Here I go again! I'm now modding my 745...
 

It's time to start a build thread on my 745td. What I have planned is a nice driving, comfortable, and peppy commuter. I'm shooting for around 160hp with no smoke throughout the power band. I'm also trying to see if I can increase my mileage from 30 to 32mpg in mixed driving. This should be a fast build, hoping to have it done by February.

Here is the start to my build. A d24t with matched set of rods, KS pistons 1mm oversize, clevite bearings.

Matching the rods..

New KS 1mm oversize pistons added to a matched set of rods....

All ring gaps checked and recorded, pistons now getting installed into block..

32mm pre chamber head that is crack free acquired! And it's straight as an arrow! Time to disassemble and port/ polish.

Gasket match and polishing done.. Off to the machine shop for a 3 angle seat grind and new guides..

Right on! Keep it up, including results!

745TD Build
 

I have read Tom Bryant's posts about matching rods. I wasn't sure how he did it, but your set up looks quite simple. And it looks like you have plenty of rods to choose from. Nice work.

Well the length of the rod is stamped on the cap something like "85" or "116" I'm not sure what that denotes but there's still variances between matched sets from the factory. I'm hoping the piston protrusion on the KS pistons will be all the same too.

I have read a lot of Tom Bryant's posts, that's where I found out about using the early 11mm cylinder heads because of the larger pre-chamber. This will be my first engine build with one of those early heads. Im hoping there's a difference in power like he states, I will also be using the NA cam.

Wow, yes those are a lot of rods! Are they the same as the VW 1.6 4-cylinder diesel engine?

Oh, and that's a very perty engine block you got there! :D