NefMoto

 Hey guys,
This is my current project 2001 new beetle. It has the stock 20v awv head on top of a avh 2l. Hopefully will be finishing up today and possibly road tuning this weekend!

(http://i1294.photobucket.com/albums/b607/darkshado87/A073BD98-B43B-41DA-8FC1-7B90F2320489_zpsaursjf9k.jpg) (http://s1294.photobucket.com/user/darkshado87/media/A073BD98-B43B-41DA-8FC1-7B90F2320489_zpsaursjf9k.jpg.html)
Pulling apart the 2l to remove pistons

(http://i1294.photobucket.com/albums/b607/darkshado87/10818B46-729A-4291-AADC-131103CE9721_zpshyyohla3.jpg) (http://s1294.photobucket.com/user/darkshado87/media/10818B46-729A-4291-AADC-131103CE9721_zpshyyohla3.jpg.html)
Pistons out

(http://i1294.photobucket.com/albums/b607/darkshado87/DC15503F-C0B4-4593-822F-4076541D03A1_zpssmfb18pi.jpg) (http://s1294.photobucket.com/user/darkshado87/media/DC15503F-C0B4-4593-822F-4076541D03A1_zpssmfb18pi.jpg.html)
Used a endmill bit on a manual milling machine. I ended up knocking the corners down to avoid hot spots

  (http://i1294.photobucket.com/albums/b607/darkshado87/9B32A0FE-6B79-4BE5-88F8-E4335D83A405_zpsezwrycti.jpg) (http://s1294.photobucket.com/user/darkshado87/media/9B32A0FE-6B79-4BE5-88F8-E4335D83A405_zpsezwrycti.jpg.html)
I got these shitty 440s from a friend, I was going to run them but one is bad and there not really what I want. Going with 550s so as I can come up with the extra loot

(http://i1294.photobucket.com/albums/b607/darkshado87/5E2D225C-9CD8-413A-8618-6CD7B120E881_zpskjjtzvdk.jpg) (http://s1294.photobucket.com/user/darkshado87/media/5E2D225C-9CD8-413A-8618-6CD7B120E881_zpskjjtzvdk.jpg.html)
(http://i1294.photobucket.com/albums/b607/darkshado87/4324ADAE-4BA8-4D97-988C-576E78A8C0F1_zpshsdhbdx3.jpg) (http://s1294.photobucket.com/user/darkshado87/media/4324ADAE-4BA8-4D97-988C-576E78A8C0F1_zpshsdhbdx3.jpg.html)
New rings and connecting rod bearings.

(http://i1294.photobucket.com/albums/b607/darkshado87/1A1F2DF3-A9AD-408E-B4D9-4B1FBBFE8009_zpsggt9yk3c.jpg) (http://s1294.photobucket.com/user/darkshado87/media/1A1F2DF3-A9AD-408E-B4D9-4B1FBBFE8009_zpsggt9yk3c.jpg.html)
That's the day back in September when I picked up the car. $450 for it... I kinda hate the fact it's a bug but I really wanted a cheap clean mk4... Was the first clean kinda mk4 I stumbled across


1.8t coming out

[URL=http://s1294.photobucket.com/user/darkshado87/media/9491A0FE-9BED-4C94-85FC-0277F7A9FD0A_zpst4b3tq4r.jpg.html](http://i1294.photobucket.com/albums/b607/darkshado87/9491A0FE-9BED-4C94-85FC-0277F7A9FD0A_zpst4b3tq4r.jpg) (http://s1294.photobucket.com/user/darkshado87/media/2E3ABD54-09B1-4BB5-AE87-790A0D72BD51_zpsopqxoaly.jpg.html)
Scooped a t04e 57trim for 100 from my buddy with a civic. He popped his d series and went for a ls b swap. Took her the local turbo shop to have new seals and balanced.

(http://i1294.photobucket.com/albums/b607/darkshado87/CBB1EFF3-CB3D-46E0-9C0D-FC2AC42E332E_zpslhcnhgkv.jpg) (http://s1294.photobucket.com/user/darkshado87/media/CBB1EFF3-CB3D-46E0-9C0D-FC2AC42E332E_zpslhcnhgkv.jpg.html)
Little bigger

(http://i1294.photobucket.com/albums/b607/darkshado87/DEB9CE50-19E8-4F44-8C88-DDFE919E4713_zpsihtlpymp.jpg) (http://s1294.photobucket.com/user/darkshado87/media/DEB9CE50-19E8-4F44-8C88-DDFE919E4713_zpsihtlpymp.jpg.html)
Short block 2l back together with modified pistons

(http://i1294.photobucket.com/albums/b607/darkshado87/13CA54FE-B939-43ED-ADD9-84B18821045A_zpspbza6a2r.jpg) (http://s1294.photobucket.com/user/darkshado87/media/13CA54FE-B939-43ED-ADD9-84B18821045A_zpspbza6a2r.jpg.html)
Waiting for parts so I cleaned the block with a wire wheel

(http://i1294.photobucket.com/albums/b607/darkshado87/0BBA98EB-6501-4E2E-BBDF-148D735C35EC_zpsai1pytgc.jpg) (http://s1294.photobucket.com/user/darkshado87/media/0BBA98EB-6501-4E2E-BBDF-148D735C35EC_zpsai1pytgc.jpg.html)
(http://i1294.photobucket.com/albums/b607/darkshado87/BD79847E-3CEA-4344-ABB0-8D20E7BACAC8_zpseyeicjji.jpg) (http://s1294.photobucket.com/user/darkshado87/media/BD79847E-3CEA-4344-ABB0-8D20E7BACAC8_zpseyeicjji.jpg.html)
And painted it

(http://i1294.photobucket.com/albums/b607/darkshado87/A18E339D-F839-4919-9DDB-286CB19B0F4E_zpsrpvaol3q.jpg) (http://s1294.photobucket.com/user/darkshado87/media/A18E339D-F839-4919-9DDB-286CB19B0F4E_zpsrpvaol3q.jpg.html)
New t3 manifold.... Looks like it will flow nice

(http://i1294.photobucket.com/albums/b607/darkshado87/5725DBB5-796B-4BDA-87CD-D6BDF2C5FBED_zpsfarsjv7l.jpg) (http://s1294.photobucket.com/user/darkshado87/media/5725DBB5-796B-4BDA-87CD-D6BDF2C5FBED_zpsfarsjv7l.jpg.html)
Had to drill a hole in the 1.8t head gasket

(http://i1294.photobucket.com/albums/b607/darkshado87/1B5B1E32-A701-40BB-9CE5-6CDC7CC3CDFA_zpsvj5afo6l.jpg) (http://s1294.photobucket.com/user/darkshado87/media/1B5B1E32-A701-40BB-9CE5-6CDC7CC3CDFA_zpsvj5afo6l.jpg.html)
Had to drill a hole in the 20v head

(http://i1294.photobucket.com/albums/b607/darkshado87/F8762D9A-5519-4EDC-90A5-A0A931FC6AB0_zpsulgspppo.jpg) (http://s1294.photobucket.com/user/darkshado87/media/F8762D9A-5519-4EDC-90A5-A0A931FC6AB0_zpsulgspppo.jpg.html)
(http://i1294.photobucket.com/albums/b607/darkshado87/4FD5DC0A-ACEC-470D-80CA-9FD03FBD71CB_zps7ctmagqm.jpg) (http://s1294.photobucket.com/user/darkshado87/media/4FD5DC0A-ACEC-470D-80CA-9FD03FBD71CB_zps7ctmagqm.jpg.html)
9lb g60 flywheel vs stock 22lb

(http://i1294.photobucket.com/albums/b607/darkshado87/36DA9EAB-2E3C-48AF-871D-8F5B8DE76868_zpsuedvsqds.jpg) (http://s1294.photobucket.com/user/darkshado87/media/36DA9EAB-2E3C-48AF-871D-8F5B8DE76868_zpsuedvsqds.jpg.html)
Just finished assembly

(http://i1294.photobucket.com/albums/b607/darkshado87/BDED5AC4-18E0-4E47-829B-D2603FE42446_zpsx672iphm.jpg) (http://s1294.photobucket.com/user/darkshado87/media/BDED5AC4-18E0-4E47-829B-D2603FE42446_zpsx672iphm.jpg.html)
2l 20v back in

(http://i1294.photobucket.com/albums/b607/darkshado87/15D43FB9-949A-4263-9DFA-E7DEE1A3F5F2_zpsgdcna1yd.jpg) (http://s1294.photobucket.com/user/darkshado87/media/15D43FB9-949A-4263-9DFA-E7DEE1A3F5F2_zpsgdcna1yd.jpg.html)
Really couldn't get much closer

(http://i1294.photobucket.com/albums/b607/darkshado87/th_3A464E6D-A658-4098-8FA9-5D8F1B5477AE_zpskchtllbm.jpg) (http://i1294.photobucket.com/albums/b607/darkshado87/3A464E6D-A658-4098-8FA9-5D8F1B5477AE_zpskchtllbm.mp4)
Startup no maf map or o2 and open hot side on turbo

Interesting build, I have never seen this milling on pistons. Only for hot spots with the 20v head, or also for valve clearance?

Yea for the 3rd intake valve. Because if the deep dish on the stock pistons compression is somewhere around 8.5:1. Plan after winter here is scat rods and je pistons

Got some road time in over the weekend! So far so good, got a lot of small things to deal wobt hardware related need some new gaskets for by wastgate adaptor I made they blew out and other small stupid stuff

Hows it running now Marty? Can you post some logs for airflow vs rpm? Curious how the 20v head flows the extra displacement!

Awesome

Any news?  :)

i sold it. still alive runs 20psi on a to4e

Wont post my other reply. Idk.
Mad dope tho.... always wanted to do a new school baja

Picked up a new project before other was done myself. 2.5 rabbit.... ordered top mount mani  intercooler already.... need to decide on turbo still unsure what to go with yet......