Josh's Beetle 2.0T Build & Pictures - REVmatch

J.Owen · #1 04-24-2007, 10:50 PM

Newest Images.

**MOFO** · #2 04-24-2007, 11:28 PM

nice, lets get this going.

J.Owen · #3 04-24-2007, 11:48 PM

So after much deliberation I have decided that I am going to be keeping my beetle and most likely purchasing a second car over time. With this in mind I have decided that the car needed to have a little go to match the show that it currently has. Rather then swap out the motor, I will be running a low boost turbo application at first and then slowly upping the boost in stages as I move along.

As a former fabricator for AWE Tuning in Willow Grove, PA i figured that I could most likely find good deals on the parts needed and fabricate as many parts as I possibly can, which would save me some money over purchasing everything as a kit. My plan for this build up is to do it properly and safely, yet be smart and cost effective.

The biggest concern for me right now is not blowing up my motor. Therefore I will be using the C2 software and 42# green top injectors to provide enough fuel to safely handle the boost. This software is available for all drive-by-cable aeg motors.

I will be documenting this build up from start to finish with a parts list and actual cost for each item, as well as any issues or short cuts I learn along the way.

Cost Counter :: $982.50

Items in hand:

- Garret T3 Turbo :: Free!
- Internal Wastegate :: Free!
- Cast 8v Turbo Manifold :: $108
- 2" 90' aluminum bend for compressor outlet :: Free!
- (3) 90' stainless steel bends for downpipe :: Free!
- mild steel o2 sensor bung :: Free!
- 1' section of 2.5" stainless .065 tube for downpipe :: Free!
- (2) 1/2" NPT --> 5/8" Barb fitting for oil drain :: $5
- 2.0" --> 2.5" silicon transition coupler :: $15
- Full Garret T3 Gasket Kit :: $15
- 1/2" NPT Aluminum Bung for oil drain into pan :: $8
- Oil feed line :: $34
- Oil Feed fitting for T3 turbo :: included above
- Oil fitting for Oil Cooler :: included above
- Garret 3-bolt wastegate -> downpipe flange :: $9
- 2.5" x 6" flex coupling for downpipe :: $35
- 710n Diverter Valve courtesy of The Cheat :: hot dog and fries at show and go
- (4) Bosch 42# (440cc) "green top" fuel injectors :: $150 from Popsicle on the vortex
- T3 1/2" NPT oil Drain Flange :: $7.50
- OEM Intercooler and piping courtesy of Techno'Trixed :: $95
- 710n Diverter Valve courtesy of The Cheat :: hot dog and fries at show and go
- Oil Drain Tube
- Silicon Couplers
- Remaining Piping
- C2 Software
- 3" MAF housing
- Boost Controller

Pictures:

Garret T3 Turbo. .42 Hot Side and .63 Cold Side. Ignore the Wastegate Actuator, I have another one in better condition.

Cast VW 8v Turbo Manifold

Stainless Steel 2.5" mandrel bends and straight piping for downpipe

T3 gasket set, oil drain fitting, intake manifold gasket, silicon 2.5"->2" reducer, 2" silicon connector

Mild Steel o2 bung, random fittings for oil and coolant.

Downpipe Flex Section, 1/2" NPT Aluminum Oil Pan Drain fitting, T3 3-bolt Downpipe Flange and Gasket...

Oil Feed Line with Fittings for T3 turbo and VW oil cooler housing.

Nick M. · #4 04-25-2007, 09:13 AM

Damn, you scored some nice deals! Should be fun

#5 04-25-2007, 11:09 AM

Josh, if you don't have access to a soda blaster/bead blaster, let me know we can clean that compressor housing right the hell up!

giff · #6 04-25-2007, 12:20 PM

Looks great, you definitely picked up some killer deals. Most people spend double that (at least) on the turbo alone.

If you need any help when the install date comes around post it up, I'd be glad to come lend a hand.

J.Owen · #7 04-25-2007, 01:22 PM

My goal for this project was to be smart, but take my time and make sure I got some good deals along the way. I wasn't really on any time frame so I have been collecting these parts for a little while now.

As for cleaning the turbo up, i am not sure if I really care that much considering once its on the car I don't think anyone will be able to see it. Its not like it will sit out in the open like on your car Jon. But I will keep the offer in mind.

#8 04-25-2007, 01:26 PM

Quote:

Originally Posted by bugasm99

My goal for this project was to be smart, but take my time and make sure I got some good deals along the way. I wasn't really on any time frame so I have been collecting these parts for a little while now.

As for cleaning the turbo up, i am not sure if I really care that much considering once its on the car I don't think anyone will be able to see it. Its not like it will sit out in the open like on your car Jon. But I will keep the offer in mind.

Offer stands Josh - if you need ANYTHING blasted and powdercoated don't hesitate to ask, and I can see what my buddy up in Pottstown is doing and can help you with anything. Speaking of which... I need to get him to sign up!

J.Owen · #9 04-25-2007, 01:57 PM

I will remember that. Once it is all up and running I will probably powder coat my boost pipes.

**MOFO** · #10 04-25-2007, 03:51 PM

i will even take a couple days off work so we can get this thing done.

J.Owen · #11 04-25-2007, 04:09 PM

how about you let me use your garage

**MOFO** · #12 04-25-2007, 04:38 PM

i said you could.

J.Owen · #13 04-25-2007, 11:56 PM

picked up my intercooler and some piping tonight. I will get the rest when the original owner gets his full Samco kit on.

Nick M. · #14 04-26-2007, 09:05 AM

Josh I need a favor, can you find me an AEG crank???

Nick M. · #15 04-26-2007, 09:07 AM

Quote:

Originally Posted by turbojettamk4

i will even take a couple days off work so we can get this thing done.

thats love

J.Owen · #16 04-26-2007, 06:39 PM

Quote:

Josh I need a favor, can you find me an AEG crank???

I have a contact at a bone yard down by the airport that deals in newer audi's and VW's. I'll shoot him a line and see if I can get some sort of response for the AEG crank.

Nick M. · #17 04-26-2007, 07:59 PM

Awesome, thanks man.

J.Owen · #18 05-01-2007, 01:04 AM

Quote:

Originally Posted by turbojettamk4

i said you could.

PT, let me know if I could invade your garage that week between the 12th and the 19th. I don't know how long this is going to take but thats the week i have a spare car.

J.Owen · #19 05-01-2007, 03:48 PM

Bosch 42" (440cc) green top injectors. Also known as ford motorsport 42# injectors. These injectors are matched to the C2 software that I will be running in conjunction with my oem MAF sensor in a 3" maf housing. This is the way the software was designed and should be handle up to 300 hp even though I will not be running anything close to that on this set-up. It would have been possible to run a smaller injector, but unfortunately I am not happy with the other options that are out there and want to make sure this runs as safely as possible.

OEM 1.8T intercooler courtesy of Rob. I need to fab up a block off plate for the map sensor flange and then i'm good to go.

giff · #20 05-01-2007, 04:26 PM

awww that intercooler is so cute!

j/k Good stuff, keep it coming!

**MOFO** · #21 05-01-2007, 05:24 PM

12-19th sounds good. i can make some room to put the beetle.

J.Owen · #22 05-01-2007, 07:07 PM

Quote:

awww that intercooler is so cute!

yeah, i know. But it will handle the 7 psi i'm gonna run at first. Plus i have all the lines to run a standard front mount later.

J.Owen · #23 05-01-2007, 07:08 PM

Quote:

12-19th sounds good. i can make some room to put the beetle.

cool. I'll let you know as the time approaches but that seems to be the best dates.

J.Owen · #24 05-11-2007, 09:58 PM

PT, Let me know if were still on for tomorrow and what time you think you'll be around. I'm excited.

**MOFO** · #25 05-12-2007, 12:14 AM

Saturday is not good. Sunday is good for some parts if you want to drop the car off or something b/c it is mothersday.