Top Gear America's Project Sipster adds 2003 TDI engine to 1981 Rabbit

Click above and to watch video after the jump
Project Sipster is now officially underway. This conversion of a 1981 Volkswagen Rabbit into a fast and frugal 70-mpg diesel car is Top Gear America's way of saying hello to the revived eco-car mindset. In the latest installment of the series, the Rabbit gets an engine transplant courtesy of CWS Tuning in Regina, Canada. One way to help boost the Rabbit's original 50 mpg up to 70 is to mismatch a transmission from a 1998 TDI to a donor engine from a 2003 Jetta TDI in order to increase the gear ratio. CWS Tuning mechanic Cam Waugh should be able to do this, but it'll be no easy task. But why listen to me describe the muddle they're making of things when Top Gear America has already written everything up nice and neat – oh, and provided a video, as well. You can watch it after the jump and be very glad you're not responsible for patching all this up into a roadworthy vehicle.
Gallery: Top Gear America Project Sipster
[Source: Top Gear America]
Reader Comments (Page 1 of 1)
bearclaws8 7:56PM (3/05/2009)
I did post this before but;
I know we're still waiting for TopGear America to get a home, and call me crazy, but I think it should be on PBS. All of the cable outlets will just spoil it with their sponsors influences. There are quite a few good shows on PBS (This Old House, NOVA) and a quality program like this could easily follow the original model (even w/o or limited commercials!). And it would be available to everyone, no need for cable or satellite and totally available in HD!
The downside? Well to keep it commercial free or limited commercials it would require the backers of TGA to help sponsor PBS (or so one would assume). But then again I'd be willing to donate to PBS to get such an amazing show on air. Call me crazy but I think this may be the best way to get TGA to everyone, HD, and limit the amount sponsors control the content.
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jharlan 8:55PM (3/05/2009)
This is great. Knowledge is power. Why are we in the US getting mediocre gasoline engine offerings while the Europeans are offered modern diesels in practically every model? We need to raise hell about this. Our suppliers and their captive politicians are not supplying what we want, and if we have to buy German cars to get modern technology, so be it!
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DasGluten 11:55AM (3/06/2009)
There are many reasons why diesel isn't as prevalent in the US as it is in Europe. The first being that most of the driving done in Europe is in cities with stop and go traffic, something that diesels do very well. Think of how most school buses are diesel. If everyone just started driving on the interstate with diesels, while they would still be getting decent milage, it wouldn't be the same as European models. The main reason diesels haven't been implemented in the US though is because of emission standards. In Europe, because of the price of gas, fuel milage is preferred over lowering emissions. While there are close to emissionless diesel fuels out there, they are not available enough for diesels to be considered low emissions. A final point is that there are not nearly as many diesel stations in the US as there are in Europe. To add to that, diesel in America can cost nearly a dollar more where I'm from. Go to your local gas station (if it has diesel) and tell me if you'd rather be paying that price. When I can get a Ford Focus for $16,000 which gets 35mpg on regular gas diesel just doesn't provide enough benefits to be worth it, yet. I think if some American car makers got on board with diesel, we could see a benefit in 5-10 years but it might be too late at that point. It comes down to where companies want to spend their research and marketing budget and, in their eyes, it's just not worth it in the US.
harlanx6 12:27PM (3/06/2009)
DasGluten: An interesting perspective, but you failed to make your case. Whether or not we drive diesels in the US should be decided by the drivers, not an overbearing government. Everyone I have talked to with a VW TDI wouldn't trade it for a Prius.
montoym 2:38AM (3/09/2009)
@ DasGluten:
It's amazing how far off you are in your assessment.
Diesels actually do far better on the open road than they do in city driving(i.e. stop and go traffic).
In regards to your school bus comment, I suspect that diesels are often chosen for the same reason that semi-trucks and other large equipment use diesel engines virtually across the board. Diesels are very good at moving large, heavy loads efficiently. At least more efficiently than a comparably-powered gasoline engine could do in the same role. It has very little to do with the stop and go aspect. Reliabilty also has a lot to do with it. Commercial diesel engines can often be used for millions of miles thus reducing replacement costs compared to a gasoline engine over the same stretch.
Secondly, your statement regarding diesel fuel costs is mostly irrelevant since the price spikes are hardly common and historical data shows diesel to be priced competitively to gasoline in the long-run. A short-term large price discrepancy is largely anecdotal and hardly proves what should be expected in the future.
Not to mention that I'm curious where you are from since in my area diesel is rivaling the price of Premium gasoline in most areas(under $2/gal) and even nationally is only about 16cents higher than regular gasoline($2.08/gal vs. $1.93/gal. from http://tonto.eia.doe.gov/dnav/pet/pet_pri_gnd_dcus_nus_w.htm). Far less than the $1/gal you claim and well within the range of making diesel a good economic choice compared to gasoline.
Michael Hippenhammer 9:04PM (3/05/2009)
I think this project makes a lot of sense. First, recycle reuse, second, the weight reduction alone should make this posible. Our 1983 Jetta diesel got a best of 54mpg of course the speed limit was 55 back then but, I drove an average of 63 mph. Now with more power and a more efficient engine and better emmisions and better gear ratio we can see what a light weight car can do with todays technology.
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russellgeister 10:11PM (3/05/2009)
your kidding whilst eco friendly its not safety friendly cars do age and as they do the body and chassis suffers on going stress eventually they lose structural integrity.is thing is 28 years old it should have been recycled eighteen years ago.
Michael Hippenhammer 12:42AM (3/06/2009)
All my Volkswagens have gone through my torturous ownership and all performed well and went on to new owners who drove them for a long time. My vanagon syncro is 23 years old and I trust it with my life. I ride motorcycels, snowboard jumping off cliffs and mountain bike hard. Safety? Don't be such a wuss. This type of project is not for everyone so don't worry it is not going to be a pandemic problem of mass death from people driving light weight cars from the past. Until the car companies can do something about the bloated weight of todays cars we can only use what we have.
Rain 10:49PM (3/05/2009)
They will destroy that engine lugging it with too tall a gear and I imagine the clutch would be short lived with the added up/down shifting.
Diesels do not tolerate lugging.
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jjcarr 8:55AM (3/06/2009)
Diesels do not tolerate lugging? What planet is that true on?
A redline of 4500rpm, ideally used in low-rpm torque intensive applications, peak torque at 1,300rpm. A design of motor that is FAMOUS for lugging. As someone who's owned several diesels, and worked on them, I can tell you that you're flat out wrong.
Rain 2:42AM (3/07/2009)
Well,JJ.
You sound as if You are convinced that lugging a diesel engine is not harmful in the slightest.
Lug away and wrap that mother out if You desire.
I'm not selling a thing but then neither am I buying,so Happy Motoring!
montoym 3:01AM (3/09/2009)
What they are doing hardly consistutes lugging. I think you are confused by the term lugging and what it actually means. It really has far more to do with driver operation and choosing a gear that's too high for the given task.
Just simply choosing higher ratios than stock for a transmission will not automatically cause that engine to be lugged. Provided the chosen ratios are not massively different such as replacing the 1st, 2nd, and 3rd gears in a car with the 4th, 5th, and 6th gears from that car. In such a case, trying to drive the car around(particularly just getting it up to a moderate speed) would be a chore and would likely cause the engine to lug quite often due to being in too high a gear virtually all the time. But, that's an extreme circumstance and not even remotely comparable to what is going on here.
For one, they are using the tranmsission from another TDI model, one which uses the same 1.9L engine as the '03 models as well. VW's engineers sure felt it fine to offer their 1998 TDI's with that transmission and didn't consider it as lugging the engine.
Additionally, the car that this engine/tranny combo is going into is much, much lighter than either a 1998 or 2003 TDI, so I really doubt the car will be working much harder utilizing the taller gear ratios they have chosen for the car.
montoym 3:26AM (3/09/2009)
I also found a few links to help explain lugging to those who might not understand what it is. Also note that neither link mentions anything about the chosen ratios in a transmission being too tall, just the driver choosing a gear that's too high.
In other words, in virtually all cases(except extreme circumstances like my example above), lugging can be solved by simply downshifting to a lower gear.
Both links reference The "Car Talk" guys Tom and Ray, but I think they give a good explanation of things in laymen's terms.
http://www.cartalk.com/content/columns/Archive/2005/August/07.html
http://www.cartalk.com/content/columns/Archive/2008/November/02.html
Roland 10:13AM (3/06/2009)
"Diesels do not tolerate lugging"
My VM Motori 2.8L I4 in my Jeep Liberty SUV gets its bet mileage in "Tall Gear"(overdrive, 5th gear) at 1600 RPM and 62 MPH. There the MPG's get into the low 30's.
Diesels love to do lugging - max torque at low RPM's.
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usbseawolf2000 11:22AM (3/06/2009)
The "eco-mindset" they are trying to set is a bad one.
Caring only the MPG while ignoring the performance, emission and safety (compromise) is not "eco-mindset". It is more like "eco-ignorance".
This may be a nice project for the high school to learn about the trade-off in the traditional engineering.
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