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I'll try to keep up - full decade of 80's material to choose from. The sounds seem to match the style of the car when you put them together. Very similar to Miller High Life and hot dogs, cheese and wine or mullets and sleeveless T-shirts....

There was a good amount of carbon at the top of the cylinders and on the pistons. I put a flex hone to it today and hoped it would clean up fine. Somehow judging by the worn-in gap and soot on the spark plugs I knew it was going to need machining to be proper. The clean-up revealed a wear lip in the bore that I can't in my good mind ignore. This is what happens when people run them too rich or too hot... the rings cut away the bore. It's deep enough that I think a +2mm bore will be in order. This would bring the engine up to a 1.9L but also bring me about 70% of the way to the cost of going to the higher hp level. I'm going to start unloading the spare parts I don't need in the classifieds here and maybe on ebay to generate some project cash to cover the additional costs coming my way.

You can see the deep lip at the top of the cylinder bore below. An overbore will remove this.





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“Of the value traps, the most widespread and pernicious is value rigidity. This is an inability to revalue what one sees because of commitment to previous values. In motorcycle maintenance, you MUST rediscover what you do as you go. Rigid values makes this impossible.”
― Robert M. Pirsig, Zen and the Art of Motorcycle Maintenance: An Inquiry Into Values
Old 10-26-2013, 07:19 PM
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..
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“Of the value traps, the most widespread and pernicious is value rigidity. This is an inability to revalue what one sees because of commitment to previous values. In motorcycle maintenance, you MUST rediscover what you do as you go. Rigid values makes this impossible.”
― Robert M. Pirsig, Zen and the Art of Motorcycle Maintenance: An Inquiry Into Values

Last edited by Lapkritis; 10-30-2013 at 10:43 AM..
Old 10-27-2013, 07:17 PM
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This is great, would def be my choice of engine pretty versatile v cost and availibility. Try and keep the momentum up we will provide moral support!

Whats the plan for cooling?
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1991 944 Turbo
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Old 10-28-2013, 12:17 PM
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Cooling plan is regular 944 rad for now. Probably do a regular air to air front mount intercooler for the turbocharger.

Dropped the block off to the machine shop Monday night after work. They're going to measure and let me know what size overbore I can get away with rather than going with the largest available. This would be a bit wiser for long term use if a rebuild is needed in the future.

Parts list coming soon for leftovers!
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“Of the value traps, the most widespread and pernicious is value rigidity. This is an inability to revalue what one sees because of commitment to previous values. In motorcycle maintenance, you MUST rediscover what you do as you go. Rigid values makes this impossible.”
― Robert M. Pirsig, Zen and the Art of Motorcycle Maintenance: An Inquiry Into Values
Old 10-30-2013, 10:46 AM
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Redsox win! No office tomorrow...
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“Of the value traps, the most widespread and pernicious is value rigidity. This is an inability to revalue what one sees because of commitment to previous values. In motorcycle maintenance, you MUST rediscover what you do as you go. Rigid values makes this impossible.”
― Robert M. Pirsig, Zen and the Art of Motorcycle Maintenance: An Inquiry Into Values
Old 10-30-2013, 08:36 PM
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Picked up the donor 02A transmission. Plan is full speed ahead for using the VW bell housing instead of the Porsche so no adapter plate games near the engine and fewer funky parts.



View inside the bell housing of the 4cyl VW 02A transmission:


These transmissions came on Corrado G60's from 1990-92 (4cyl only) and also Passat 16v's from the same era. A few TDi vehicles also had the hydraulic clutch 02A 4cyl transmission but those are more rare. The specific example I have is from a Passat but is visibly identical to the G60 on the outside except for the tiny code printed on it.

I'll be chopping it up for parts and documenting the dissection in this thread for you guys to follow. So fittingly here's the 80's track for the occasion:

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“Of the value traps, the most widespread and pernicious is value rigidity. This is an inability to revalue what one sees because of commitment to previous values. In motorcycle maintenance, you MUST rediscover what you do as you go. Rigid values makes this impossible.”
― Robert M. Pirsig, Zen and the Art of Motorcycle Maintenance: An Inquiry Into Values

Last edited by Lapkritis; 10-31-2013 at 05:56 PM..
Old 10-31-2013, 05:53 PM
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Essentials for breaking into a VW 02A transmission:





Quick measure of depth for the shaft on 02A before breaking it apart:



Quick measure of depth for the shaft on the 944:



Pull 5th gear off... need a cheese head tool (triple square) that is normally used on CV shaft bolts. Some later trans used a T60 torx on top of the gears. Good instructions here: http://pics.tdiclub.com/data/517/21336gearswap.pdf



Pull all the 13mm bolts out of the inside of the bell housing and around the differential case half. Pull the shift tower out and also the lower support for the shift tower here. Also remove the T45 torx top and bottom... there are 4 total. There is also a 5th T45 that is in a crevice below 5th gear. These must all be removed or the case won't come apart:



Quick pry apart and you're in:



Another T45 holds the reverse mechanism in place, that's your first step in here- pull that sucker out:

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“Of the value traps, the most widespread and pernicious is value rigidity. This is an inability to revalue what one sees because of commitment to previous values. In motorcycle maintenance, you MUST rediscover what you do as you go. Rigid values makes this impossible.”
― Robert M. Pirsig, Zen and the Art of Motorcycle Maintenance: An Inquiry Into Values
Old 11-03-2013, 03:25 PM
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These all just lift out as long as you got all the nuts bolts inside the bell housing out:









944 housing compared to the 02A:

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“Of the value traps, the most widespread and pernicious is value rigidity. This is an inability to revalue what one sees because of commitment to previous values. In motorcycle maintenance, you MUST rediscover what you do as you go. Rigid values makes this impossible.”
― Robert M. Pirsig, Zen and the Art of Motorcycle Maintenance: An Inquiry Into Values
Old 11-03-2013, 03:30 PM
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Clamped down... it's about to get real.



Sawzall with a wood blade does nicely:







Cleans up easily with an angle grinder. I chose to leave the ribs and a little more meat for strength.






I still have to make a 1/4 plate to connect the G60 housing to the torque tube. I'll try to find material to take that on next weekend.





1986

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“Of the value traps, the most widespread and pernicious is value rigidity. This is an inability to revalue what one sees because of commitment to previous values. In motorcycle maintenance, you MUST rediscover what you do as you go. Rigid values makes this impossible.”
― Robert M. Pirsig, Zen and the Art of Motorcycle Maintenance: An Inquiry Into Values
Old 11-03-2013, 03:42 PM
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Why weren't you able to use the transmission from the donor passat? Was it an automatic? Just curious. It's cool to see how quickly you are getting into this.
Old 11-03-2013, 07:23 PM
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Great question. The donor Passat was a 5spd FWD. You can't use the transmission because the bell housing is half of the transmission housing; it would be far too long (pics below you can see the seam where it ends rear of the axle cups). You might be able to chop one down and weld a thick, flat aluminum plate to drill and attach to the 944 torque tube but that would be more work when there's an alternative available that is 1/2" shorter than stock 944.

Passat trans showing it's too long:
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“Of the value traps, the most widespread and pernicious is value rigidity. This is an inability to revalue what one sees because of commitment to previous values. In motorcycle maintenance, you MUST rediscover what you do as you go. Rigid values makes this impossible.”
― Robert M. Pirsig, Zen and the Art of Motorcycle Maintenance: An Inquiry Into Values
Old 11-03-2013, 07:52 PM
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"its about to get real" awesome!
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Old 11-04-2013, 02:57 PM
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Flywheel arrived today in the mail.

G60 flywheel that we'll use for this application is on the right ( VW part #028105269B ). The old dual-mass flywheel from the Passat is on the left.



Note the ring gear for the starter is opposite.



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“Of the value traps, the most widespread and pernicious is value rigidity. This is an inability to revalue what one sees because of commitment to previous values. In motorcycle maintenance, you MUST rediscover what you do as you go. Rigid values makes this impossible.”
― Robert M. Pirsig, Zen and the Art of Motorcycle Maintenance: An Inquiry Into Values
Old 11-04-2013, 08:05 PM
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Notes on the adapter plate between the G60 bell housing and the torque tube:

Stock 944 pilot bearing protrudes from the mating surface of the 944 block to transmission by ~.25".

The bell housing of the 944 is ~.25" taller than the G60 when measured between the torque tube flat face mating surface and the mating surface of the block to transmission. Shown here:



The pilot bearing of the 20v crank protrudes from the block to transmission surface by ~7/8". The snout of the crank goes out 1" but the taper of the pilot bearing hole sets it back in 1/8".

In order to maintain the same depth of penetration by the 944 drive shaft into the pilot bearing the adapter plate should thus have a thickness of ~7/8" to be right on the money. The pilot bearing hole in the snout of both crankshafts is about identical and around 1" deep.

Rough first take at a template to attach to the G60 housing; still need to mark up the 4 holes for the torque tube mounting bolts:



I think you could cut one from 6061 by hand... if you wanted to get real fancy you could have someone waterjet or CNC one out. I might go with the precision machining... two plates of flat stock (one plate 1/2" thick and one plate 3/8" thick) instead of finding a chunk of billet to machine to correct thickness. Undecided if this will all be welded together or bolts. I'm leaning to the welding...
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“Of the value traps, the most widespread and pernicious is value rigidity. This is an inability to revalue what one sees because of commitment to previous values. In motorcycle maintenance, you MUST rediscover what you do as you go. Rigid values makes this impossible.”
― Robert M. Pirsig, Zen and the Art of Motorcycle Maintenance: An Inquiry Into Values
Old 11-06-2013, 03:53 PM
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Parts ordered are starting to show up...

JE pistons are a work of art. These are sized +1MM for the bore to be refreshed in the block. Dropping these to the machine shop over the lunch hour:






1986:

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“Of the value traps, the most widespread and pernicious is value rigidity. This is an inability to revalue what one sees because of commitment to previous values. In motorcycle maintenance, you MUST rediscover what you do as you go. Rigid values makes this impossible.”
― Robert M. Pirsig, Zen and the Art of Motorcycle Maintenance: An Inquiry Into Values
Old 11-22-2013, 08:01 AM
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Rods came in night delivery along with an 82mm Cometic head gasket. The rods and pistons make this an ~800hp capable bottom end.





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“Of the value traps, the most widespread and pernicious is value rigidity. This is an inability to revalue what one sees because of commitment to previous values. In motorcycle maintenance, you MUST rediscover what you do as you go. Rigid values makes this impossible.”
― Robert M. Pirsig, Zen and the Art of Motorcycle Maintenance: An Inquiry Into Values
Old 11-22-2013, 04:13 PM
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Stopped by the machine shop tonight and found the block was just set on the bore machine.



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“Of the value traps, the most widespread and pernicious is value rigidity. This is an inability to revalue what one sees because of commitment to previous values. In motorcycle maintenance, you MUST rediscover what you do as you go. Rigid values makes this impossible.”
― Robert M. Pirsig, Zen and the Art of Motorcycle Maintenance: An Inquiry Into Values
Old 12-11-2013, 08:13 PM
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This thread ROCKS!

And the vids aren't bad either...
Old 12-12-2013, 05:03 AM
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Old 12-12-2013, 07:07 AM
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Old 12-12-2013, 12:17 PM
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