Author Topic: Franken-TD for an '84 Coupe: Like i need another hole in my build thread  (Read 66493 times)

Reply #225November 23, 2014, 12:30:51 pm

TimpanogosSlim

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Re: Franken-TD for an '84 Coupe: Like i need another hole in my build thread
« Reply #225 on: November 23, 2014, 12:30:51 pm »
Just took my coupe on it's 2nd outing! Down around the corner to fill up the tank. 6.75 gallons of diesel + a couple three ounces of power service winter additive.

Still don't have the clutch adjusted right, still battling air in the injection system, steering is way stiff with the belt off the power steering pump (need to look into that again).

I'm not entirely sure i got the speedo cable attached right. Frozen fingers.

Saw EGTs as high as 600f, but this was a very short drive. And there is no exhaust system post-turbo. Mostly I'm just happy the EGT gauge is working. I spent $20 on a 90's vintage DEFI gauge, including shipping! And then about $80 on the probe, including fittings, etc.

The exhaust coming through the rain tray is pretty bad, especially where the windows are so hard to roll down. Need a DP fabricated in the worst way, but i want to install a 'rocco k-bar or eurosportacc 4-point lower stress bar first, so the fabricator knows what he has to fit around.

Oil pressure gauge seems to be working normally but I'm about to buy a real VDO gauge and sender from egauges


Reply #226November 23, 2014, 06:36:34 pm

TimpanogosSlim

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Re: Franken-TD for an '84 Coupe: Like i need another hole in my build thread
« Reply #226 on: November 23, 2014, 06:36:34 pm »
Have i mentioned that i hate the alternator bracket i have? I have the arrangement where the alternator has to come up against gravity to tension the belt. Apparently it slipped and fell during my quick drive to the filling station.

So yeah no water pump either, but the whole drive was about a quarter mile.

I got back under the car and re-tensioned the belt and put several more pounds of torque on the adjuster bolt.

Gonna have to find a way to pull it up toward the IP bracket. Probably build something i can tension with a turnbuckle.

I mean for now. Come spring i will be looking into retrofitting AC, and I'll invest in Mk2 alt bracket, bigger alt, etc.

Also, considering i drove about a total of a quarter mile, i'm a little surprised that i was already spotted by a local vw enthusiast that i vaguely know. Not a lot of coupes out there.
« Last Edit: November 23, 2014, 07:27:49 pm by TimpanogosSlim »

Reply #227November 26, 2014, 11:45:58 pm

TimpanogosSlim

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Re: Franken-TD for an '84 Coupe: Like i need another hole in my build thread
« Reply #227 on: November 26, 2014, 11:45:58 pm »
In the rain the other day, determined that the taillight gaskets are a major point of ingress for water in the trunk. The left one got doubled up with 1/4" high density weatherstripping which seems to have sealed it well. Gonna do the other on black friday, and do the gasket on the trunk lock button at the same time.

Also have new license plate lights. Both of the original ones are cracked and missing chunks.

So close. So many little things to deal with.

Ordered the lower front 4-point brace from eurosport accessories today, on sale for about $150 + ship. Doing this first before sways because i want whoever fabricates my downpipe to deal with clearance issues right up front.

Also because i have bad cornering habits and don't want to wreck the frame.

Reply #228November 28, 2014, 04:00:28 pm

TimpanogosSlim

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Re: Franken-TD for an '84 Coupe: Like i need another hole in my build thread
« Reply #228 on: November 28, 2014, 04:00:28 pm »
Got the power steering belt back on. It's slipping and squealing on hard turns. I sort of don't want to give up the power steering even though i have a manual rack complete with the bottom link and weather boot, just needs some new rods.

Went and showed it off to friends.

About 6 miles on this build now.

There seems to be some smoke rising near the fan, but only when i'm not moving, and I wonder if it's just my exhaust exits there. Nothing seems scary hot. No burnt wires.

Further update: Found the PS reservoir below minimum, filled to max with dexron.

fyi i saw EGTs as high as 600f and as much as 3lb of boost, but i was just tooling around side roads at up to 35mph.

No smoke once it's warmed up. Has to be pretty warm before i can push the cold start back in and not smoke and/or struggle though. I may need to advance the timing a bit.
« Last Edit: November 28, 2014, 07:46:50 pm by TimpanogosSlim »

Reply #229November 29, 2014, 01:53:32 am

vanbcguy

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Re: Franken-TD for an '84 Coupe: Like i need another hole in my build thread
« Reply #229 on: November 29, 2014, 01:53:32 am »
Further update: Found the PS reservoir below minimum, filled to max with dexron.

For what it's worth, VW uses a special power steering fluid that's not compatible with much else.  Might want to check on that fluid choice...  VW uses a partially or fully synthetic hydraulic fluid depending on the year, it is nowhere near the same as what North American built cars use.  Pentosin CHF-11S is the most common.

VW power steering pumps are expensive - they also generally never fail when the correct fluid is used.
Bryn

1994 Jetta - AHU M-TDI - Jezebel Jetta
2004 Jetta Wagon - 1.8T - Blitzen

Reply #230November 29, 2014, 04:09:15 am

TimpanogosSlim

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Re: Franken-TD for an '84 Coupe: Like i need another hole in my build thread
« Reply #230 on: November 29, 2014, 04:09:15 am »
The cap on the reservoir says "USE ONLY ATF-1" in stark contrast to what is said in the bentley about never using ATF.

Near as i can tell, that basically means dexron.

More confusingly, when i started looking up the fluids listed in the bentley, the non-vw ones that still exist appear to be classed as automatic transmission fluids by their manufacturers.

I don't have an owner's manual in the car. It's a 1984 jetta deluxe diesel and a lot of parts are stamped 11/83.

.:Sent by pneumatic tubes


Reply #231November 29, 2014, 04:29:06 am

TimpanogosSlim

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Re: Franken-TD for an '84 Coupe: Like i need another hole in my build thread
« Reply #231 on: November 29, 2014, 04:29:06 am »
It does seem likely that they mean pentosin atf1, which is yellowish. What i found in the reservoir was red.

.:Sent by pneumatic tubes


Reply #232November 29, 2014, 11:13:31 am

TimpanogosSlim

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Re: Franken-TD for an '84 Coupe: Like i need another hole in my build thread
« Reply #232 on: November 29, 2014, 11:13:31 am »
With the reservoir topped up and the belt a little more tensioned the power steering seems to work fine.

Verified that the tank sender is completely dead. Open circuit with the ohm meter.

Reply #233November 29, 2014, 05:56:50 pm

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Re: Franken-TD for an '84 Coupe: Like i need another hole in my build thread
« Reply #233 on: November 29, 2014, 05:56:50 pm »
Turned up the fuel a bit and took it for another spin. Thought I'd go up the hill and see about buying some strut dust caps from rabbid

I'm seeing the same EGTs peaking at about 600f on my vintage jdm boy racer egt gauge, now boosting to about 10psi which might be where my nxs manual boost controller is set - dunno really. I haven't messed with it's setting since it arrived.

Making good power, no smoke when warmed up so i might turn it up again.

Sometimes it doesn't even want to start without the cold start lever pulled out. More evidence i may need to nudge up the timing.

Made it about half way up the hill when the outlet hose on the oil cooler slipped off and i left a nice slick.

Eventually my buddy showed up with, my jug of used brake fluid. we looped back home and i got more oil. installed a new hose clamp, tighter this time.

Made it up the hill, got the parts, headed down the hill, a block from home the outlet hose slipped off.

So i'm not going on any more long drives until i can get to the house of hose and get some 1/2" Gates LOL, which is the product i have on the turbo oil feed and drain. It's flameproof and rated to something like 3000psi. The stuff on the oil cooler is, some other product, rated to 300psi, and apparently gets soft when hot.

The fake VDO oil pressure gauge buries it's needle, even when the engine is warm. So either it's a real piece of crap, or maybe my oil pump's overpressure device isn't working properly, or something. My real gauge and sender arrived so maybe i will get a chance to install them tomorrow.

I have another pump, if it comes to that.

Reply #234November 30, 2014, 12:25:39 am

theman53

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Re: Franken-TD for an '84 Coupe: Like i need another hole in my build thread
« Reply #234 on: November 30, 2014, 12:25:39 am »
It is probably not oil rated. I had a store sell me "oil rated" once...turns out it was heater hose and did exactly what you said yours did.

Reply #235November 30, 2014, 11:33:11 am

TimpanogosSlim

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Re: Franken-TD for an '84 Coupe: Like i need another hole in my build thread
« Reply #235 on: November 30, 2014, 11:33:11 am »
Yeah that's possible.

the guy at the desk decided he needed to have a conversation with me about my application instead of just giving me the high-temperature hydraulic hose i asked for.

I'll be less polite next time.

Reply #236November 30, 2014, 08:26:28 pm

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Re: Franken-TD for an '84 Coupe: Like i need another hole in my build thread
« Reply #236 on: November 30, 2014, 08:26:28 pm »
Today i finally installed door speakers. Some used kenwood excelon 5x3 coaxials that i bought and replaced the tweeter caps on.

So what i learned was, the reason why sites like crutchfield have such a hard time finding speakers that fit mk1 map pockets is not because there are so few options but because it turns out that the fitment is very close.

My excelons had a rectangular mounting plate, and most of that had to be cut off before they would fit in the speaker pods. Pain in the buttocks.

I initially feared that i had made a horrible mistake because there was a lot of buzzing and distortion but i found the major sources of buzz and after a few hours the speakers had shaken out the dust of their long slumber and right now are sounding pretty decent, if small.

Also it's normal for new capacitors, even film capacitors like i used, to go through some changes when first used. With electrolytic caps it's about forming the dielectric, but even in films you have microscopic points of vibration and physical change.

I'm a big proponent (and foolish collector) of vintage home audio speakers. I know that car audio is a wholly different game and i do try to get lightly used when i get used. In either case, electrolytic capacitors are the first component to fail.

I installed my genuine VDO oil pressure gauge. This one is from their "vision" series and true to it's marketing, it presents itself with an evenly lit dial of almost pure white numbering. Which looks out of place between the amber-on-purpose Defi EGT gauge and amber-and-green-on-purpose Di Pricol boost gauge. I'm going to try replacing the 194 bulb with a 194NA. Yes it came with the little colored condoms, in red and green. the red one produces a pinkish effect.

The fake VDO sender is still attached to the tee on top of the oil filter flange.

Rear passenger side marker keeps going dim, has to be jiggled. must remember to find my can of DeOxit and give it a spray and jiggling.

Found the bulb and holder for hazard switch illumination under the passenger seat. Bulb still good. Hazard switch illuminates now. yay.

Found the bulb holder for the cig lighter / ash tray illumination too. bulb bad. Found a 14v unknown wattage bulb with wire leads in my parts bin, soldered it in, too dim. I should do something with LEDs. I do have a bunch of 180 degree T1 LEDs. I could put a few green ones around the lighter and a few warm white ones around the ash tray, which i plan to use to store the filler cap key or something. Smoking is so 70's.

Wired in my genuine-looking chinese fog switch. This one: http://www.ebay.com/itm/180614374201 -- took a few weeks to arrive from hong kong. Looks great. The locking springs had to be bent a bit to work, just like the genuine-looking chinese headlight switch.

It's a two position fog switch. I put together a Y splitter so that both positions light my period-correct kmart-grade KC Hilites fog lights. No pigtail to match and my relay is out by the battery so i just followed the DIN terminal markings and it works great.

I have lm7810ct regulators in from mouser to replace the regulator on my cluster. haven't done it yet. Tach does funny things, like going to 0 when the headlights turn on. If anyone on this forum needs one, i can drop one in the mail. They cost less than a buck from mouser, and i was ordering $140 worth of other parts from them anyway. It's disgusting that mk1autohaus charges $28. I bought 4 so i have 3 spare.

'rocco-style license plate lights are in - an upgrade because they don't have big chunks missing that let water into the trunk. I have a replacement gasket for the lock/button i need to put in. passenger side tail still needs weatherstripping.

Discovered that the HVAC illumination is also missing. I don't even know what this looks like. Leaning toward four of my T1 warm white LEDs in series + a resistor. iirc their forward drop is more than 3v so they won't need much of a resistor.

Yesterday i also got the driver window regulator working with some squirts from a can of Liquid Wrench White Lithium Grease spray. I found a flexible straw that fit it's nozzle, and was able to direct it's foamy goodness to the back of the regulator track in a few points.

And then i gave the same treatment to the door latch and lock hardware. Works a lot better now. I can lock the door from the inside but i don't get the same positive latch feel as i get from the lock barrel. Something must be bent. And now i have a lock barrel that blackens the key with grease every time. I need to get out the air compressor and flush the barrel with WD40 and then with compressed air. All three of them.

Poured a small bottle ("treats up to 40 gallons") of Diesel Kleen into the full-minus-11-miles tank. I know this is foolishness but please forgive a little foolishness. I figure it's likely more or less the same stuff as diesel purge, which some people burn straight. Noted here for honesty. Wondering if there is something, anything up with my sketchy injection pump. I do have a line on some other turbo spec pumps, but those will need to be re-sealed.

I haven't bothered to re-fill the oil yet. I hope to get over to the House of Hose tomorrow over lunch. I envision myself tomorrow or tuesday night with my halogen work lights over the engine compartment installing new hose. Or maybe just removing the oil cooler and working on it on the porch, and then back to the car. I would really like to turn up on club night (wednesday) with my coupe.

Reply #237December 01, 2014, 08:45:12 am

EcoTX

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Re: Franken-TD for an '84 Coupe: Like i need another hole in my build thread
« Reply #237 on: December 01, 2014, 08:45:12 am »
So what did you do to finally get it going down the road better?

In your other thread you were having issues with cold starts and just moving it down the driveway IIRC

Did you just tinker with your timing and fuel till it acted right?

Reply #238December 01, 2014, 08:47:20 am

TimpanogosSlim

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Re: Franken-TD for an '84 Coupe: Like i need another hole in my build thread
« Reply #238 on: December 01, 2014, 08:47:20 am »
I still have hard cold starts. I think my shift linkage was way off and my ps pump was running dry and misbehaving, and i was underfueled. I think i can still tweak up the fuel a bit and i am pretty sure that my timing is retarded.

.:Sent by pneumatic tubes


Reply #239December 03, 2014, 09:16:24 am

TimpanogosSlim

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Re: Franken-TD for an '84 Coupe: Like i need another hole in my build thread
« Reply #239 on: December 03, 2014, 09:16:24 am »
Lost keys. Feck. There's a locksmith who can cut keys from the lock number. Guess i know where i will be on saturday, after breaking into my own car.

.:Sent by pneumatic tubes