back from the dead.hillfolk is back yall mk2 coop build

[hillfolk'r]

lol.sometimes the simplest things stump ya..i was up at the shop last nite,to get the headlights wired up...simple right?yea it was but im frazzled from work and the crackheads upstairs....
so the other nite i determined that one hot and the ground on the right beam was reversed...so i cut the connectors and swapped em...all set..NOT!!!
so now i texted trevorbr like help!!!!
i was so frazzled i pulled a bulb out and ohmed it out..im still like huh?
go old school and i grab a battery and start hookin wires...so after playin with a hot bright bulb and bein half blind i got the terminal pattern...
if you look at the h4 connecter viewed from the bulb side,its the right term thats earth,not the middle one...so now i cut and reconnect(again) the right connector(it was correct to start)
its the left side that was wrong...so i cut and reconnected that and finally yay they are bright on low beam,and bright on hi beam!!!
i woulda posted last nite but photobucket was messing up...
then i went for a ride down a taxiway around 10pm and freaked out a flock of deer and had like 25 deer run in front of me!!! errrrrrrttttt...guess what the brakes work!!!!almost wadded up sootyvag before i was legal!!!
so heres some pics.....
yay,lights


and i put in the grille and dont look at the tape holding the grille spoiler on temporarily

and of course,the plate..im not sure about leavin it right there.it seems the cops hassle the kids for that around here...
i still gotta drill and mount(heh,mount) the grille spoiler....but of course,the upper left hand grille clip broke,and i crazyglued it,and it broke again..ill hillfolk somethin up for it i guess..then i can put the spoiler on...
i gotta get it on the road,cause one of my pa buddies needs me to come down labor day weekend...


i havent even hooked up the side markers yet..dont know what to dothere..make them work with the blinkers?or work with the city or parking lights and a relay so the also flash with the flashers?lol playin with stupid lights like its a life decision
got a good deal on the side markers tho off ebay..got them and 2 8V emblems for 35 shipped

[theman53]

Whatever you decide post a video. I have marker lights and never put them in. Don't know what to do with them, so whatever you do I will decide if I like it or go a different route.

[hillfolk'r]

hey i got no time to post...sootyvag is on the road!!!!
lol
yea im thinkin to have them on with the city lights,and put relays in so they alternate flash with the blinkers
i saw a wiring thread somewhere years ago on that..i like to make things complicated
i already got some horn toots from the" mk4 punks" too ridin around last night
i got a bunch of stuff to make it a little better..gotta put in the carpet,the recaros,set the toe,and put on the trunk weatherstrip,and rain gutter weatherstripping...but i just had to roll it last night
i told my girl,i got my vw  "member" back last night,u know,the" p" word...and it feels so good!!!

[hillfolk'r]

yay.sootyvag in my driveway finally
i got the recaros and carpet back in
i got a roll of that double sided foil/jute insulation thats been sittin around for a few years i used on the trans tunnel.the orig stuff had all that tar stuff cracking off,but the rest of the floor insulation was in good shape.
i gotta put the rear seat in too.and the only door panel that is in is the drivers side.
and before it rains i gotta install the new raingutter weatherstripping.
from looking it seems like people install it usin crazyglue and not weatherstrip adhesive..any suggestions for a good crazyglue?

[theman53]

I sell this stuff 3M bought and is now scotchweld, but it was called Rite-lok. You should be able to find a loctite equivilant but it is really good stuff. They just set a record not too long ago by picking up a forklift and suspended it for over an hour. I think it is on Youtube. At any rate the general rule of thumb is the thinner the "super glue" the better the bond will be. They set the record with SI-100...stands for surface insensitive 100cps.

[hillfolk'r]

good to know..im gonna look for it..man in a way i miss ohio.i could go to cleveland or akron and find any wierd obscure item i ever needed..now in new york its sort of lame for sourcing supplies.
but anyways ill find it somewhere.
of course i didnt get anything good done today.i pulled the alternator tensioner,and got a nice rumbley bearing.so i took the number off it and will try to get one in my shop tomorrow.i pulled the alternator apart to check the bearings and they were ok.so i cleaned the slip rings and the voltage regulator connections and reinstalled it...maybe it was the rust in the pulley grooves that wiped the new belt i put on.or maybe i didnt retension it soon enough after running it in cause i saw some rubber dust floatin around after a few drives...
so i grabbed a new belt tonite at advance(wow they had one) and put it on at dusk by flashlight in the driveway.then i let it idle for a few mins and retensioned it..id like one a little shorter but at least im not maxed out on the tension and its floppin all over still.so i think ill be good if i replace that tensioner bearing.
i really should swap a tall 5th gear into it.even cruisin 45 zones its singing,and i can cruise main st in 5th gear if i want.its like a truck real short geared.
i should stop complaining hey it looks cool as hell!
id like to finish getting the interior back in before i go to my friends place this weekend
its normally a 2 hr drive.ill figure itll take 2.5
i think the springs are settling in nicely because theres places in the driveway that have peaks and i was kicking the spoiler as i was working on it.ive scraped 1 or 2 times,not bad,but i didnt expect it either.
ill be honest,theres definitely  tire ruts in the driveway making this look exaggerated, but its still hard to get your shoe under the center
slow and low is ok with me....lol i really gotta get that 79 tdi-m running again

[hillfolk'r]

uh oh....i" think" my ip is goin....after i got to pa for the weekend..its gutless...itll rev max rpm,but no power.i looked for suction leaks,found none.fuel line is clear when running...checked lift pump with a vacuum guage,it pulls liklike inches,and i see it pulling fuel..i checked the return banjo..its not blocked.i pulled the sender out of the tank.nice and clean.now,driveability?no missing but part throttle over 2500 its so rattly and pingy..sounds like maybe the advance is stuck?...if you rev it up from odle,its real lazy revving up,like it soes suck air,but again i see no air...tonite ill try running it from a can and maybe pull the" ksb" solenoid from the front of the pump and seeif the advance piston is stickin?
hey if i need the pump redone im sure you guys can help.
i did a cyl drop test all hit fineand my under car water seperator is removed too...
fuel drained from filter was cclean
i see 8v /fury now rebuilds pumps..i just want a stock rebuild nothin special.its been redone once and the place put dual o rings on the throttle shaft,nice feature...
btw its like a" turbo" pump,but has the crap hooked up for altitude compensation instead of boost...its a 91na...want pics lemme know

[hillfolk'r]

well i made a tool(dad did actually) to pull the regulator out...it was intact.i swapped another one..same thing.i can tell when i rev it up,its all slow to rev...i guess im gonna pull the pump off this weekend and tear the top off and the advance covers and see if i can find a problem
heres the tool dad made to grab the 2 flats.a wrench was spreading



my buddy tobster and his new buy,an 84 gti.what a steal.2200$ and its got a built 2.1 and a rebuilt aptuning tranny with a quaife


note the mk2 rocco 16v in his driveway too



sootyvag after he clayed and rubbed out the paint,while i fixed a fuel leak on his gti...lookin sweeeet

[theman53]

I hope you find the IP problem... You don't think it could be a fuel restriction somewhere do you?

[hillfolk'r]

hey thanks for the reminder....i had the sending unit out...free and clear
thanks for reminder cause i took out the check valve at the tank,and i can blow thru it both ways!!i got a new old stock one tho....
yea i blew thru the line from the filter back thru to the tank..yummy tasting fuel.
im using the mk3 tank,the sender/pickup is a little different...
and no air in the clear inlet line when its running...
update tonite:
thanks punkvideo81 (evan)
he has a friend thats gonna sell me a "mk1 rabbit na" pump off a runner for 75 bux...gonna pick it up saturday,yay


hey i got 1 question tho:
the 91 pump has "long" delivery valves,the mk1 rabbit pump has short ones if i remember right...
can i swap the delivery valves and guts from one to the other?

i" think" i got some mk1 rabbit injector lines laying around....well at least i got 3 because i cut one to make an adapter for my bosch pop tester.i only had 1 line that fit the tdi style injectors and they have larger thread.

im sure i can mix and match stuff hopefully to get it right...
i figured swapping the deivery valves would be easiest tho if i cant find a whole set of rabbit/mk1 lines

[theman53]

I know others like Libbydiesel who have swapped the entire delivery valve setup over and had no issues at all. IIRC they swap everything inside the valve not just the outer bodies.

[hillfolk'r]

yes.10-4 copy that big motha trucka 
ill swap over the whole thing.body,spring,valve,and shim or whatever else is floating around in there.
since im bored tonite ill limp it to the shop and install some interior bits.i gotta grab a can of vinyl paint.years ago i was dumb and cut a hole in the drivers side kneebar for the radio and now i dont want it there.i got an extra grey kneebar so ill dye it black.
i dont think ill get ambitious enough to actually put a radio in,so ill fake the hole with the new south guage panel and some nonfunctioning guages

[libbydiesel]

You will need to adjust the max fuel after swapping the delivery valves but after adjustment I have not found any discernible difference in running.  

[vwroadkill]

on the Knee pad that your dyeing black... a cabby should be available.. they fit and you dont have to dye it black..
thanks for your help earlier... hell I got one somewhere around the shop..

[hillfolk'r]

hey no prob on the help earlier...yea i had fun with that pump today,what a! ##%&**&%##$$%%&!!!!!
i got the pump no problem,thank you punkvideo81 from his friend....it was sitting for a few years in a schoolbus/ storage shed:)
i swapped the delivery valves and put the tab on for the solenoid..i brushed the dirt off around the inlet banjo and return and filled it with a combo of atf and diesel..
note:one delivery valve from the 91s pump had the valve stuck in the body.i could push the center with a punch so i let it go
i started on it around 6:15pm,and was done at 12:15am...nice 6 stressful hours...
i had it running by 930,but after a little ride around the shop,i pull back in and its idling and it quit..im like wtf? so i start it and it cranked like it was losin prime and fired..i an around the front and it was gettin lumpy and i saw tons of air in the supply line and it quit again..jeez criminy!!..so dad fires it up and im lookin with a light and theres fuel misting in the air!!!!darn it,darned pump shaft seal!!!i know it looked nasty shoulda changed it on the bench!!!
reason it took so long was it probably took an hour to find my pump gasket kit.i salted it away and hid it on myself....
we" practiced" pulling a seal on an old pump laying around and finally i said lets just go for it...
wait it gets better,i drilled a few holes and threaded a screw in and the screw popped...i finally got it but what a pain...and to top it off putting the new seal in it started ok and got crooked enough i couldnt get it out so i was able to stack washers on the shaft and use the gear to push it in...oh sometimes things go bad from the start...i was tense cause i didnt wanna use dads car to go home and screw up his plans.i just wanted it fixed...maybe not my best moments wrenching but i got it done ok....and yea i turned the fuel in...it felt ok,but the screw was looking at me saying turn me turn me:)
i turned it in to the lock collar,probably a little more than 1/2 a turn and earballed the idle so it wouldnt run away...definately a noticeable improvement and id get a slight little haze when id blip the throttle hard...
i think i need a little more though so its worthy of my" sootyvag" europlate:)
ill see how it hazes during the day.i want enough so i know its a diesel,not like my 79 that makes headlights disappear  at night:)
thank god i had a seal tho or i woulda been stuck like chuck!!