Bugasm99's 2.0 Turbo build up thread.

[bugasm99]

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 all 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.

Specific Topics of Interest.

What if my swing valve has 2 long studs and one short stud?

What do I do about the Air Pump / Secondary Air Injecion System?



Cost Counter :: $1,031.50

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
- OEM Intercooler and all piping courtesy of Techno'Trixed :: $95
- T3 1/2" NPT oil Drain Flange :: $7.50
- (4) Bosch 42# (440cc) "green top" fuel injectors :: $150 from Popsicle on the vortex
- Oil Drain Tube :: Free, it was the guys last day
- Silicon Couplers & Remaining Piping :: $126
- Autometer Boost Gauge :: $14 "i got it on ebay"
- Boost Controller :: made one, $8 in parts
- C2 Software :: $375
- MAF Flange :: $23, ATP


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.

[iScott]

Hell to the yes. Good luck, Josh.
Really excited to keep up with this.

[The Cheat]

josh--

come see me at show and go. i'll be with karen, gina, and the beetle crew. got a 710n diverter for you you can have if you buy me a hotdog or something.

[bugasm99]

your awesome. I will definately be there and I might even add some fries to that order. You'll have to get your own drink though.

[iScott]

Originally Posted by bugasm99

You'll have to get your own drink though.

That's just wrong.

[bugasm99]

Originally Posted by iScott

That's just wrong.

you have to leave something to the wants. nah, i'm pretty giving and i'll defnately show my appreciation. this is the reason i like the vw community.

[Porkchop]

Woohoo! I'm looking forward to this thread!

I have a special request: a "before" mpg and an after... I'd like to know what effect the turbo setup has on economy. Is that possible?

[bugasm99]

definately. I'll add it to the top post, but right now I am averaging about 350 miles out of a full tank. I think this is a little low, but i also throw a system rich code every now and then which leads me to believe i tend to burn off more fuel over time as the ecu adapts.

[The Cheat]

Originally Posted by bugasm99

your awesome. I will definately be there and I might even add some fries to that order. You'll have to get your own drink though.

it's all good man, it's been lying around for months and i figure if it helps someone out, then it's all worth it.

[Pelican18TQA4]

Pics Josh, we want pics!

[bugasm99]

pics added up top.

[bugasm99]

So it seems that myself and 3 other ebay users were scammed by the user USAmotorsport on the injector auction. This means that I am out $200 and my fuel injectors go back on to the needed list. I guess i will just have to keep my eyes out for another good deal.

[Black01Beetle]

ouch dude, stupid scammers, will you not get reimbursed with paypal? or did they not accept it?

at any rate, that's just NOT cool....

[bugasm99]

I am hoping to get reimbursed for at least some of it, but I am unsure if that is going to happen. As I understand it, PayPal can only reimburse you using funds that exist in the other parties PayPal account. With that said, if the other party can spend all the money before PayPal processes everything, then there will be no money left to reimburse with.

Fortunately for me, i was able to break out my internet detective skills and I have the name, number, and address for the ebay member, as well as the name, number, and address that they were having their purchased items shipped to. I plan to use this information and contact the local authorities down there as their income from this was well over $1000, and from their recent ebay transactions they have managed to spend most of it, on baby clothes, diapers, and video games.

As of today the person closed down there ebay account, but their paypal account is still open.

[flip240]

ah! custom turbo setup, sounds like fun!!

[SilverSportNOLA]

PayPal reimbursed me for all but $25 of one bad deal I had ... it was only an $80 or so deal though.

Well, for buying car parts .... if they sell Honda Parts ... check them out, I never had problems buying over 3K worth of VW parts (most new from reputable dealers) ... but buying parts for the Del Slo ... even parts from some of the used part dealers didn't fit the application they were supposed to, and I had 3 sellers just flake and disappear becuase the auction ended with a lower price than they anticipated I guess.

I guess I should stop trying to convert any Honda owners to Dubs.

[bugasm99]

I am not sure this seller even knew what item they had listed and what it was for. I have a feeling they simply duplicated a previous auction they had seen for a random item. This person had sold the same item to 4 different buyers by collecting paypal payments, and then offering a "second chance offer" to another buyer.

After researching the seller and their other auctions, I somewhat feel bad for them as all the items they purchased using our funds were baby clothes, diapers, and other miscellaneous baby items. I just left them an email with my forward intentions, and as a personal note I let them know that their were other ways to provide for a baby other then scamming others on ebay.

[SilverSportNOLA]

Get their kids SS# .... maybe you can claim them on your return next year ..... hahaaha

[bugasm99]

Some more parts arrived today from ATP and Vecco Performance (an ebay store). Unfortunately Vecco forgot an one of the items I purchased so that was shipped out today and will get here next week some time. Luckily I am in no rush for this stuff as everything seems to be working against me at this point.

On another note, the search is on for some more injectors. Volkstech, one of my clients and a local VW performance / Maintanance shop deals with C2 Motorsports directly so I will probably just order the software and injectors right from them. Anyway, on to the pics.

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.

[bugasm99]

Picked up a set of injectors from a guy on the vortex who was putting together a big turbo 1.8T set-up. Barely used and he let them go for $150. This brings my injector total to $350 after the crappy ebay incident.