Not to thread jack but...

Check out Napier Precision they make some nice flares in different varieties.

Also...damn nice work not only on the conversion but with the Jeep on a whole, just really impressive! Keep up the good work

 

I'd love to know what your avg MPG's are this thing!

Great work again!
Bryson

 

I did check them out before buying but their flares are big like the Bushwacker ones. They are too big for my little 31" tires.

 

You know this will take some time right ;>)
My wife took it on a holiday the last 4 days and it's still got over 1/2 tank.
I think we need to fine tune the Malone stage 4 tune as it does spew a fair bit of black smoke when you shift.

 

Yes. The weather has been bad up here with wind storms and tons of rain. The weekend is supposed to be sunny so I will see what I can do about a video.

 

Their "cut out" style flares are actually smaller than Bushwacker's flares (on purpose) as they're meant not to cover tires like the Bushwacker flares do.

I was thinking of the flat flares honestly as they don't get into the rear door like you were talking about and on the newer XJ the flat flare just looks great

Either way, your Jeep kicks ***

 

OK, finally some video.
Lots of tire spin in 1st and scratch in second.

 

Just read this whole thing; love it. I've rebuilt two of those damn TDI's. I hope you upgraded from that awful plastic impeller water pump. You don't seem to be the kind of guy that needs this info, but don't forget to change the tensioner, et al when you do the cam belt changeover. It's an interference engine so when the cam belt fails those nice little valves get rammed up into the valve train. Ask me how I know

Anyway, great build, love it! What kind of power do you think you're pushing?

 

lol bad luck with some bent valves eh?

I thought the OE pump was a metal impeller

 

Dude. This is awesome!!! Nice work! A few questions:

- What's with the orange can of death?
- Are you using the G13/G14 coolant or something else?
- I noticed the XJ's "open" coolant bottle. Are you concerned about sludge from the air exposure?

 

like the clean look of this JK man.

 

Hey, alright! Runnin like a champ! Still hard to believe this was your wife DD. Theres so much (quality) work and attention to detail. She must be a good partner!

 

Thanks to all.
The engine only had 57,000km on it so I did not do the belt yet.
I still have a stage 2 cam to put in but probably wont do that till the Spring and do the belt then.
My ZJ has had an Isuzu diesel in it for the last 10 years and always had Fram filters.
No death yet.
The antifreeze bottle says G12, is there a reaction problem with air and the G12 fluid?
One thing I learned decades ago, if I "say" its her DD then the cost is never questioned. ;>)

 

There are many better filters than FRAM... ones that actually filter the oil, lol.

Geez, a cam too?! I thought you were going to back off the tune!

Well, the VW system is sealed and uses a pressure cap on the coolant reservoir to release pressure. This is in contrast to the newer Jeep setup where the coolant reservoir is open to the atmosphere. I'm not sure about G12 specifically, but that series is an organic acid coolant like DEXCOOL is, and, aside from early formulation problems, a lot of the problems were blamed on the coolant being exposed to the atmosphere in certain vehicles. I've learned a lot on this subject recently as one of the ****ing head gasket's let go in my Duramax The OE VW system is praised for actually being a "lifetime fill", so it makes me wonder what a change like that would do.

 

Oh no, they weren't bent, they were rammed up and impacted with the guides, etc. Complete mess. Frank's TDI was somehow able to salvage the head.

Ya know it is possible that the OEM one is metal. I got the car from my sister after she opted to have some no-name shop change out the cam belt. Well, they didn't change all the other parts they were supposed to at the 100,000 mile mark as well because the tensioner failed about 2k miles later. VW wanted $6500 to fix it...I did it for $1800. That's probably where the plastic impeller water pump came from too now that I think about it...