It is tough to weld cast, I would just bolt it together and maybe run a gasket on the turbo and exhaust mani side. I think crazy andy used 3/8" but 1/2" would work too right in between the turbo and mani and it shouldn't get you into trouble on the firewall at all.
Quote from: theman53 on February 27, 2014, 07:51:18 amIt is tough to weld cast, I would just bolt it together and maybe run a gasket on the turbo and exhaust mani side. I think crazy andy used 3/8" but 1/2" would work too right in between the turbo and mani and it shouldn't get you into trouble on the firewall at all.To answer the concern at hand, I used a 3/8" exhaust flange water jet cut from mild steel, ran gaskets on each side, adn used longer studs. It fits in a MK1 with plenty of room between it and the firewall.http://www.mandrel-bends.com/catalog/flanges-gaskets-36/header-flanges-194/volkswagen-209/volkswagen-8v-one-piece-header-flange-1-2-mild-steel-2358.htmlGood choice on the Volvo oil cooler; I had to go aftermarket since there are no Volvos of that vintage in the local yards.
Also kept snapping off the front crankshaft oil seal flange bolts. Snapped two of the smaller ones when I tried torquing them to 15 foot pounds. Still not sure what's going on there? Ran down to the junkyard and salvaged some bolts for the rear seal. We'll see if that one goes easier.
Quote from: mcpook on April 02, 2014, 11:36:27 amAlso kept snapping off the front crankshaft oil seal flange bolts. Snapped two of the smaller ones when I tried torquing them to 15 foot pounds. Still not sure what's going on there? Ran down to the junkyard and salvaged some bolts for the rear seal. We'll see if that one goes easier. Those bolts don't go to 15 ft-lbs, I don't recall the spec off hand but it is more like 7 ft-lbs. If I recall correctly there is one or two larger bolts on the flange, those have a higher torque spec (around 15 ft-lbs) but the others are all much less.I did EXACTLY the same thing assembling my TDI a few weeks ago. Replaced them with new bolts from my FLAPS after we noticed it didn't feel right torquing up.
Washer on the dipstick tube is normal, it retains an oring in the bore.Excellent pix, by the way.
hm, prothe pistons?
hey, what fittings did you use for the valve cover breather?
...BTW your Bieber avatar is awesome.-Malone
I did similar, but I made a new plate and tapped it for the pipe fitting. If you have a leak around that area, don't immediately blame the gasket. Welds are sometimes hard to get leak proof without grinding the stops and starts...it doesn't look like he did, but if he welded both sides you should be fine.