Few lightened flywheel questions - FITTED

[leigh_harty]

My 16v is my daily driver and my commute it 95% carriage way and motorway so the traffic light issue/kangaroo'in isn't that much of a concern. So I'm going for safe performance...

 1, what's a safe weight to be taken down to?
2, any special requirements when fitting? Longer or shorter bolts? Spacers needed? Or just a simple swap around.
3, the place I'm taking the flywheel too are recommended by awesome gti so I presume they know what there doin, but what parts of the flywheel get butchered?
4, I'm putting a new crank seal in and a new oem clutch and again, this should just be replaced as normal and fit correctly to fly?

I've read up about the changed affect in inertia, how does everyone else rate this mod?

I'm all about learning new things so please share your wisdom people.

[Paul86S2]

1. About 5kgs is a safe weight for the 02A lightenend flywheel.
2. It would be wise to fit new VW flywheel bolts and these come with thread lock on them. Only a couple of quid.
3. Read this club gti thread, he did mine and has done lots of others
http://www.clubgti.co.uk/forum/showthread.php?t=200146
4. Yes the standard clutch fits exactly as it does on a standard flywheel.

I've not noticed any traffic light issue / kangaroo in mine. The only issue I've noticed is that the tickover is slightly higher. If you have aircon it will get higher still with the aircon on.
Pick up is a lot quicker and really noticeable in first and second, engine braking is less pronounced with the lightened flywheel but then again you should be using your brakes for that.
I would say this has been the most noticeable performance mod I've made to my car.

Paul

[Ess_Three]

I've not noticed any traffic light issue / kangaroo in mine. The only issue I've noticed is that the tickover is slightly higher. If you have aircon it will get higher still with the aircon on.

You can cut the wire from the switch to the ECU that tells the ECU to select a higher idle speed - then the idle is spot on with a light flywheel. 

[leigh_harty]

I've not noticed any traffic light issue / kangaroo in mine. The only issue I've noticed is that the tickover is slightly higher. If you have aircon it will get higher still with the aircon on.

You can cut the wire from the switch to the ECU that tells the ECU to select a higher idle speed - then the idle is spot on with a light flywheel. 

I have aircon but never on.... and cutting wires? me or the engine will end up dead!

Cheers guys 

[bmw156]

light flywheel for a road car, i wouldnt bother with the hassel IMO.

if the engine is already out then yeh maybe.

and i was always told you shouldnt skim a standard flywheel as they are cast and the material inside might not be brilliant.

also are you going to get it all ballanced right with the crank once skimmed. as i dont fancy a 5kg lump on metal spinning at 6k and wobbling its way off. or tearing its way off.

my mate saw a westerfield chopping in half by a exiting flywheel

[leigh_harty]

gearbox coming off. replacing the crankseal so im putting a new clutch in a lightened flywheel.... ank 6k?... pffft i carry on till 7k   

thanks for your concern though 

[Ess_Three]

and i was always told you shouldnt skim a standard flywheel as they are cast and the material inside might not be brilliant.

Why? Because the cast iron may be liquid inside still?
The flywheel is machined cast iron...so the inside will be just the same as the bit that VW has already machined.
It's perfectly fine to lighten the flywheel - as long as you don't go silly.

also are you going to get it all ballanced right with the crank once skimmed. as i dont fancy a 5kg lump on metal spinning at 6k and wobbling its way off. or tearing its way off.

Do you think VW balance the crank along with the flywheel?
No.

You balance the flywheel...and you are good to go.

[Paul86S2]

Hotgolf who lightened and balanced mine said he checked a few standard flywheels and they all were well out of balance.

I can't see why you wouldn't bother on a road car.

I presume you are worried about flaws in poor castings but if the casting you are lightening is crap then its just as likely to fail before it is lightened.

Paul

[Ess_Three]

Hotgolf who lightened and balanced mine said he checked a few standard flywheels and they all were well out of balance.

He also says that every ABF flywheel he's looked at have the drillings in the same place...which means they aren't dynamically balanced by VW - no surprise there, neither are the cranks.

So if the standard weight flywheel isn't too well balanced, then lightening one and not balancing that wouldn't be any worse, and lightening one and then balancing it would make it better.

I can't see why you wouldn't bother on a road car.

Unless it was for traffic manners...or for someone who has no idea how to modulate a throttle and clutch?

[Wayne]

Nothing wrong with a lightened flywheel if done correctly.