Mk1 Golf conversion to VNT diesel power - page 1 - Upgrades (non engine related ) - VWDiesel.net The IDI, TDI, and mTDI source.

• Mk1 Golf conversion to VNT diesel power by regcheeseman on 27 Apr, 2010 18:45
• Seeing as I'm detailing other bitts of this project elsewhere on here, some may be interested in the intended recipient...
  
  Started out as a 1983 1300cc mk1 Golf Driver
  
  
  Taken home and stripped out
  
  
  Rolled and bits restored
  
  
  
  Notched chassis rails to slam it.
  
  
  Vinegar soaked and 'rustbuster' epoxy masticed
  
  
  Starting to remove seam sealer and attack rust
  
  
  Get 'em started young
  
  
  lots and lots and lots of holes welded up, seams welded paint stripped
  
  
• #1 by 745 turbogreasel on 27 Apr, 2010 18:56
• Nothing cleans like a lot of paint!
• #2 by regcheeseman on 27 Apr, 2010 18:58
• Big hole cut out
  
  
  Big hole filled - note RHD car now has direct action brake servo (a big one too)
  
  
  More epoxy mastic
  
  
  Filler
  
  
  more paint
  
  
  Not happy with the slam panel - so plated that as well.
  
  
  All wiring hidden under wing
  
  
  Tidied
  
  
  Modified my ebay cheapy IC with a simple stencil  
  
  
  Breaks cover for a quick photocall
  
  
  Home made wheels - spot the mistake?  
  
  
  
  
• #3 by rallydiesel on 27 Apr, 2010 19:52
• I've gotta get me a Rabbit. I'm jealous of your build.
  
  As for the wheels, is the channel too far in the centre of the barrel? Would that make it difficult to get the tire on?
• #4 by rabbitman on 27 Apr, 2010 23:25
• Wow that's nice , how long did it take to get to that point?
  
  What coilovers are those?
  
  I like the wiring job, it always bugged me how they run right across the engine bay.
  
  What's that bottle under the left fender?
  
  Nice work, keep it up
• #5 by regcheeseman on 28 Apr, 2010 03:33
• Quote

  As for the wheels, is the channel too far in the centre of the barrel? Would that make it difficult to get the tire on?

  
  Difficult? - No, impossible. 
  
  

  Quote

  What coilovers are those?

  
  Ebay cheapys that came still wrapped in a box in the back of the car.
  
  

  Quote

  What's that bottle under the left fender?

  
  I could lie and say water injection - but in reality, I messed up. 
  It was due to be an expansion/overflow for the radiator - I'd assumed the top fill rad had an overflow at atmospheric pressure like a motorbike setup - it doesn't so the bottle is now removed and sat in the garage cupboard.
  
  
  
• #6 by regcheeseman on 12 May, 2010 08:01
• Few more pictures of progress
  
  Rear end
  
  
  Front end, my IC fun wasn't completely wasted. Shame about the dog poo bags!
  
  
  One manky gearbox tidied up
  
  
  Block well on the way (WAITING FOR GIRDLE!!!!!)
  
  
  Marked up the manifolds for some port matching and a bit of flow work.
  
  
  Finally - toys. mmmmwahahahahahahahahahahaha!
  
  1Y/AAZ head, 1Y manifold, MK4 VNT turbo, MLS gasket, ARP studs
• #7 by Turbinepowered on 12 May, 2010 11:17
• Wonder how long that's all going to stay white.... 
  
  Lookin good!
• #8 by regcheeseman on 27 May, 2011 18:37
• Ok, I'd forgotten the thread so by way of a little update....
  
  

  Quote

  Wonder how long that's all going to stay white....

  
  Not long....
  
  
  The more I looked at the white and black the more I disliked it.
  
  knocked myself a pump together out of a few old pumps, few hours of swearing, and fiddly assembly.
  
  
  
  Lot's of cleaning, rubbing down, spraying, polishing to get to this stage
  
  It's AAZ based, got a 10mm head from a TDI (up from 8mm), running on the AAZ camplate and set up with 1.10 mm lift.
  It's got a GTD boost pin and spring, gov mod and aaz limiter blanked off.
  
  Started to put he headlining in, ignored advice and did it my usual way, fitted the back, pulled the front taut and glued that, held nicely by bulldog clips bought from staples. Then did the side, I'm well happy, no creases or sags.
  
  
  made some custom rear 'door' cards
  
  
  painted my inlet manifold.
  
  
  Got dish?
  
  
  Had to push the Golf out into the sun, the calipers are on, maybe a bit 'barry' but I like them
  
  
  My boy was straight in it, cool kid.
  
  
  And the rear end just gets better with fat rubber to beef it up
  
  
  Engine going in next week 
• #9 by regcheeseman on 29 May, 2011 19:04
• A few more hours work and the motor is off the stand and ready to go in.
  
  Red clutch should give me at least another 20 brake.
• #10 by regcheeseman on 31 May, 2011 06:54
• My sketchy 20 year old engine hoist got put into use, this was bought by my cheapskate parents from god knows where (£1 shop?) and is actually sold as an engine hoist. It consists of a a few tiny pulleys and some worn looking thin cord.
  However, as it's done many times before, it lifted a motor and gearbox in.
  
  
  After a few minutes faffing the first mounting bolt slipped home and the gearbox mount temporarily made with some webbing. The hoist can be removed
  
  
  All is not sweetness and light, the oh so easy gearbox mount is 55mm away from where it should be so it's back to plan A - make it from worthing caddy's pattern.
  
  
  And the alt fouls the oil cooler by about 3mm. so that has to be cut out. 
  
• #11 by Grey_Smoke on 31 May, 2011 15:33
• WOW, that engine bay looks good!!!!!!  eh, scrap good, it look amazing!!
• #12 by rallydiesel on 31 May, 2011 17:02
• Looks great.
• #13 by regcheeseman on 28 Jun, 2011 17:58
• My turbo VNT linkage has been modified to suit the bowden cable operation.
  
  
  
  Not happy with the arrangement for the sensors, so I went and bought some decent tees in the right size.
  
  Finished the first stage of the exhaust, just got to add the hangers and tidy it up a bit.
  
  2.5" from turbo to rear beam (and potential for a straight through side exit pipe )
  And then a 2" system and token silencer box and discreet turndown exit
  
  All in stainless, the manky bit is an pre-used section cut from an old downpipe but it'll clean up like the rest
  
  Bored of waiting for bits to turn up and needing to get into the loft I had to take the car off the stack of blocks it's sat on for 2 weeks and get it out of the garage.
  
  Certainly sits a bit better with some weight in the front
  
  
  With the loft sorted and rain threatening I tried to push the car away again. (here's where I start collecting scene points by the bucketload)
  
  
  It wont go back in the garage, the less than 2" tall step up is whacking the sump, I ended up fashioning ramps to put it away.
  
  
  
  Exhaust is finished and wrapped, had to make a bracket to keep the gearchange cables out the way.
  Wired the turbo sensors, made the cables for the VNT
  Fitted the spangly new clutch hose - thanks to http://www.helcarkits.co.uk/
  
  
  
• #14 by rallydiesel on 28 Jun, 2011 20:22
• I love it all!