Author Topic: ~My 91 GLI to 1.6TD conversion build up~ (Read 100629 times)

53 willys · « **Reply #105 on:** October 24, 2008, 10:29:10 am »

here is a few shots of the single round headlight conversion I did (smoked E-codes).....I made/converted my square headlight radiator support to a round.....it was a PITA!!
also you can see my intercooler piping...

adjustable intercooler bracket

53 willys · « **Reply #106 on:** October 24, 2008, 10:31:54 am »

Quote from: "zukgod1"

Quote from: "53 willys"
well I got it running and driving.......problem is when I pulled it out of the shop last night to drive it.

I go around the block 2 times...on the 3rd run the heater core blew open and filled my car with coolant :cry:

the other problem is it feels like I am not getting into 1st gear...the shifter is all the way over but it feels like 3rd when I take off...maybe my trans linkage is out of adjustment???

pretty bummed about it....I wanted to have this car done but now I gotta go back to my regular job...

Trans linkage is a pain in the ass to adjust without that little tool but we can get it.

The heater core is another story.
I don't want to bum you out more but that's not a fun job. Have to completely remove the dash so don't be reassembling anything up there right now.

I suspect maybe the necks got weakend when you replaced the hoses, they are famous for leaking after being messed with.

Good new is you have a guide, been there done that so no worries.
Let em know when you are going to start on it and I'll see if I can come help. Now that I've done it I don't think it's that bad but that first dash swap was nerve racking.

At least it runs so you are on the correct path. It's all the little things that seem to take up the time.

thanks Dan!!
I have been calling around to find a ALL metal heatercore....are the replacements all metal or are they plastic like stock?

I HATE plastic heatercores!!!!

thanks for all your help Dan

zukgod1 · « **Reply #107 on:** October 24, 2008, 10:48:42 am »

I doubt you would have a problem with the plastic core Mark.

Once it's in there it wont get any abuse..

Pick one up and I'll do my best to come by and assist.

I was able to get that trans about 90% assembled last night so I HAVE to get that van done and out of my driveway ASAP..

arb · « **Reply #108 on:** October 24, 2008, 11:20:10 am »

Looks great ! Where did you get your blue intercooler hose ?

53 willys · « **Reply #109 on:** October 24, 2008, 11:33:53 am »

Quote from: "arb"

Looks great ! Where did you get your blue intercooler hose ?

thanks!
the blue intercooler hose came from an Ebay seller..."just intercoolers" the guy who owns it is an ASS...but the prices cant be beat....I REALLY wanted Black or red hose for my project...but the price of the "just intercooler" kit was sooo cheap that I could not resist...if I wanted red or black hose it would have cost me a extra $100+ the ebay seller only has blue hose....
also check out siliconintakes.com...lots of good stuff on there and fast shipping too

zukgod1 · « **Reply #110 on:** October 24, 2008, 11:34:59 am »

Quote from: "arb"

Looks great ! Where did you get your blue intercooler hose ?

http://stores.ebay.com/Just-Intercoolers

Smokey Eddy · « **Reply #111 on:** October 24, 2008, 02:03:39 pm »

That looks SO perfect. I wonder how much that has increased in value... Invaluable!!!

53 willys · « **Reply #112 on:** October 24, 2008, 03:54:22 pm »

Quote from: "Smokey Eddy"

That looks SO perfect. I wonder how much that has increased in value... Invaluable!!!

thanks buddy! I'm pretty happy with the way it's turned out

BTW if you want a sticker or two let me know :wink:

53 willys · « **Reply #113 on:** October 24, 2008, 03:58:03 pm »

new glow plug relay is on it's way my Deutz relay did not work right...
I also have a new heater core $45...it's at the shop...I will hopefully get this car ready by the beginning of next week....

Dan I need your help adjusting the shifter linkage....I dont have the little VW shifter plate....do we need it???

zukgod1 · « **Reply #114 on:** October 24, 2008, 04:31:10 pm »

Quote from: "53 willys"

new glow plug relay is on it's way my Deutz relay did not work right...
I also have a new heater core $45...it's at the shop...I will hopefully get this car ready by the beginning of next week....
Dan I need your help adjusting the shifter linkage....I dont have the little VW shifter plate....do we need it???

I don't have one either, we can get it adjusted.

TurboJ · « **Reply #115 on:** October 24, 2008, 05:26:36 pm »

That's looking really good! Congrats!

BTW; I hope you will soon send pictures of your front bumper with the new I/C in place. Is it going to fit with the original 'big bumper'?
Interested since I have a similar intercooler for my Jetta too.

zukgod1 · « **Reply #116 on:** October 24, 2008, 06:03:47 pm »

Quote from: "libbybapa"

http://www.vwdieselparts.com/forum/viewtopic.php?t=7676

The link within the link is broken.

Meaning the link over at vwdieselparts is broken.

53 willys · « **Reply #117 on:** October 24, 2008, 08:23:26 pm »

Quote from: "TurboJ"

That's looking really good! Congrats!

BTW; I hope you will soon send pictures of your front bumper with the new I/C in place. Is it going to fit with the original 'big bumper'?
Interested since I have a similar intercooler for my Jetta too.

Thanks
yeah the IC fits just fine with the stock big bumper....I did have to do some trimming tho....but it is very minimal......looks stock IMHO
I will post some pics in the next day or so...

53 willys · « **Reply #118 on:** October 26, 2008, 02:12:03 pm »

Quote from: "libbybapa"

VWCaddy's link is still good in that thread.

Here it is to save clicking.

This is the 150 DPI scan of the actual tool on Roger Brown's site. You should just be able to Right-click and Save As and print it out 1 to 1 on card stock, etc.

Andrew

thanks Andrew!!! that's sweet!.....problem is I cant get it to print the right size :oops: ....do VW dealers stock this tool?? is it spendy?

53 willys · « **Reply #119 on:** October 26, 2008, 02:36:23 pm »

Well I got the heater core out!! WHAT A PITA!!! I was getting WAAAAAY pissed trying to get it out with the dash in....I finally just pulled the whole dash out..it made it MUCH easier then...

I saw and read the heater box rebuild write up on vortex...my heater box foam was falling apart and rotting BAD...so I decided to rebuild it this week end..this is what it looks like right now. I still gotta cut out the foam sticker sheets...supposedly walmart selling all colors with sticky backs...I could only find the "assorted colors pak" with sticky backs....so I will have a black, red and blue door on my box! :lol: no biggie nobody but the people reading this will know..lol foam sticky back pak was $2.68.

here are the parts...

I also pulled the cluster out to do the gas to diesel tach conversion...problem is nobody has any info on modding the MFA style tachs

I was kinda anticipating this so I bought a "parts diesel KMH Canadian cluster" form "Burn your money" I thought I might be able to mix and match some parts but the cluster I had was VDO/MFA and the diesel cluster I got from Tyler was motometer/non MFA
soooo I had to just swap the cluster housings..the parts cluster had a crack in the clear plastic.

at first I really wanted to keep the white face gauges I had.....but now that I look at the black I think I like the black better

but now I gotta sale the white pyro and boost I just bought

so PM me if you want a smoking deal on some new white faced isspro gauges..

old cluster..16v gas

new diesel cluster with tach...I should probably get a MPH odo for it....but I'm kinda digging the KMH odo...it gives it a euro feel :lol: