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View Full Version : TDI girdle machining

PASSENGER
08-20-2010, 02:14 PM
I machined this girdle setup for a guy with a 2l 16v tdi project.
You can see I machined the the top of the main caps, than surface ground them, as well as drilled and reamed them for 3/16" dowels.

The water jet girdle profile was provided to me, and I first started with surface grinding it flat so I could work with a true surface.

I than machined a step in the perimeter of the girdle to form the main cap receiver bosses, you can see they are also drilled and reamed to accept the dowels installed in the main caps.

After the step was machined I ground that surface to again get the plate flat. Than we measured the step height from a installed main cap to the edge of the crankcase and transferred that measurement to the girdle and took a lick off the top of the receiver bosses so that everything is bang on.

When the girdle is installed you can lift the crank case by it with out any screws holding the girdle or mains to the block, this thing is locked tight:Cheer:

http://i94.photobucket.com/albums/l83/935racer/P1010159.jpg
http://i94.photobucket.com/albums/l83/935racer/P1010160.jpg
http://i94.photobucket.com/albums/l83/935racer/P1010168.jpg
http://i94.photobucket.com/albums/l83/935racer/P1010169.jpg
http://i94.photobucket.com/albums/l83/935racer/P1010166.jpg
http://i94.photobucket.com/albums/l83/935racer/P1010171.jpg
http://i94.photobucket.com/albums/l83/935racer/P1010170.jpg
http://i94.photobucket.com/albums/l83/935racer/P1010173.jpg
http://i94.photobucket.com/albums/l83/935racer/P1010175.jpg
http://i94.photobucket.com/albums/l83/935racer/P1010176.jpg
http://i94.photobucket.com/albums/l83/935racer/P1010177.jpg
zstroken
08-20-2010, 02:17 PM
That is the way a girdle should be made, not with spacers between the caps!
SPEEDSHIFT
08-20-2010, 02:20 PM
Nice.
PASSENGER
08-20-2010, 02:20 PM
That is the way a girdle should be made, not with spacers between the caps!

My thoughts exactly. Between that and the fact most girdle you see are laser or water cut pieces that are anything but flat, they are ADDING stress to the case.
SPEEDSHIFT
08-20-2010, 02:25 PM
How is that one cut? Looks like WJ to me?
PASSENGER
08-20-2010, 02:29 PM
How is that one cut? Looks like WJ to me?

WJ, I don't like having anything laser cut much over .25" if it needs to be any sort of flat.
hatemi
08-20-2010, 03:04 PM
A fair bit better than our girdle :D That place isn't the first thing to explode in this build for sure.
Whitbread
08-20-2010, 03:10 PM
That thing is b!tchin. Should help hold Louis's monster motor together.

Have you worked out a price on it? Or is it the "if you have to ask, you can't afford it" range haha?

I've been planning on doing the same setup for my motor. Already have the chunk of plate, just need to find time to play with it :bang
PASSENGER
08-20-2010, 03:25 PM
That thing is b!tchin. Should help hold Louis's monster motor together.

Have you worked out a price on it? Or is it the "if you have to ask, you can't afford it" range haha?

I've been planning on doing the same setup for my motor. Already have the chunk of plate, just need to find time to play with it :bang

Well it wasn't cheap, but it wasn't expensive either, but that is just my opinion, I've been told I have expensive taste:lolly:
Louis mentioned maybe needing more girdles done. I wish the poor guys head wasn't butchered.
LReiff
08-20-2010, 03:58 PM
Well it wasn't cheap, but it wasn't expensive either, but that is just my opinion, I've been told I have expensive taste:lolly:
Louis mentioned maybe needing more girdles done. I wish the poor guys head wasn't butchered.

You don't have expensive taste because cheap doesn't make reliable hp! Looks beautiful!
Whitbread
08-20-2010, 08:27 PM
Well it wasn't cheap, but it wasn't expensive either, but that is just my opinion, I've been told I have expensive taste:lolly:
Louis mentioned maybe needing more girdles done. I wish the poor guys head wasn't butchered.Haha, as long as your good taste goes beyond just metal :Cheer:

Well, you built it, and now they will come :bow:. I would plan on at least 3-5. There's people out there with money. Hell, I'd even buy one from you if I wasn't a stubborn ass about doing everything myself. But I'm sure you're the exact same way haha.

Yeah, Bill really gave Louis a :kick: on that one. I get to fix it this winter, wohooooo....:doh:

I recently had a fully ported and done up ALH head from Bill brought to me by a customer to put on his car. The deck surface looked like it was done on a bridgeport with a dull single carbide fly cutter hand cranked across the surface, all 4 exhaust vales were visibly different heights, ports weren't even gasket matched, and the port job was terrible. Hardly anything beyond a cartridge roll was done. Needless to say, I had to take it apart and redo everything. I think the customer said he paid somehwere around $1000 for that crap too.
PASSENGER
08-20-2010, 09:49 PM
Haha, as long as your good taste goes beyond just metal :Cheer:

Well, you built it, and now they will come :bow:. I would plan on at least 3-5. There's people out there with money. Hell, I'd even buy one from you if I wasn't a stubborn ass about doing everything myself. But I'm sure you're the exact same way haha.

Yeah, Bill really gave Louis a :kick: on that one. I get to fix it this winter, wohooooo....:doh:

I recently had a fully ported and done up ALH head from Bill brought to me by a customer to put on his car. The deck surface looked like it was done on a bridgeport with a dull single carbide fly cutter hand cranked across the surface, all 4 exhaust vales were visibly different heights, ports weren't even gasket matched, and the port job was terrible. Hardly anything beyond a cartridge roll was done. Needless to say, I had to take it apart and redo everything. I think the customer said he paid somehwere around $1000 for that crap too.

Ah so your fixing it, have fun with that, its in about the same shape the other head Bill did that you fixed.
Louis already sent me the head but I declined working on it, the head is ****ed. Valve seats are all ****, he ground the port right into the seat, and the seat sealing area so all even if you re cut the seats you still wouldn't get full contact area. He also tried cutting a top angle into the seat which really only went into the deck of the head, but in a counterbore sort of way, I figure you'd lose 10-15cfm on that alone. The ports are all over the place...

Nothing that can't be fixed but sure as hell wasn't worth any money.
hatemi
08-21-2010, 02:48 AM
And wasnt that guy supposed be the super duper head porter dude in US for TDIs...
Whitbread
08-21-2010, 10:56 AM
And wasnt that guy supposed be the super duper head porter dude in US for TDIs...Yeah, key word is supposedly LOL. Kinda funny though, I haven't seen a peep out of him having anything to do with heads or porting since Louis posted the pics of Bill's "work".
bh10
08-21-2010, 11:16 AM
Looks awesome, might grab one for the wife's TDi.LOL

I will put money on someone coming in here and claiming they already made something just like that for their "program" and its far superior.
LReiff
08-21-2010, 01:00 PM
Looks awesome, might grab one for the wife's TDi.LOL

I will put money on someone coming in here and claiming they already made something just like that for their "program" and its far superior.

bif LOL
Whitbread
08-21-2010, 01:15 PM
I will put money on someone coming in here and claiming they already made something just like that for their "program" and its far superior.And it'll be titanium.

:pop:
PASSENGER
08-21-2010, 01:27 PM
And wasnt that guy supposed be the super duper head porter dude in US for TDIs...

Really? More like hackasaurus rex.

Looks awesome, might grab one for the wife's TDi.LOL

I will put money on someone coming in here and claiming they already made something just like that for their "program" and its far superior.

LOL
If its anything like that disaster of a cage it will add to the hilarity!

And it'll be titanium.

:pop:

No no, it will be some exotic alloy we can't (aren't intelligent enough to) know about:bs:
hatemi
08-21-2010, 02:30 PM
That came from ARPs secret stash. Total Hush Hush space age stuff but you can order one from ZZCustoms/Greggels ;)
roachie
08-21-2010, 03:21 PM
Am I reading that the cage was posted on another forum with less than stellar components?
PASSENGER
08-21-2010, 03:28 PM
Am I reading that the cage was posted on another forum with less than stellar components?

No that beetle cage that was posted here, when building a cage the idea behind the bars is to transfer the load/impact through the different bars so that the structure does not collapse. But if you look at that one, none of the bars are positioned to transfer any energy or support each other.
dvst8r
08-21-2010, 03:30 PM
So Dave I take it is finally done, the nightmare is over... :lolly:
roachie
08-21-2010, 03:37 PM
No that beetle cage that was posted here, when building a cage the idea behind the bars is to transfer the load/impact through the different bars so that the structure does not collapse. But if you look at that one, none of the bars are positioned to transfer any energy or support each other.

Damn, I though it got destroyed on the VW boards. I didn't pay much attention to the design, pics not to clear on my end.
PASSENGER
08-21-2010, 05:44 PM
So Dave I take it is finally done, the nightmare is over... :lolly:

Lol yeah, this thing gave me some grief, nothing about doing the job itself, it just seems there is some voodoo attached to this things as everything within ten feet of the damn thing failed:nail:

Damn, I though it got destroyed on the VW boards. I didn't pay much attention to the design, pics not to clear on my end.

It very well may have, I wouldn't know. I think I do recall Greg being about as accepted on tdiclub as he is here.