31 PM

it runs, i drove it to take the pic.

6/2/2009 9:09:28 PM

how good is the tune?

6/2/2009 9:29:06 PM