I'm a bit late in starting a build thread for my G3F Beta #9, but here's the first installment from back in April-May:
I'm posting my build of Beta kit #9 for those interested in the Smyth Performance G3F mid-engine sports car conversion for the MkIV Jetta and 4-door MkIV Golf. My particular build began with a 2004 Jetta TDI (BEW, 5-spd, 180,000mi, bad cam/lifters, etc.) purchased specifically for this project.
I hope to help provide some small insight into the conversion process through the following time lapse videos and progress posts...
My Build Specifics (with TDIClub sources):
BEW 1.9 TDI
Chrome journal replacement cam, slotted bearings and cap mods (Frank06)
Passat cast iron exhaust manifold ported to Darkside Developments GTB adapter (RyanP)
Garrett GTB2260VK (RyanP)
SDI Scroll intake (RyanP)
4-Bar MAP (RyanP)
Firad +80% injectors (RyanP)
O2M EFF 6-Speed (RyanP)
Peloquin LSD (RyanP)
South Bend Stage II Silent Endurance clutch/pp
Audi TT front suspension/brakes for both front and rear
Type 20 long flow air/water intercooler (very low restriction, rated to 350HP)
Hey Bob, glad my old photos were some use in your radiator mount project. I'm on the hunt for shifter parts from your vintage donor; my early one (1999.5) is causing me some problems! I love to watch your time-lapse stuff, thanks for going to the trouble.
Smyth G3F Beta-build: 1999.5 Jetta TDI donor, Malone Stage 2 Tune and injectors. Love my Roadster; the G3F will be my daily driver. Build details here:http://www.g3f-jlphil.blogspot.com/
Wow, if you have the newer iteration shift cables, cable bracket that bolts to the tranny, and shift tower from atop the tranny, I would be glad to buy em. Save me laying on my back under a Jetta at the Pick and Pay! I already have the cast aluminum shift box and shift handle, just need everything else. Let me know if that's doable, and thanks again
Smyth G3F Beta-build: 1999.5 Jetta TDI donor, Malone Stage 2 Tune and injectors. Love my Roadster; the G3F will be my daily driver. Build details here:http://www.g3f-jlphil.blogspot.com/
While I'm waiting for Audi TT suspension parts, time to make changes to some engine parts: I modified the coolant pipe that runs across the front of my BEW TDI engine to route the heater fitting towards the front (nipple on right) rather than the rear. I cut off the last bend that went back to the heater core, removed about 10" of pipe, and welded it to the remainder.
The exhaust manifold is stock VW Passat, ported to a Darkside Developments GTB flange to mount the GTB2260VK turbo. The boss for the EGR had to be removed to clear the SDI scroll intake. The hole was welded shut with some Ni rod then ground. After checking fit it will be black ceramic coated.
I'm working some BEW TDI engine upgrades: here are photos of the turbo/exhaust/intake setup. I'll need to mount it all to the engine to test fit and determine the placement of the support bracket for the AWIC. Firad +80% injectors have also been installed.
The gtb2260vk is mounted to a Passat manifold ported to a Darkside adapter plate, the AWIC will be supported with a fabricated bracket welded to the SDI intake. The total plumbing consisted of only two 180 degree elbows (2.25" and 2.5"). I'm keeping the SDI ASV; there's a thread with instructions to convert the wiring to my BEW harness.
Overall a fairly compact package.
Last edited by bzeien; 11-13-2012 at 04:39 PM..
Reason: image content
Smyth G3F Beta-build: 1999.5 Jetta TDI donor, Malone Stage 2 Tune and injectors. Love my Roadster; the G3F will be my daily driver. Build details here:http://www.g3f-jlphil.blogspot.com/
Smyth G3F Beta-build: 1999.5 Jetta TDI donor, Malone Stage 2 Tune and injectors. Love my Roadster; the G3F will be my daily driver. Build details here:http://www.g3f-jlphil.blogspot.com/
Hmm. It shows up on my screen, when I check the image in the photo album it's there but says "Picture Waiting Moderator Approval"; perhaps it takes some time to be approved? Or the image quality/size?
Smyth G3F Beta-build: 1999.5 Jetta TDI donor, Malone Stage 2 Tune and injectors. Love my Roadster; the G3F will be my daily driver. Build details here:http://www.g3f-jlphil.blogspot.com/
To minimize the overall size of the intake/AWIC assembly I decided to eliminate mounts and weld the intercooler directly to the SDI scroll manifold (after shaving off the threaded mount on the manifold side of the AWIC). This gave some additional clearance between the AWIC and turbo hotside/exhaust piping. I'm fabricating a stainless heat shield to mount beneath the intercooler.
Last edited by bzeien; 12-26-2012 at 05:17 PM..
Reason: re-paste images
Bob, the last pic I can see is on post #14, quite a while back.
Cheers, John
Thanks John, some others were having similar trouble viewing my images; perhaps it has something to do with my image uploads? They are not very large and appear ok in my album. I'll ask a moderator for info.
Bill S. mentioned that he can see them while Redjoker and John P. were having difficulty...is anyone else having viewing issues?
PS: I checked that my FFCars album is public and all of the images are (I think) correctly linked, although some say "moderated" while others do not...
PPS: All of the pictures in the album from 12/25 to date have a note that says, "Picture Waiting Moderator Approval".
Last edited by bzeien; 01-03-2013 at 02:30 PM..
Reason: PS:, PPS:
Smyth G3F Beta-build: 1999.5 Jetta TDI donor, Malone Stage 2 Tune and injectors. Love my Roadster; the G3F will be my daily driver. Build details here:http://www.g3f-jlphil.blogspot.com/
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