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Bugasm99 - '99 2.0 GLS

52K views 390 replies 83 participants last post by  bugasm99  
#1 · (Edited)
Last Update 03.04.10



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Mods::

Engine:
- Turbonetics T3 Super60 turbo
- C2 42# software
- Bosch 42# "green top" injectors
- OEM side mount intercooler
- Forge 007p diverter valve
- Forge billet boost controller
- Custom 2.5" exhaust with turndown after resonator
- Polished Manifold and piping w/ 3" MAF housing
- V-Band throttle body
- evap, sai, egr, etc. removed.
- Wiring harness relocated under frame rail.
- relocated braille battery

Transmission:
- G60 14lb. Flywheel
- VR6 Clutch Disk
- VR6 Pressure Plate

Running Gear:
- Mason-Tech Air Struts
- Universal Air AH2 bags w/ Baak2Basics brackets
- Zimmermann Cross Drilled Rotors
- Mintex "red box" Pads
- BBS RS178 17"x9.5"
- 1.3" and 1.5" adapters
- Falken Ziex ze512, 215/45

Exterior:
- Votex Front Clip w/ relocated corner markers
- Color Matched Headlight surrounds
- Debadged Hood with air inlet
- Concept roof
- Freedom Design Spoiler
- Red/ Clear Tailights
- Flat Black rear logo
- Stubby Antennae
- Diesel Geek 'Panzer' skid plate

Interior:
- OEM beige leather
- Reversed Cluster (large tach / small speedo)
- Color Matched Dash Trim
- Re-Wrapped OEM Wheel in beige Perforated leather
- Audi TT shift knob
- Turbo S door pins
- Autometer sport comp boost gauge
- VIAIR Pressure Guages
- A little bit of Camo
- A gift card to the liquor store.

Awards ::

05 Spring Show & Go - Englishtown, NJ - 3rd Place, NB Mod.
07 Spring Show & Go - Englishtown, NJ - 2nd Place, NB Mod.
07 VW Superjam - Maple Grove, PA - 1st Place, NB Mod.
07 V.A.G. Fair - York, PA - 1st Place, NB Wild
07 DJD Halftime Show - Jersey - 1st Place, NB Mod.
07 H20i - Ocean City, MD - 3rd place, NB Wild
08 Spring Show & Go - Englishtown, NJ - 2nd Place, NB Mod.
08 Volksfest - Campbelltown, PA - 1st Place, NB Mod.
09 Fall Show & Go - Englishtown, NJ - 3rd Place, NB Mod.

As Seen in ::

PVW Readers Rides - Jan. 08
 
#2 ·
Welcome back! We've been waiting for you...... :lol:

Lovely to see your New Beetle again! ;)
 
#7 ·
I love your Beetle, it's looking great. I wanted to know how you went about color matching the inner part of your headlights. I've been searching for aftermarket headlights, and haven't had too much luck finding many, so this is the next best bet.

I really appreciate your help. Keep rockin' the Bug!!
 
#8 ·
Mattsbug | The front bumper is actually the US votex bumper which I then smoothed and reshaped a little to match the original Euro votex bumper. I also removed the indicator lights which are mounted up next to the headlights. The turn signals are now located along the bottom in the fog light position.

n2vdubz | When I had the front end of the car painted I disassembled the headlight housings and had them painted along with the bumper. If you do this I recommend going to a trusty body shop and walking them through the process. My body shop ended up cracking a housing and neither one truly fits well anymore.
 
#21 ·
The bumper is actually the US votex front with all of the turn signal and indicator holes in it. I looked into having a Euro votex bumper imported and it would have cost a fortune, plus I would have still wanted to shave the upper indicators.

I actually had a broken oem beetle front bumper sitting around and ended cutting the missing sections out of the old bumper. This was then bonded to the areas that needed filled and smoothed over.

The turn signals are actually rewired to the foglight location and I do not have foglights. I am looking into getting a euro rear bumper cover to complete the smooth look.

as for performance. I did notice an improvement with the intake chip and exhaust. At the same time my car now had 100,000 on the clock and the clutch is sleeping so I can't feel it anymore.

The exhaust is a 2.5" straight through design that I had custom built when my car was turbo (yes at one point it was turbo). Without the turbo is lags in the bottom end, but once off idle it levels out and smooths out in the upper rpm's. This makes it fun on the highway, but around town it can feel a little sluggish. especially since 1st gear is so short.

I can't say that I have really taken advantage of the chip yet. Soon I will be purchasing a USRT short ram intake manifold and a techtonics 260' cam and will remap the chip to allow the motor to breathe a little better. I think this is when the motor will really wake up.
 
#23 ·
Billsbug said:
I won't even ask for details on the turbo to 2.0 engine swap...:rolleyes: :D
It was a 2.0 with an early ATP turbo kit. I left for college with $30 and the turbo kit was the only thing I knew could get me money quick. I regret that decision every day.

Billsbug said:
So no cat converter and no muffler? :confused:
I still have the cat, but the cat is ~2.5" anyway so no size restriction there. and there is a rear muffler, just no center resanator and the rear can is a straight through design.

Billsbug said:
Upgrade the cam? Never heard of anyone modding the cam on a NB.
Well, it is the same AEG motor that is found in the early golf/ jetta so all mods apply. The techtonics came is a good cam that the ecu can adapt to and does not require replacing the valve springs as the single valve springs in the aeg will bind with a high lift cam.

The USRT manifold is netting ~ 10 whp and with the cam and head work I am hoping to gain in the range of 20 whp. This may not seem like a lot for the money, but this is pretty consistent over the whole range and not just a spike at the top of the power band.

I am not trying to build a drag car here so I want usable power over the whole range. My goal is to compete in some track events starting next summer so a peppy engine and a lot of suspension work is in the works. This is also part of the reason for the cleaner, less bulky front end.
 
#24 ·
Awesome. I love the TSW Trophys. I can't wait to get mine refinished. My best friend and room mate from college lives/owns a shop in Conshohocken. I go out that way atleast 3-4 times a year if not more, so maybe we'll bump into eachother. Keep up the awesome work. :)
 
#25 ·
what shop??? I actually live in east falls and my girlfriend lives in roxborough. I pass through Conshy on my way to and from work every day.



oh, and here is a pic of the USRT intake manifold that I keep referring to, the only catch is as of right now I will end up being a guinea pig to see if it will fit within the cramped engine bay of the beetle.

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