The Rebirth of Smokey Eddy - The 1.9 Saga

[honda_is_the_best]

Today after work im hopefully welding a new downpipe as the one from the 1.6 rubs the bottom of the car at a certain rpm.

Grey_Smoke has been kind enough to send me a passenger fender and turn signal pig tails with his uncle who was visiting and lives near me!! (HURRAY!) for a very reasonable price too, i'm very greatful. I'm meeting his uncle on wednesday to pick them up.

I still need to book a time for the windshield to get replaced. I got extra days this week otherwise it would have been today.

RadoTD came over the other day and we drove each other's cars. There is something special about an AAZ powered Corrado. And his grin while driving my car re-assured me that my hard work might possibly be worth it once the jetta is a little nicer to look at.

I've got plans to paint the interior black as well. My friend tried out this dupli-colour vinyl & carpet paint and it works great on the vinyl - not so great on the carpet. So I think i'll take the seat covers off and the carpet out and soak them in a bath of dye instead of spraying them with a can.

Also, is there any chance that the pushrod in my transmission could be too long for the clutch set up i have? If not, Im thinking i should have found the 210mm plate that the pushrod pushes against. Could the 200mm one im using with the 210mm clutch, P.Plate and FW be fouling it up at all?
the reason i ask is my speedo jumped a couple times on hard accelerations and that clutch should never slip...
Could there be a slipage happening in the transmission anywhere? It definitely takes more torque than the old stock one but my stomach sank when i saw the speedo jump from about 70-80km/h...

ps. Expect to see a pretty sweet update from RadoTD and I. It has to do with intercoolers we're stoked about it.

fuelly is retarded and wont take my trip mileage vs. fuel consumption. it goes off of the odometer reading vs. the previous fill up... which i think is stupid
anyways, i took 2 seconds to figure out my mileage and it is DISSSMALLL

19.0469393 MPG

that's over 12L/100km.

you know ed, i was wondering the same thing. just did a new clutch in the 4 dr rabbit. used an ABA flywheel and pressure plate with the stock 200mm center ring that the push rod pushes against. and i had to let all the adjustment out of my cable to even get the right cable tension.. its not right, i can tell that for sure. but it works grand. i think the 210mm center ring has a little more dish to it, towards the trans side..

and ed, if your clutch were slipping, your speedo would do nothing, because the trans wouldnt be turning, or wouldnt be turning the same speed as the engine. so, if your speedo is jumping around, thats not necessarily a bad thing. it means your tires are breaking loose and spinning. 

[Smokey Eddy]

Oh yeah good point...
could the transmission slip internally?
i just am astounded that my little creation could spin them at 70km/h in 3rd gear. What's that in mph? like 40?

[Smokey Eddy]

Thezorn, thanks for the post. RadoTD showed me the exact same thing last week! Looks like it would work fantastically. I just need to find new fittings to go into my turbo and i'm set. (mine is filled with JB weld)

[honda_is_the_best]

Oh yeah good point...
could the transmission slip internally?
i just am astounded that my little creation could spin them at 70km/h in 3rd gear. What's that in mph? like 40?

usually when the trans slips internally, it doesnt hook back up, you pull the box, open it, and fix all the broken pieces.
spinning at 40 mph doesnt sound out of the question..

[Smokey Eddy]

Figured this needed to be updated since the forum is back

So i just changed (to pass a VI)
Windshield!!! =D
rear drums, wheel cylinders, shoes, front hub, wheel bearings (except for the passenger hub & bearing), lowered the car, finally got an antenna but the cable is too short to reach my deck ...
I also made a lower brace for the intercooler
I put some pins through my bumper because it was messed up
my rear structural bumper had sheared off bolts from me trying to take it off way back when and the shop doing the VI welded (under my instruction) the bumper to the car. I didn't want to deal with drilling and taping. They only charged $40.
i built a sub box and got an 1800watt amp for it. it's in the trunk now.
I added a muffler to my exhaust. This will look familiar. I had it posted in a muffler thread.


I also fixed my license plate lights, side marker light, reverse lights, turn signals & headlight switch.

I just bought a remote start from canadian tire (so its a crappier "Prostart" brand but i made sure it was warrantied). Will do a write up on the wiring for that for those interested. The point is that on the chair lift going up for my last run of the day I can start the car and it will idle until i get down and hopefully have melted any snow on it and warmed up a little.

Also, will be using RadoTD's boost controller. He said he'd make one up at work one day! =) I'm still limited by boost pressure. I don't like to push my T3 much at all past 20psi. I think i'll set my controller to 16 or 18 pounds.

[Smokey Eddy]

And this will hopefully be my new downpipe soon...

[8v-of-fury]

EDNA, looking guuud buudddy.

Me are be liking the boost piping! Is it mandrel bent exhaust tubing? Hows the AAZ treating you, and what size is that DP gonna be? Either way man gonna be nice.

[Smokey Eddy]

It's an intercooler kit from ebay. Its all aluminum. The exhaust is 2.5" ID. I have to ream out two of the stud holes though. sigh. i tried yesterday and filled my hands with steel slivers using my dremel
RadoTD is coming over tomorrow with his dye grinder (spelling?) anyways should get sped up after tomorrow. He is also going to help me cut the pipe for the down pipe and then weld it at work.

[Smokey Eddy]

ok he just texted me literally 5 seconds ago saying he stole a welder from work and is bringing it tomorrow...

[Smokey Eddy]

Oh about the aaz uhm... its got less "zip" than the half breed like i've been saying but it torques the @!#$% out of the tires in like 4th and 5th gears... since my speedo and everything will be working i'll post some videos of it slipping the tires like crazy on damp pavement at like 80km/hr.

[Thezorn]

Oh about the aaz uhm... its got less "zip" than the half breed like i've been saying but it torques the @!#$% out of the tires in like 4th and 5th gears... since my speedo and everything will be working i'll post some videos of it slipping the tires like crazy on damp pavement at like 80km/hr.

Where did you pick up those mandel bends Eddie? was it local? im looking for the exactly the same stuff.

[Smokey Eddy]

The exhaust, Lordco. The aluminum, eBay.
The exhaust was two 180 degree bends.

[Thezorn]

The exhaust, Lordco. The aluminum, eBay.
The exhaust was two 180 degree bends.

The exhaust is what I was intersted in. Thank you sir. Ill give lordco a call on tuesday. where they farley cheap?

[Smokey Eddy]

Ah Chris farley how we miss him.
Yeah they gave me some sort of discount. Like 15$ each or something.

[Smokey Eddy]

As promised, thanks to RadoTD:

I'm proud of my self for this weld having not a welder for my self and for being buttwelds i think it turned out really well!
I blame the Argon for such clean welds.


I got the parts from Lordco Autoparts.
The parts exluding the flange (i recommend sourcing a better one than mine as it had to be modified to clear the waste gate plate on my T3. It also didn't match the holes perfectly) are as follows:
Line. Part number. Item. List Price.
171. 42322. U-Bend Pipe. $41.99
VIB. 4556. SS Flex Coup. $87.99

I paid roughly 50% of the list price for the items. I got 2 U-bends.

One bend we cut a 117 degree bend and from and the other U a 90 degree bend.
The flange is offset from perpendicular to the flex (the straight part that goes under the car) by 27 degrees.

Why get 2 u-bends then? because you're almost guaranteed to EFF it up at least once.

Tools required: angle grinder with at least one cutting disk and one grinding disk. A protractor. A paint pen. A tri-square helps. So does a regular square. Any straight edge. We used a level in combination with the grinding disk on the grinder to do the fine touches. A welder. MIG worked really well with Argon/CO2 as our inhibitor. RadoTD told me the ratio but i forgot already. It's the recommended mix for steel.

If you can rent or borrow a MIG welder i strongly recommend doing so to make your down pipe. it took us an astonishingly small amount of time since we had the angles and measurements to follow from my old refrigerant pipe down pipe.
MIG is very easy to set up and even easier to use.
My past experiences have been using shielded flux wire which was messy and terrible. The inert gas welding was completely different.