My 16v build, continued

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ob wan
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Re: My 16v build, continued

Post by ob wan »

and which of the cv's are the weakest, the inner or the outer?
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Re: My 16v build, continued

Post by PapaJo »

ob wan wrote:and which of the cv's are the weakest, the inner or the outer?
Mainly the non oem no name branded ones. Meyle are good. Long shaft behind motor and outer cv's snapping where the spline shaft ends on the cv cup and the ring retaining the ball bearings are the most common failures.

Depends on the driving and maintenance on cv's too.

I had a stripped short spline stub and cv cup splines on left inner cv that fits into the diff spider gear and left inner cv broken ring that retain the balls many moons ago on a n/a motor. That said it was still all oem.
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Re: My 16v build, continued

Post by ob wan »

touch wood... I have never had driveshaft failure.... but I don't want to tempt fate here...
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Re: My 16v build, continued

Post by panic-mechanic »

Outer cv breaks way easier than inner. Snaps it on the outside where the splines start
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Re: My 16v build, continued

Post by ob wan »

so much torque, the chassis twisted coming off the line.... is what I'm thinking when my car comes on boost... it feels like it wants to lift one wheel and pee on a fire hydrant..
bushes are fine, anyone fitted a lower strut bar and felt a difference?
I soooo badly want to do rose joints at the pivot points but those joint are pretty expensive...
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Re: My 16v build, continued

Post by PapaJo »

Lower strut bar makes a big difference on the handling.

Do you have an anti roll bar fitted on the front? Are you using standard mounting rubbers in your engine and gearbox mountings?
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Re: My 16v build, continued

Post by ob wan »

everything is std... no arb fitted, yet
afraid that I will get the button clutch bite with solid mounts on the engine and gearbox
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Re: My 16v build, continued

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hierdie ding loop hard!!!!! sien uit na 2 dinge in my dag, werk toe ry en huis toe ry....
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Re: My 16v build, continued

Post by ob wan »

so yesterday I took the limiter from cutting spark to cutting fuel, now it feels a lot smooth higher up close to the limiter.... could it be that when I hit the limiter the unburnt fuel causes a backfire which has the same effect on the turbine as not having a dumpvalve causing flutter to the intake wheel? causing a resistance to the exhaust wheel? usually it fired gunshots out the exhaust and on one occasion people on facebook in my area thought shots were being fired and called in the cpf....
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Re: My 16v build, continued

Post by PapaJo »

ob wan wrote:so yesterday I took the limiter from cutting spark to cutting fuel, now it feels a lot smooth higher up close to the limiter.... could it be that when I hit the limiter the unburnt fuel causes a backfire which has the same effect on the turbine as not having a dumpvalve causing flutter to the intake wheel? causing a resistance to the exhaust wheel? usually it fired gunshots out the exhaust and on one occasion people on facebook in my area thought shots were being fired and called in the cpf....
:driving: Gunshots is fun !! IMO cutting spark is safer on the motor.
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Re: My 16v build, continued

Post by ob wan »

hello all

encountered a new problem last week, I broke 5th gear, so decided to pull the gearbox and strip it to clean it properly
everything cleaned and a new 5th from the agents later... I start to assemble as per brokevw.com

1st shifts smooth right through to 5th, no problem there...
start to downshift, 5th to 4th is fine, but 4th to 3rd won't engage, doesn't even grind, all other combinations are perfect, 2-1, 3-4, 5-3, 3-1

so I removed the box again, switched the 3rd-4th synchro hub the other way around with a new synchro ring aswell, assembled and still the same...

I can't find any faults that is noticeable by eye, even changed the selector shaft bolt on top of the box...

I'm stumped, please help
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Re: My 16v build, continued

Post by PapaJo »

Check the indents where the 3 dogs sit inside the shift drum. When you select to 4th the drum should not push over too far to prevent the dogs from popping out. Check that. Looking at the indents inside the shift drum you will see they are not in the centre as one side is slightly shorter. The inner drum on the shaft and outer shift drum need to align and 3 dogs sitting in the indents and when shifting over to 3rd and 4th the dogs should not pop out.

The spring clips behind the dogs should be in opposite directions and the ends must not be starting and ending on the same dog.

Was the inner drum of the 3rd/4th gear removed and refitted the same way as that could offset the shift drum?

Does the syncro have a small lip where the dogs fit in to prevent them to move in the direction of the shift drum movement?

When all gears and selectir forks are installed, the gate must line up on all for the finger to move back and forward without needing sideway movement.
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Re: My 16v build, continued

Post by ob wan »

put a 20v manifold on... very happy

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Re: My 16v build, continued

Post by PapaJo »

Any gains from changing to the 20VT manifold?
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Re: My 16v build, continued

Post by PapaJo »

Is gearbox sorted now?
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Re: My 16v build, continued

Post by Mocha »

Ob wan, is it a straight fit?


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Re: My 16v build, continued

Post by THANAS »

At least reply to PPJs post after asking for help and receiving a detailed list of things to check. Some people.
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Re: My 16v build, continued

Post by PapaJo »

Mocha wrote:Ob wan, is it a straight fit?


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No, you need to cut both and use the flange on head from 16V and weld 20VT onto it. (Aluminum weld).
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Re: My 16v build, continued

Post by Mocha »

Yeah I feared it wouldn't be so simple. I'll just have a plenum made rather. Unless theres some crazy sort of flow advantage having the 20v intake.

Would suck to cut up two intakes to make one.


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Re: My 16v build, continued

Post by PapaJo »

Mocha wrote:Yeah I feared it wouldn't be so simple. I'll just have a plenum made rather. Unless theres some crazy sort of flow advantage having the 20v intake.

Would suck to cut up two intakes to make one.


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This type of conversion is normally done due to limited space in engine bay. For a smallish turbo it will be fine, but large aftermarket turbo and you start choking the boost due to the volume of the manifold collector when you crank the boost up. Short runners and small collector is good for low down spool, but you sacrifice torque. Longer runners give you better torque and more Kw's.

That why I asked earlier if there was any noticeable advantage in fitting this.
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Re: My 16v build, continued

Post by Mocha »

Would a gt28 be considered large enough to warrant the low down spool advantage? Where do they spool actually, with lets say a standard 16v intake setup?

Sorry for seeming ignorant, I'm very green and its my first build.


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Re: My 16v build, continued

Post by PapaJo »

Mocha wrote:Would a gt28 be considered large enough to warrant the low down spool advantage? Where do they spool actually, with lets say a standard 16v intake setup?

Sorry for seeming ignorant, I'm very green and its my first build.


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Start your own thread and what you have and plans and then we take it from there to discuss. I hate hijacking other people's threads.

Gt28 is considered a medium framed turbo. Many variants and spool up is determined by a number of other factors too.
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Re: My 16v build, continued

Post by Mocha »

Sorry for seemingly hijacking.
I got carried away with my question about the manifold.

Just observing builds for tips.

Thanks for the insight though PapaJo.


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Re: My 16v build, continued

Post by ob wan »

PapaJo wrote:Is gearbox sorted now?
no uncle, will strip it again as soon as time permits, been sooooo busy with work I can't even go to the loo without having to answer the phone... :crazy:
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Re: My 16v build, continued

Post by ob wan »

Mocha wrote:Ob wan, is it a straight fit?


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the outer runners do not match up perfectly so I used a flap disc to match it up, then welded it and voila, hopefully I can get some dyno time next week and will post the graph, but it opens up a lot of working space where the turbo sit, plus the manifold does not get heat soaked from the turbo as before
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