Absalom's Build Thread #2 - Revenge of the Oil Burners

Like everyone else, I can't wait for the TDI swap. I'm just up in Westinster, so close to your future location. If you do the swap here in Colorado, there are lots of us to come by and help out with it.
That's great to hear. I'm on the fence right now; do I start the swap here in AZ where I have a strong network to help out or do I start the swap in CO after the move where I don't know anybody. Decisions ...

Traffic is ok. It really depends on where you are going and when. I work downtown during standard working hours so for me its not great but I deal with it.
Ok, that's good to hear. I'm sure it can't be any worse than Phoenix in parts.

This thread has the best of everything! My DD is, and most likely will always be, a VW. And my weekend warrior is the 4Runner. I've always had VW's. Curious as to why you're planning on going with the 4cylinder TDi vs. something like a Touareg V6 TDi? Haven't done any research....maybe size/fitment is your reasoning?
Awesome, VW make great DD's! Why the 4cyl vs the V6? Very good question! The 4cyl, due to their wide availability in several different affordable VW models has a huge audience and following. The V6 comes in the expensive Touareg and nothing else.

The 4cyl has an adapter plate already made, huge power potential, and unfaltering reliability. That all being said, I reserve the right to toss that 4cyl in the dump if it's too anemic for my truck! But with 400 ft lbs, I think she'll be just fine :D
 
Small Update

Keeping myself busy while I scour the country for remaining suspension parts. LC coils, TRD struts/coils, UCA's and steering bushings are en route.

Removed spare tire, painted rear hatch sill, gathered some DOM and heims for adjustable panhard bar, adjusted tranny linkage (was never done post body lift) and dipped emblems.

My sloppy steering bushings

The spacers in the rear are massive and squish the springs down the size of sports car springs. It's no wonder this rides so rough.

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Before

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After

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Easy Tire Balancing!

Going to use about 9oz per tire.

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That's great to hear. I'm on the fence right now; do I start the swap here in AZ where I have a strong network to help out or do I start the swap in CO after the move where I don't know anybody. Decisions ...

Easy decision, really. You already have help in PHX, and based on the thread activity here, you already have a ton of people willing to help in the Denver-Metro area. Me included.

So maybe base it on other factors :)
 
Rear bumper trim looks good. Any advise on take that trim off without breaking the clips?...
I pulled up first from the trunk latch, and then worked towards the sides. Getting back in is a little trickier.

Easy decision, really. You already have help in PHX, and based on the thread activity here, you already have a ton of people willing to help in the Denver-Metro area. Me included.

So maybe base it on other factors :)
Very good point! Time will tell, or if a great wrecked 04-06 TDI came along!

Good luck with the new build!
Thanks a lot man, I'll need it!
 
Did some gentle wheeling today. Did surprisingly well considering the spacer lift. No issues!

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In the beautiful Arizona desert!

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Big shoutout to [MENTION=92990]Backseat_Yeti[/MENTION]. Huge deal on brand new UCA's, AND he threw in a whole bunch of bushings for free. Big thanks!

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Glad to see those side vent's gone!

I'm curious though why go with a VW Engine and not a imported Toyota Turbo Diesel?
 
Quote:
Originally Posted by GSPRunner View Post
Hopefully those vents on the fenders are staying

Sadly, they were the first thing to go along with the extra 15 hp they added :/


Dude! The Auto Zone's bullshit isle has some very impressive, horse power adding, modifications.
At least add these to your list if you make the mistake of removing fender vents.
Triple plated chrome vehicular enhancement baby! Woo Hoo!!
 

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Great minds think alike, long live the '02 sport thundercloud! We both returned to the game with one recently.

Interesting engine choice, they definitely have an excellent reputation. I will follow that with much intrigue.
 
Glad to see those side vent's gone!

I'm curious though why go with a VW Engine and not a imported Toyota Turbo Diesel?

Several reasons. TDI's have a MASSIVE tuning community. I want a decent amount of power and the folks on TDIclub are pros at massaging magic from these 1.9 liter lumps. I'll be looking at 190 hp and 350 tq with just a few mods.

Availability. While the BEW motor that I'm using isn't quite as common, TDI's in general are very common. I'm actually surprised no one else has done this swap yet considering just how common they are! 4bt weighs nearly 3x as much IIRC.

Familiarity. I currently own two other TDI's (ALH and CJAA) and am very comfortable working on them. Actually this brings me to another point. These motors are so fun and easy to work on. The ALH especially! I have VW-specific diagnostic programs already purchased as well. I used to despise VW's ... and then I bought one of their diesels. You need to drive one, they're stupendous.

Looks like that will be an interesting build. I live in Arvada and will be on the lookout for you.
Thanks for checking in. As the weather heats up (though it never really cooled off) in Phoenix, we grow increasingly excited for our move to CO. When it's finished, be sure to come by for a test drive!

Still waiting for the diesel

Hell ya man, I love your passion. As you might guess this is a very large undertaking with an equally large shopping list. I've rushed projects in the past, and while it does satisfy my impulsiveness I end up not enjoying the journey as much as I should because it's so hurried and poorly planned.

This is a truck that we don't plan on selling for a long time. It's a third vehicle for us, so we can afford to have it just sit for longer periods of time. When I did my original runner, it was my DD. Which meant if I couldn't finish a project in one day, I was walking to work the next morning. This time around I'm doing TONS more research, planning and networking. It's crucial that I have most of my parts gathered before dismantling a perfect running truck. It's also equally important that I have a good group of tradesmen as friends to assist with the technical details; wiring, welding, fabwork, etc.

The shopping list is quite extensive and requires lots of searching and legwork to gather. Here's a small snapshot of the big pieces I need before I begin the swap:

  • Donor 2004-2005.5 TDI Car (Not terribly common and even harder to find in good condition)
  • R150F Transmission
  • Acme Adapters and Custom Flywheel
  • Custom SBC Clutch
  • VNT17 Turbo (for Cupra)
  • Immo delete and Stage 3 Tune
  • PD150 Injectors
  • Custom Wiring Harness

Also keep in mind, while the diesel swap may be the most exciting part of this build thread (at least for me), the truck needs to be perfect, chassis and suspension -wise before I feel comfortable pulling the motor. In the end it will be a do-it-all truck; tons of torque for towing, amazing off road, etc. It's a labor of love that I've been looking forward to many years. The swap is stage 2 of this build, stage 1 is almost complete!

Stay tuned :)


Great minds think alike, long live the '02 sport thundercloud! We both returned to the game with one recently.

Interesting engine choice, they definitely have an excellent reputation. I will follow that with much intrigue.

3rd gen is best gen! I see we each left T4R's for a brief stint with Bavarian toys. Did you keep your Audi? Plans for your new runner?
 
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The ALH especially! <b>I have VW-specific diagnostic programs already purchased as well.</b> I used to despise VW's ... and then I bought one of their diesels.

I'm flying to Houston to bring a 2001 Golf TDI home to Phoenix this weekend. It's a fixer, so hopefully you have a VAG-COM and might be willing to help a brother out...

The shopping list is quite extensive and requires lots of searching and legwork to gather. Here's a small snapshot of the big pieces I need before I begin the swap:

  • <b>Donor 2004-2005.5 TDI Car (Not terribly common and even harder to find in good condition)</b>
  • R150F Transmission
  • Acme Adapters and Custom Flywheel
  • Custom SBC Clutch
  • VNT17 Turbo (for Cupra)
  • Immo delete and Stage 3 Tune
  • PD150 Injectors
  • Custom Wiring Harness

I responded in the "What did you do to your 3rd Gen today" thread, but posting here too. <b>Have you given any thought to going to one of the insurance auctions down near 21st Ave and Broadway?</b> That might provide you a better chance at finding your donor, since I see a few VWs at yards lately down in that area.

Good luck and I'll keep an eye out for your 2004-2005.5 TDI BEW...
 
I'm flying to Houston to bring a 2001 Golf TDI home to Phoenix this weekend. It's a fixer, so hopefully you have a VAG-COM and might be willing to help a brother out...



I responded in the "What did you do to your 3rd Gen today" thread, but posting here too. <b>Have you given any thought to going to one of the insurance auctions down near 21st Ave and Broadway?</b> That might provide you a better chance at finding your donor, since I see a few VWs at yards lately down in that area.

Good luck and I'll keep an eye out for your 2004-2005.5 TDI BEW...

Regarding your ALH, 480.779.8307 whenever you're ready. I got VCDS on standby ready to rock. We'll dial that sucker in.

I check Copart and IAAI daily. Unfortunately, they have limited stock and lots of fees. So while I'm not ruling them out, I'm certainly leaning towards a private party transaction at this point. I actually have a line on a Beetle I'll most likely get. Right now we're trying to figure out the logistics of stripping down a car at a house with 1 car garage and 2 slab parking spots. It's possible, I just want to make sure I have methods to bring the body to scrappers ASAP after full tear down.
 
Definitely subbed to watch the progress on this one. My 3.4 is starting to get old and tired. I've told myself that I'll either sell this down the road and get an 80 or 100 Series, or I'll do an engine swap of some sort. Would love a diesel and I too have experience with TDI's and like them a lot.
 
Regarding your ALH, 480.779.8307 whenever you're ready. I got VCDS on standby ready to rock. We'll dial that sucker in.

I check Copart and IAAI daily. Unfortunately, they have limited stock and lots of fees. So while I'm not ruling them out, I'm certainly leaning towards a private party transaction at this point. I actually have a line on a Beetle I'll most likely get. Right now we're trying to figure out the logistics of stripping down a car at a house with 1 car garage and 2 slab parking spots. It's possible, I just want to make sure I have methods to bring the body to scrappers ASAP after full tear down.
If you need a car trailer to haul away the carcass (pun intended) let me know as I have access to a dual axle hauler given a little notice.
 
3rd gen is best gen! I see we each left T4R's for a brief stint with Bavarian toys. Did you keep your Audi? Plans for your new runner?
It was those damn awful cars that brought you back too huh? I still have the S4, sold the A4. I have similar plans to you (besides the small matter of an engine swap) in an purpose built overland/camping/trails type vehicle.

How goes the shopping list? There are a few quite hard to find items there.
 
** Stage 1 Complete ***​

This update comes a little late and won't do much to satisfy the diesel-hungry mobs. However, it's an important part of the process and money well spent.

Lift install was a breeze, Light Racing UCA's are fantastic, and TRD's ride about twice as well as my old Eibachs ever did. I am experiencing some stiffness in steering and have narrowed it down to either the tight tolerances of the new LBJ's or (less likely) a shot rack. However, as of writing this, it's much less tight than immediately after the install.


Looks a tad excessive with the 2" body lift

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New Monroes, extended sway bar links, and LC springs

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My DIY DOM adjustable panhard bar

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TRD's, Bilstein 5100's, and Light Racing UCA's

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Rust Removal and Chassis Resto Time!

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Next up, 2" body lift is out and .5" body lift is in. Sliders en route and headed down south soon to pick up 5 speed transmission.
 

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