January 3, 2013
I got everything back together and started the motor on December 22. I had an exhaust leak because I re-used a steel gasket between the turbo and header pipe. The new gasket I got from Jeg's was too thick for my liking. I tightened down the new hardware and it helped a bit but it is not 100%. The other issue I have is the oil return line. My inner CV boot is about 1/8 of an inch from the oil return line fitting at the block. When I lower the car onto the ground, the clamp on the fitting is touching the CV boot. I have a solution which is to weld a bung into the oil pan and have the oil return line go around the axle and to the pan. Here are the parts below (minus the oil pan). I will get it welded in the next week or so and take more photos of the finished product. The clearance I gain will let me lower the car another inch or so with peace of mind. I have had an ST Coilover suspension waiting to be installed for two years.
Here is the rebuilt Rotomaster TO4B that Blaylock Turbo did.
I am finishing up the last few bolts on the turbo installation. The GTI poster in the background is from the 1980's. I am glad I finally have the garage to hang it in. The second photo is the turbo bolted to the exhaust manifold and header pipe with stainless steel bellows.
While under the car, I took a photo of the exhaust flange at the end of the stainless steel header pipe. I went to Napa Auto Parts to get a new 3 bolt gasket. The part # is 31369 and fits like a glove. The inner ID is 2.5 inches.
Here is a picture from below the turbo showing the oil drain before any line is attached.
Here is the finished product. It was nice to see a clean engine bay again. It is the dead of winter now so I have to wait some time before I take the car out for a spin. This car probably has not seen snow since the 1980's and I don't intend to change that.
November 25, 2012
Oil line fitting photos are below.
I pulled the receipt from Blaylock Diesel Service. The invoice was dated 4/24/08, TO4B rebuild for $425. I installed the rebuilt turbo in the Rabbit Gti two years later turning the key on July 7, 2010. The mileage on the car was 56,401 at the time. I removed the turbo two days ago with 59,117 miles. The delta is 2716 miles. I would say the seals have been an issue for the last few hundred miles. The car was smoking pretty bad in the last 25 miles. Here is a list of things I need to get.
November 23, 2012
Black Friday, er, the day off allowed me to pull the turbo. I suspect the oil seal(s) are toast on the Rotomaster TO4B as part of the Callaway Turbo set up in the 1983 Rabbit GTI. The car has been smoking - an indication of oil blowby. I have had some issue with oil leaking from the turbo. The turbo does not have more than a few thousand miles on it. I emailed Blaylock turbo about the issue over the summer. They were not too much help but it was clear something did not seat right with the oil seal(s). I am sending it back to them and see what is going on here. Below are some pictures of the turbo, oil leak, and the garage. Stay tuned.
I bought a used BBS air dam last month. It has the provision to fit around the Rabbit Gti fender flare so it was a no brainer to go after this one. They are hard to find. The one installed on the Gti now must be for a Rabbit without a Gti air dam. It never really looked right while the previous owner did their best to make it look as good as they could. They removed the Gti fender flares and installed and trimmed a set from a Rabbit Convertable or Mk1 Jetta.
The BBS air dam that I just got last month came to me painted in silver so I gave it to the good hands of TR Ramsdell at C+G Autobody in Beverly. I got word that it was finished this week so I picked it up today. It looks awesome - perfect paint match for the Cashmere White on the Gti. I can't wait to install it. I will flip a coin to see which Gti is going to DustOff but suspect this one is coming.
The black bumpers on the car have been an eye sore since I got the car from California. Actually, the front bumper was pretty new so I can't complain too much. The rear bumper had the black paint missing in spots so the aluminum was showing. I planned on getting them powdercoated for long term durability and great looking finish. I contacted Powder Coating Alternatives in Greenland, NH. The young lady on the phone was very customer service oriented (a rare feature with business these days). I brought them there to get a qoute and then settled on Raven Black for a color. They came out great. I installed the finished product and they looked great on the Gti. I brought the car out to the Broke Down show in Gardner, MA the day after I installed the bumpers. Someone was nice enough to take a photo of the car that day.
November 21, 2010
I installed a rare set of gold 15X7 BBS RA polished lip rims with brand new Kumho Ecsta tires this week. I got these from the original owner who purchased them from a BBS warehouse in the late 90's. He never installed them on his 79 323i BMW and then built up a nice set of BBS RS's. I went ahead and purchased longer 35mm lugs in black from Turner Motorsport and fresh BBS center caps from Black Forest Industries. I think they look solid on the car. I am considering a coil over suspension to tighten up the wheel gap but I am mixed about slamming the car. I like the stance in the front but the rear could come down about 1.25 inches.
July 25, 2010
I finally had some time to install a boost gauge today. I am seeing 7lbs of boost on a new VDO boost gauge that goes up to a 15lb scale. The turbo spools sooner than my other callaway turbo Rabbit. I also got under the car to drop the oil pan. I removed the oil pan baffle - scraper that I felt was not helping the oil drain back into the oil pan which has trap doors for an efficient pick up of oil. In addition, I reclocked the turbo about 15 degrees to offer more clearance from the firewall. Below is a picture of the boost gauge installed. I used a 2" (51mm) hole saw bit to get through the dash bezel. Then a dremmel sander wheel was used to get the extra mm needed to fit the gauge.
I am very happy with how this project turned out although not finished and still only have 50 miles on this rebuilt turbo so far. This car is going to be a great cruiser even with the 2H close ratio transmission. I will swap out for a higher 5th gear. In the meantime, I have to wire up the light for the boost gauge, order a green diffuser for the bulb, get some exhaust flange bolts for the long term, and replace a missing bolt and nut for the front sway bar. In addition, I will seek help from Bill to get the water injection working.
July 7, 2010
Bill and I got some more time on the project to the point where it started right up at the turn of the key. Actually we needed some help from the battery charger as the battery was down a few volts. Before that we installed a new silicone coupling 3.25" diameter (see the bright blue in the first photo below) at the throttle body, throttle cable grommet (mine disintegrated or found a new home), RedLine synthetic oil 15W-50, Pentosin Blue G11 Long-life Coolant, oil baffle, and connected the last of the vacuum lines. Underneath the car, we had to re-install the H&H sway bar which connects to the front of the A-Arms. Finally, once the car was started the engine was timed to TDC at 950rpm per the specification from the Callaway Install manual. The techtonics exhaust sounds so good at idle. I can't wait to hear it under load.
Here are some pictures of the engine bay and the water injection next to one of two Mecca oil filters that reside under the hood. Please don't mind the timing light.
July 1, 2010
Bill finished up the down pipe this past weekend. It came out very well. Many hot hours and labor were put into this one. I will let the pictures speak for themselves. As for the overall status, we are very close to turning the key to hear this this roar. We should get some time over the holiday weekend and no later than July 5.
June 17, 2010
I have been slacking off on the updates but honestly, progress has been slow and life has been getting in the way on the weekends. Bill put the final touches on the down pipe. He's got the patience and skills to weld. It came out great. It needs a bit more work and one more test fit before it will be called a finished product.
May 24, 2010
Bill and I had a small window of opportunity to remove the Gillet Power Sound exhaust system from the Gti yesterday. I felt pretty bad about making one cut before the rear beam to remove it. The exhaust was pretty quiet and has a nice gloss tip on it. It can easily be welded back together to offer a few more years of service in another project down the road.
May 17, 2010
This past Saturday was all about getting a new down pipe made out of stainless steel stock to maintain a 2.5" diameter from the outlet of the turbo all the way to the tail pipe. Bill put his welding and fabrication skills to work before I could turn on the camera.
May 11, 2010
Bill and I have had some time over the past few weekends to clean up a few items and sort out the small stuff. You will be surprised how much time it takes to sort out the small things. I want to take care of anything that might be a weak point down the road. For example, the stock relay shaft bushings were toast. I ordered Teflon bushings to handle the heat from the turbo. We also replaced the drive flange seals. We pulled each motor mount with the goal to replace them with heavy duty ones. However, they were in good shape so we aligned the motor back where it was after replacing the timing belt and updated tensioner. I will remind everyone difficult accessing the passenger side and drivers side motor mounts are. Putting everything back everything back together, raising and lowering the motor is no fun either. All you have to do is get the bolts started and your in good shape. Below are some pictures from a few weekends ago.
As of now, I am waiting for some G11 coolant and Redline MTL gear oil so we can fill up the engine with new fluids. The next step is to button up the bay and then begin manufacturing the down pipe with some stainless 2.5" stock. We can't replace the passenger side axle, which received two new CV boot kits, until the down pipe is finished and installed.
April 24, 2010
My good friend Bill and I finally tore into the Rabbit Gti to begin the Callaway Stage I install on Saturday. We have three turbo installs between the two of us. I headed up to his house so we could work in his clean garage. I had a few boxes of parts including a rebuilt TO4B turbo and some various Callaway bits. The rebuilt turbo has been waiting years to be installed. We had no issue removing the intake and exhaust manifolds along with the down pipe from the car which had the nice dual outlet manifold and down pipe.
Below are some pictures from the weekend. We experienced a few delays as I forgot the Callaway exhaust manifold at home and we had to make a tool run to secure a tap to chase some threads in the same exhaust manifold. I have some heavy duty motor mounts, timing belt, and a 2.5" Techtonics Tuning Stainless Steel exhaust on the way which will be installed soon. Meanwhile, I have a 2.25" Techtonics Tuning stainless steel exhaust sitting new in the box but we think bigger is better especially keeping the option open to go stage II with the intercooler and 5th injector in the future.
I have been sitting on a rebuilt Rotomaster TO4B since April with anticipation of moving forward with Project Callaway Stage I. I also bought new exhaust manifold studs, bolts, and gaskets. Seeing as the car once had a kit installed, I am certain the install should go rather smoothly as the block already has a provision for the oil return. In addition, we'll keep the install of the turbo system simple by not going beyond stage I which means no intercooler, obtrusive intercooler pipes, and no Miller Woods Microfueler to operate an injector at the throttle body elbow casting from Callaway. Recently, my friend Bill who installed a stage II Callaway Turbo kit in my old Mk1 Scirocco, has had some success with a Warm-Up Regulator from UnwiredTools, model UTCIS-PT which is pictured below.
It provides enough fuel to each of stock Bosch Fuel Injectors and while delivering the correct Air Fuel ratio per his wide band throughout the RPM range. This is music to my ears and shows that there is a work-around away from expensive stand alone fuel management systems and additional injector controllers which from all intents and purposes is what the Microfueler was invented for. Below is a part breakdown by New Dimensions of the stage I turbo kit. New Dimensions bought all inventory, rights, and tooling from Reeves Callaway in the early 90's respective to the Volkswagen application. While New Dimensions is now under new ownership as of 2007, "Turbo" Tim Hildabrand is still available in certain forums offering parts for these turbo kits.
Small photo shoot taken of the Rabbit Gti in May of 2007
This car, by far, has the most interesting history of any of my former or current cars. Back in the fall of 2001, I saw an ad for a 1983 Rabbit Gti for sale in California. Within the ad, there was an opportunity to purchase a Callaway Turbo kit with the car. I was far more interested in the kit than the car once I thought about the logistics of getting all of it back to the east coast. At the time, I did not have a car for which to install the kit on so I was no at all opposed to getting the whole package: car and parts.
The owner, turned out to be the original, purchased the car brand new in 1983 and then proceeded to spend an enormous amount of money on major modifications for the time. This included a Stage I Callaway Turbo kit which was later upgraded to stage II. Andy King at R&A Applied Arts was local to the owner. Therefore, he was responsible for the installation and upgrades to the car. R&A Applied Arts was and is one of the most respected authorized Callaway Installers on the east coast.
The owner moved to California in 1984 and had to have the Turbo removed in order to abide by the strict CARB, California Air Research Board, emissions. As a result the turbo kit was removed by the company who would eventually purchase the tooling, inventory, and rights to the Callaway Turbo Systems as it related to the Volkswagen in the early 90's.
I decided that I wanted to move forward with just the Turbo parts. The downside was that the owner would not ship the parts. Months passed by. I finally got the courage to make and offer on the turbo parts and car in March, however, the car was just sold in the week that I inquired. I purchased the turbo parts and made a wedding trip to California that Spring. In doing so, I boxed up the parts and shipped them back to the east coast. The parts went on a 1984 Rabbit Gti that I would purchase later on.
I got in touch with the new owner of the Rabbit in hope of getting copies of the receipts associated with the turbo kit that I had owned. The owner never did follow through with my request. Nonetheless, more than two years go by and I saw the Rabbit Gti up for sale in May of 2004. The ad was about five days old and I immediately inquired on the availability of the Gti.
Although I had already installed the Callaway kit onto another car, I had visions of restoring this Rabbit back to what it looked like in 1984 with the Stage II kit, wheels, et cetera. I wanted to make it happen and did not want to let this car go by again. In addition, the car looked a lot better than it did two years previously. This owner fixed any and all problems with the car from mechanical to aesthetics. Just by the ad on the internet and through my conversations with the owner, I was more than confident that I wanted the car in an obsessed demanding way.
The car arrived three weeks later. I intend to compile some Callaway Turbo parts to either come up with a stage I or stage II kit. Please get in touch if you have any parts laying around perhaps collecting dust. This car is begging to have a turbo installed. I am open to Stage I as installation would be simpler and I could still enjoy 5lbs of boost. If you can help out, please email me. In addition, if you have any experience with R&A Applied Arts, I would love to hear about them.
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