[Vwdiesel] Swap Costs

[LBaird119 at aol.com]

  I didn't really keep track of the time we spent on doing Dad's conversion.
I just told him he couldn't have afforded it (wasn't practical actually) if
he paid me for all of my time.  I'll give my best recollections of what it
took.

> I'm finally going to have the 1.6NA engine removed and a 1.6TD installed
>  along with power steering added in my Caddy. Need a flange made for a
>  direct 2 1/2 inch turbo exhaust pipe

  It probably took me an hour or so to make one.  I made 4 at once so it
was likely close to 2 hours total once you deduct the cutting and flat filing
time.  Just as easy to drill out several, of course the fly cutter we have is
crap so it takes about half an hour each just to bore the center hole!  Only
the one is fully complete so far.

>  and a new filter box for intake

  We took the easy way out.  We used the complete air filter and intake
piping from the donor TD Jetta.  :)  Only had to make one bracket to hold
it in.  A2 air filter housings mount differently, with big o-ring/rubber
bands.

>  made. Probably should change clutch and rear seal, timing belt/adjustment
>  etc.

  About 2 to 3 hours to do all this.  Don't forget the tranny pushrod seal
and
possibly bushing, in the front of the tranny.  If the engine's been dry for a
while (likely) do a new water pump.  There will also be an hour or three to
swap brackets and accessories from your engine to the TD.

I don't know if there will be room for intercooler since power
>  steering and aircon will be used.  How many hours of shop labor would be
>  reasonable for all of this? I wonder if a flat rate negotiation would be
>  better?

  A really slick fit would be to use a 944 intercooler, section out the lower
radiator support area and stick it there.  Not a cheap thing to do and figure
a half a day to fabricate it, with the engine out.  Then there's plumbing it
in.
Otherwise you're probably looking at putting it over the transmission and
ducting it in from the front or a hood scoop.  You might use a couple of
Geo Metro intercoolers under the battery, in the fender or such, plumbed
in parallel.

  The two of us put in about 4 to 5 hours working details out after the
engine was in.  Things like mounting the fuel filter, welding the elbow
to the turbo flange, connecting various hoses and wires and mounting
the air filter.  We didn't have PS or A/C to deal with either.  We did have
a center console to mount too.  We just tacked a straight pipe to the
elbow to get us to the muffler shop.  The 2 1/2 inch exhaust with an SS
braided flex ran about $250 or slightly over.
     Loren