Clutch and gearbox ?

[polo_td]

Hi
I have been around for a while now and i am deeply impressed with the knowledge u guys have.
So when i now start a new phase of the polo 1WTD´s life some things needs to be sorted.

so!

This week i´ve started a new project, my turbo converted polo diesel will now be updated.
The engine will produce approx. 170bhp and 230Nm.
Now i really need this forums help.

Clutch, what can i use? 200mm?? or even bigger with mods?
Can i use the G40 clutch with my flywheel?

Gearbox is there ant thing u can do to increase the stiffness and strength?
Do i have to do any thing at all??

Gearbox is 8p, ratios, can i change any thing to get the revs down and increase topspeed?
The difference between the gearboxes like che, ceg i.a? i know the ratios are diffrent but is there any thing to gain material wise?

please help is needed fast in this so please help me out here??

thomas
Sweden

[vw-edje]

Hello Thomas,

Welcome on this forum! i hope you can read all the treads in Dutch

We are very curious how you made the turbo on the diesel engine.   The free space in the front is rather small to place a decent turbo close to the exhaust manifold.

AFAIK the only option is to place a 200mm clutch with a sintered disc (for handling the power) and a strengthened pressure plate (pressure group?! ).

For the gearbox i don't know any mods, only the oil passage of the 5th gear can be modified (to be found on this forum). This increases the lifespan of the gearbox.

I think the "longest" gearbox is the original G40 gearbox (AJV?) i think they can handle the power for a while.

There are guys here with a lot more experience with this kind of tuning material.

[polo_td]

pics comming up now.





This time the manifold will be better and the pump will be special made etc etc.

thomas

[JJ]

Nice ride

Original place for your carjack

[polo_td]

Thanx
When the airbox was gone it was so empty in that area.
So i thougth why shall i allways have to pic everything out of the trunk if i´ve got a flat tire(it always happens when u fully loaded u know)...

thomas

[The_Maxx]

nice polo, strange place for the carjack, but i understand the reason for it. And truely, you will need the tools more under the hood than in the trunk, where it originally belongs.
but you said about flat tire, yes, but you still need to take the spare wheel out of the trunk then. Or did you placed that somewhere else?
I just want to say one thing: its not an audi you know  But i like the foglamps in the grill.

About the gearbox: 8p is commenly used in polo 1990-1994, but because its a 5speed, the fifth gear can cause troubles (its just a 4speed gearbox with an 5th gear glued on)
Maybe you can search for a g40 gearbox, also 5speed, but stronger because of the increased HP of the car.
Clutch: 200mm? i dont think that will fit. Just use a g40 flywheel and clutch. You can decrease the wheight of the flywheel, there are some people who have done that. Just search arround on the forum.

If you dont understand something (because of bad translation or something. I think some of the people here, can translate and explain it to you.

[polo_td]

This update is something beyond the ordinary.
Now the pump is modified into a monster just for this engine.
You can read what is done and see a clip of the test run on the flow bench.
Many thanks to Göran "diesel mech" Lindgren.
************************************************** *****************************
OK, then it was time for the 2nd upgrade of the pump, Edition R


Do not miss the movie clip I have made for the sake of you readers, further down the topic.

The following was the first performance upgrade.
Replacing rotors 80-10 mm
Change the direction from right to left using wire EDM, among other things ;-)
Then the pump is delivering about 230% more fuel than stock, ended up on about 80 cc of fuel.


Edition R is reworked like this:
Modified RPM controller weights, it was not enough speed first round, now it will be sufficient.




LDA, cover with specially sharpened stick to get more fuel at full turbo boost pressure and eliminate smoke in large quantities, it will probably smoke a bit anyway, but not as bloody as before




Regulator Spring, changed from a separate idle spring into an integrated spring-in controller package (VAG 2.4 d)




Modified controller bridge for longer travel of LDA = more fuel around 100cc @ 1500 rpm
Test run of the bench and shot.



Movie Link here http://www.youtube.com/watch?v=aXl8x9dOC9k

Happy Midsummers eve wishes Göran "diesel mech" Lindgren
************************************************** ******************************

Thomas
Sweden

[Gekke Gerrit]

Cool!
Are you open for production-orders?

[Jaap]

impressive!

Bye Bye firewall?


I'm interested to see the LDA lumpy bit fitted inside the enginebay!!

[polo_td]

Me too but i´l get it sorted.
Will mount it next week, pics comming up then.
Jaap
How´s your Giesel going?
Thomas

[polo_td]

Hello!
Now I come back.
I've lived in the garage this weekend.
Worked constant from Saturday 08.00 until Sunday 19.00 without sleep, when we really needed to be done.

We have set up some odd ideas about this project.
One of these was to do a metal widening on a car in a weekend:)
And that, without having done it before.
Can say that it went well!
Plus that we grinded and adjusted all dents etc

My early ideas with urquaattro etc was thrown in the bin and scrapped because I had a couple of new thoughts and ideas.
Finally Me and Martin had a  "new" way.
We take the hourglass broadening, racing, bergcup, DTM, and 90's design throw it  down in the blender and what do you get?
see in this sequence:


Work in progress!!!


Front wing with wheelarc extensions!


Blurred image, but an idea with wheelarc extensions.


Ready for transport, without wheelarc extensions.

I will add a pics rear wiew later ther you realy can se the total with over the "ass"

Thomas

[polo_td]

Now the car is assembled and pump performance in the beginning.
A very difficult period, I can promise, but now you can drive the car in the rain, This update has been hard,working around the clock more or less.
But just wanted to show how the car looks now.

Please enjoy !!!!!!
First car last summer.










What do you think?
Will all the work be visible !? : thumbup:: D

 thomas

[JJ]

Wow, looks sick! 

Very well done, widened with the right proportions

[Steilheck]

Nice job, "last summer"-edition was a .... erm ... disaster imo 

This summer edition: prize magnet! 

[The_Maxx]

i liked it more in black, but the wheels are looking good!

what kind of foglights are that? not original, but they fit well i see. Thats why i ask