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Engine Specific Info and Questions => IDI Engine => Topic started by: lord_verminaard on November 04, 2008, 03:12:00 pm

Title: Wife's Project: 86 Golf NA (maybe TD?)
Post by: lord_verminaard on November 04, 2008, 03:12:00 pm
Figured I may as well go ahead and start a build thread.  Even though nothing is being "built" at the moment, and the car was mostly "unbuilt" when we got it.  :D  Here's the car:
(http://lh6.ggpht.com/_mDxOuTI25gI/SQ9sNMx6NGI/AAAAAAAABuk/GI5aIovB1rI/s800/1103081342_01.jpg)

'86 Golf N/A Diesel, bought off of a member on here in Columbus.  Car is actually in really good shape overall.  She gives off a good "vibe" so it should be a great little car.  The engine was already out of the car when we got it, apparently it needs rings as there was a lot of blowby, according to the P.O.  The tranny actually grenaded itself, which is why it was taken off of the road.  The injection pump has been recently rebuilt, and it has an aftermarket "Topline" cylinder head, that actually looks quite good.  Wiring is all stock and un-molested, interior is in great shape, there are some dings here and there but no evidence of an accident, and the only rust to worry about is around the windshield.  Car even has power steering and A/C, both very good creature comforts for the Wife. :)  I also have a decent head unit with aux. input that was in my Scirocco when I bought it, I was going to junk it but it looks like it will fit in this car nicely.

First things first, I found an ACN tranny (.75 5th, 3.67 final) from a nice fellow just down the road in good working order.  Next, time to tear down the engine.
Cylinder head:  Looks good!  No cracks.
(http://lh6.ggpht.com/_mDxOuTI25gI/SQ9sGi7As3I/AAAAAAAABuI/VjJ0X4gQbI0/s800/1103081341a_01.jpg)

Pile of junk that all eventually needs to find it's way back on the car:
(http://lh4.ggpht.com/_mDxOuTI25gI/SQ9sB0MVuZI/AAAAAAAABuE/1ViMiff1EbE/s800/1103081340a_02.jpg)

And the bottom end:
(http://lh4.ggpht.com/_mDxOuTI25gI/SQ9r3bg7mjI/AAAAAAAABuA/5LgeB-t_wz0/s800/1103081341_01.jpg)

Everything looks really good in there.  Rods and mains are all tight, I did find out why it had an aftermarket head though- there are valve indentations on all of the pistons.   :roll: No big deal.  I'll have the machine shop give them a quick skim.  If it's in the budget, they will also be Swaintech coated.  There was a lot of oil on the #4 glow plug so I'm going to assume that was the cylinder that was not sealing properly.

So....  I have a T3 that needs rebuilt and a 1.6TD manifold that was originally going to get used on my M-TDI build for the Scirocco, but I was thinking how nice it would be to use it on her car.  Not going for tons of HP, but she likes to drive- I have a plan for building a boost-enrichment device to use on the N/A pump, the aim is for around 100hp- would be a good little runner.  It all depends on the budget.  Hope to have the engine fully stripped down this week and off to the machine shop for a measure/hone/hot bath and I'll have the pistons skimmed and probably get the crank checked and polished too.

If we could get this car on the road by December we will be in business!

Stay tuned-

Brendan
Title: Wife's Project: 86 Golf NA (maybe TD?)
Post by: riddleyo on November 04, 2008, 03:27:50 pm
Hah! That car looks very familiar! Looks just like mine except with two extra doors. And you bought it in Columbus, the same city I bought mine in!

Looks like a nice project you have going there. Can't wait to see a turbo on it.
Title: Wife's Project: 86 Golf NA (maybe TD?)
Post by: burn_your_money on November 04, 2008, 09:32:54 pm
I like it. Save the headaches and stay NA. AC and PS are more then enough trouble for that little car :lol:
Title: Wife's Project: 86 Golf NA (maybe TD?)
Post by: lord_verminaard on November 10, 2008, 08:39:17 am
Update- Block, crank, and pistons are at the machine shop.  Also, got a chance to use the parts washer and bead blaster at the Porsche shop.  I'll have pictures later, but I cleaned up the brackets and pulleys, boy do they look nice!  Going to paint the iron brackets and pulleys but keeping the aluminum ones bare.  The next time I go out I'll bring another pile of stuff.  The plan right now is to clean up the head a bit.

Pics later.

Brendan
Title: Wife's Project: 86 Golf NA (maybe TD?)
Post by: dubbinchris on November 10, 2008, 08:52:38 am
Wow it's awesome to see my old car get the love that I didn't have the time to give her. I'm so glad that it's been garage kept all the years too.  I had no idea about the reason for the aftemarket head. I hope it turns out to not need a rebuild and the pistons turn out okay.  I'll be keeping an eye on this thread.

-Chris
Title: Wife's Project: 86 Golf NA (maybe TD?)
Post by: dubbinchris on December 09, 2008, 03:04:31 pm
Any updates man?   I'd love to see how you're coming.
Title: Wife's Project: 86 Golf NA (maybe TD?)
Post by: lord_verminaard on December 10, 2008, 11:18:59 am
Slowly.  :)  Saving money for parts, right now I'm in the middle of a forced bathroom renovation.  :P  After that, I need to work on getting heat to the garage, it's too freaking cold to work out there.  I did get the block and crank back from the machine shop, and they look NICE.  I want to paint the block and other parts but it's too cold, hence the heat in the garage.

On top of that, I might be selling the gasser engine out of my Scirocco, so I need to figure out how to get her car out, pull the Scirocco in, and pull the engine out of that.  I really need a bigger garage.  :(  I'll try and get some pics up soon.

Brendan
Title: Wife's Project: 86 Golf NA (maybe TD?)
Post by: arb on December 10, 2008, 11:51:20 am
Quote from: "lord_verminaard"

On top of that, I might be selling the gasser engine out of my Scirocco, so I need to figure out how to get her car out, pull the Scirocco in, and pull the engine out of that.  I really need a bigger garage.  :(  I'll try and get some pics up soon.

Brendan


Reminds me of my favorite comic - The image is of a guy adding onto the front of his over-flowing garage - basically doubling the size. His wife looks at him like he's nuts - he says: "I did a feasibility study and its cheaper to add on than to clean it out."

Do you have a basement so you can paint the block before surface rust starts to form again ?
Title: Wife's Project: 86 Golf NA (maybe TD?)
Post by: lord_verminaard on December 10, 2008, 03:37:23 pm
I do, but I know that wouldn't fly with the wife.   :lol:

Brendan
Title: Wife's Project: 86 Golf NA (maybe TD?)
Post by: arb on December 10, 2008, 04:13:47 pm
Quote from: "lord_verminaard"
I do, but I know that wouldn't fly with the wife.   :lol:

Brendan


Some times its better to beg forgiveness than to ask permission. But, my wife almost always says yes, so I always ask.

Maybe you can get the heat going sooner than later.
Title: Wife's Project: 86 Golf NA (maybe TD?)
Post by: lord_verminaard on January 08, 2009, 10:29:12 am
Update, almost a month later.   :roll:   Lots of stuff going on, plus the holidays and whatnot....

Anyway, the Wife's car got moved around back (by pushing it through the neighbor's yard) and now it's wrapped up tight in a tarp.  Meanwhile, the Scirocco got it's engine and trans pulled and they are off to go in to two different race cars.
(http://lh5.ggpht.com/_mDxOuTI25gI/SVZjdiEgSGI/AAAAAAAAB5Q/CW28o5fpwVU/s800/1227081217.jpg)

With the help of a propane-fired heater, I got the job done without freezing to death, although space was pretty tight.  :P  So the other day, I decided to push the Scirocco out and paint up the block and brackets/pulleys that have been bead blasted.  I think it turned out pretty good!

Aluminum brackets that are blasted but staying bare:
(http://lh3.ggpht.com/_mDxOuTI25gI/SWVlcCqF-4I/AAAAAAAAB7M/Tq1kB2R0tRc/s800/IMG_0431.JPG)

Pulleys, iron/steel brackets:
(http://lh3.ggpht.com/_mDxOuTI25gI/SWVlQlRDZJI/AAAAAAAAB68/2EHeMwfvVIA/s800/IMG_0429.JPG)

Crank, freshened up and still in plastic:
(http://lh5.ggpht.com/_mDxOuTI25gI/SWVlivIRg2I/AAAAAAAAB7Y/F3U83-ev2aE/s800/IMG_0432.JPG)

Das block:
(http://lh3.ggpht.com/_mDxOuTI25gI/SWVlMB-tSOI/AAAAAAAAB60/pn63RbfTik8/s800/IMG_0428.JPG)

(http://lh3.ggpht.com/_mDxOuTI25gI/SWVlHYp8v4I/AAAAAAAAB6s/w-0teuC2mAo/s800/IMG_0427.JPG)

(http://lh5.ggpht.com/_mDxOuTI25gI/SWVlCF_X6TI/AAAAAAAAB6k/be5b4-z67yc/s800/IMG_0426.JPG)

(It was dry in these pictures, so it's a little brighter than I thought it would be, but I think it will look ok once all of the accessories are on it.)

So the project is on hold for a little while, I just received an $840 order from GAP for a ton of Corrado parts, so that little project will be next but after that we will go on with the Golf.  In the meantime I might send the pistons out to get coated once we get a feel for what our budget is looking like.

Stay tuned!

Brendan
Title: Wife's Project: 86 Golf NA (maybe TD?)
Post by: zukgod1 on January 08, 2009, 10:36:03 am
Good work!
Title: Wife's Project: 86 Golf NA (maybe TD?)
Post by: dubbinchris on January 13, 2009, 05:26:32 am
Great to see things moving along a little.

What sort of stuff are you doing to the Corrado?

Thread on that?
Title: Wife's Project: 86 Golf NA (maybe TD?)
Post by: Turbinepowered on January 13, 2009, 05:32:56 am
Looking slick!

My father looked at me like I was crazy when all my cast aluminum Fox parts were cleaned up and painted cast iron grey. I like your reverse look, cast aluminum block and bare brackets.

Stock diesel bracketry, or is that a serpentine setup? I'm not familiar enough with transverse wizardry to tell...
Title: Wife's Project: 86 Golf NA (maybe TD?)
Post by: lord_verminaard on January 13, 2009, 10:41:18 am
Quote from: "dubbinchris"
Great to see things moving along a little.

What sort of stuff are you doing to the Corrado?

Thread on that?


No thread... at least not yet.  The water pump is failing (aka leaking about a gallon of coolant every two weeks) and it also leaks on the serp belt, so it slips and I snap a belt about twice a month.  :P  Thermostat is shot so the car never warms up, the chains are starting to make a little noise too, plus I'm pretty sure the clutch is shot.... so you see where I'm going with this.  :)  I have another VR6 head that I am going to port and do a valve job on, plus Ti retainers and high-rate valve springs, then a Mk4 headgasket to raise compression, chains, clutch with lightened flywheel, crackpipe and thermostat and waterpump, and I am in a group buy for DRC 268 Cams that will get thrown in as well.  Should make for a nice result.  ;)  I won't be starting that work for another couple of weeks since right now it's the only mode of transportation me and my Wife have.

Quote from: "Turbinepowered"

Stock diesel bracketry, or is that a serpentine setup? I'm not familiar enough with transverse wizardry to tell...


Yup, stock stuff.  This car was loaded with power steering and A/C.  ;)  So that means a million pulleys and belts.  I'd love a serp conversion but it's not necessary right now.

Brendan
Title: Wife's Project: 86 Golf NA (maybe TD?)
Post by: lord_verminaard on March 30, 2009, 03:21:03 pm
Digging this back up.  Updates will be coming pretty soon.  I have a couple big boxes of parts thanks to Myke_W and GAP, and the engine build will start (I hope) pretty quickly.

Laura and I decided to bump this project forward, as she lost her job recently and while before, we had the convenience of working close to home and I could drop her off, it might not be the case when she finds a new job, so she needs some wheels.  I replaced the water pump on the Corrado but the rest of the work is being put on the back burner until this is closer to completion.

We have some car-jockying to do, as my Scirocco (without an engine) is taking up the garage so we need to switch and put it outside where her car is currently sitting.  What sucks is I have to go around the block to get the car from the back to the front.  Still have to figure that one out....  :P

Brendan
Title: Wife's Project: 86 Golf NA (maybe TD?)
Post by: lord_verminaard on April 13, 2009, 09:21:19 am
Moar updates, moar pictars.  

Started out on Sunday pushing the girl out in the driveway.
(http://lh6.ggpht.com/_mDxOuTI25gI/SeKHpv1lE7I/AAAAAAAACIs/EHF5i5Mealw/s800/IMG_2467.JPG)

First order of business, modifying the block and head for updated cooling.  First, the block, all cleaned up:
(http://lh6.ggpht.com/_mDxOuTI25gI/SeKH0VouTNI/AAAAAAAACI8/UgMcDe2_XvM/s800/IMG_2469.JPG)

And the AAZ head gasket...
(http://lh3.ggpht.com/_mDxOuTI25gI/SeKH44IFG6I/AAAAAAAACJE/O1-iMd7xlXc/s800/IMG_2470.JPG)

Now THAT's a beefy headgasket!!!
(http://lh5.ggpht.com/_mDxOuTI25gI/SeKIBn70UdI/AAAAAAAACJU/znmHXNYL3rw/s800/IMG_2472.JPG)

Punched the hole location in the block, using the gasket as a template:
(http://lh3.ggpht.com/_mDxOuTI25gI/SeKIJlwq1TI/AAAAAAAACJk/3I9C0_HnRX0/s800/IMG_2474.JPG)

Annnnnndd....... Drill!
(http://lh3.ggpht.com/_mDxOuTI25gI/SeKIRWjTyZI/AAAAAAAACJ0/vCZOpP_natM/s800/IMG_2476.JPG)

Repeat 5 more times (with my ancient drill that has this awesome feature of "self-loosening" the chuck so I have to pull out the chuck key and re-tighten it about every 2 minutes!!!) and chamfer the holes and clean it up, and ta-da!
(http://lh6.ggpht.com/_mDxOuTI25gI/SeKIVdqq-HI/AAAAAAAACJ8/gH6Kzo031no/s800/IMG_2477.JPG)

And, had to do the same thing to the head, though it was much easier drilling.  :D
(http://lh6.ggpht.com/_mDxOuTI25gI/SeKI6UumOAI/AAAAAAAACK4/OHVk6SyJbmM/s800/IMG_2484.JPG)

Here's a shot of the "custom hand-dressed pistons".  :D  As you can see, they all took a hit from the valves at one time.  No biggie.  They are getting packed up and sent to Swaintech this week.
(http://lh6.ggpht.com/_mDxOuTI25gI/SeKI_LhnMqI/AAAAAAAACLA/nmSR04r5pAw/s800/IMG_2485.JPG)

This one was the worst, also evidence of an injector leaking.
(http://lh6.ggpht.com/_mDxOuTI25gI/SeKJD54Uo_I/AAAAAAAACLI/GFTQeFxVCYc/s800/IMG_2486.JPG)

Next up, block heater!  Every diesel needs one of these, especially in Ohio.  I'm really surprised this car didn't have one before, since it had just about every other option.
(http://lh4.ggpht.com/_mDxOuTI25gI/SeKImiFvJlI/AAAAAAAACNU/vu5fU126bMY/s800/IMG_2481.JPG)

I had to knock out the center freeze plug, it took the biggest punch and the biggest hammer I had to free it.
(http://lh6.ggpht.com/_mDxOuTI25gI/SeKIeiYR_sI/AAAAAAAACKM/VKoRExrbxjk/s800/IMG_2479.JPG)

(http://lh5.ggpht.com/_mDxOuTI25gI/SeKIiC4G3-I/AAAAAAAACKU/G33tchibgT0/s800/IMG_2480.JPG)
 :banghead:

Yay!
(http://lh3.ggpht.com/_mDxOuTI25gI/SeKItfmrBnI/AAAAAAAACKk/yDGkP721qsg/s800/IMG_2482.JPG)

Next up, I bead-blasted a whole mess of parts last weekend, time to paint them.
(http://lh6.ggpht.com/_mDxOuTI25gI/SeKJXYUuyNI/AAAAAAAACLg/HpQNEOMtV8o/s800/IMG_2489.JPG)

(http://lh6.ggpht.com/_mDxOuTI25gI/SeKJfrV5pcI/AAAAAAAACLo/RsHtiOxV4tc/s800/IMG_2490.JPG)

Manifolds- A2 GTI gasser intake manifold, (not blasted) and TD exhaust manifold.  The bead blasting was not quite enough to cut the rust on the exhaust manifold, I'll need to apply another type of treatment.
(http://lh3.ggpht.com/_mDxOuTI25gI/SeKJoP3setI/AAAAAAAACLw/oL-d6Sw16Zs/s800/IMG_2491.JPG)

Yay, painted parts!  I used the wrinkle-finish on the valve cover, it was not quite done "curing" yet in this picture so the camera shots look funky.
(http://lh5.ggpht.com/_mDxOuTI25gI/SeKJtm-U9iI/AAAAAAAACL4/N5VXmNzzk5I/s800/IMG_2492.JPG)

(http://lh5.ggpht.com/_mDxOuTI25gI/SeKJ1nZQJ8I/AAAAAAAACMA/45MECrCH3z4/s800/IMG_2493.JPG)
And the art-shot of the day:
(http://lh6.ggpht.com/_mDxOuTI25gI/SeKJ4uvZU9I/AAAAAAAACMI/u9Gva-iUMhc/s800/IMG_2494.JPG)

Almost time to put this thing together!  It's gonna look good under the hood too!
(http://lh5.ggpht.com/_mDxOuTI25gI/SeKJPcXJTQI/AAAAAAAACLY/K4sjHVbErtI/s800/IMG_2488.JPG)

And a before shot of the engine when we picked it up:
(http://lh5.ggpht.com/_mDxOuTI25gI/SeKHagHYR_I/AAAAAAAACIU/TqQkHGpsqmk/s800/DCP_0024.jpg)

One step at a time.....

Brendan
Title: Wife's Project: 86 Golf NA (maybe TD?)
Post by: TurboJ on April 13, 2009, 09:42:31 am
Nice work!
Which manufacturer made that head gasket BTW?
Title: Wife's Project: 86 Golf NA (maybe TD?)
Post by: subsonic on April 13, 2009, 11:26:27 am
You are going straight to a 3-hole?  That's going to drop your CR a bit, although perhaps not if you have a fair amount of protrusion.
Title: Wife's Project: 86 Golf NA (maybe TD?)
Post by: lord_verminaard on April 13, 2009, 04:41:00 pm
Quote from: "TurboJ"
Nice work!
Which manufacturer made that head gasket BTW?


It's a Victor Reinz, I got it from Myke_W here.

Quote from: "subsonic"
You are going straight to a 3-hole? That's going to drop your CR a bit, although perhaps not if you have a fair amount of protrusion.


Yup, though it had a 3-notch fiber gasket on it before, the head obviously was swapped so who knows if the 3-notch is proper for the protrusion, but I didn't even bother to measure.  A little less compression isn't all that bad since this will be a turbo car.  :)  The Swaintech coating will build up on the piston crown, though if it is enough to significantly alter compression, who knows.

Brendan
Title: Wife's Project: 86 Golf NA (maybe TD?)
Post by: lord_verminaard on May 05, 2009, 09:47:23 am
More pictures coming soon.

Updates:  Got the crank installed.  Re-used the original thrust bearings, and even though I used stock size bearings, all of the clearances and end-play are dead on.  I love VW engines.  :)

The pistons are back from Swaintech, and they look sexy.  Myke is checking on piston pin circlips, as most of the old ones went flying across the garage when I popped them out- so I need those before I can finish the bottom-end.

I dropped off the head at the machine shop yesterday- I was originally going to just clean it up, put in new valve stem seals, and slap it on, but it's really dirty and the valve seats don't look real pretty.  So it's getting a valve job and he's gonna go ahead and hot-tank it too.

I also power-washed the engine bay.  Man does it look better.  That will make working on it much more pleasant.  :)

I'll do my best to post more pictures later.  I've literally not had enough time to even upload them.

Brendan
Title: Wife's Project: 86 Golf NA (maybe TD?)
Post by: arb on May 05, 2009, 11:22:06 am
Looking good. Do you have the baffle for under your valve cover ? It will reduce oil looses through the breather.
Title: Wife's Project: 86 Golf NA (maybe TD?)
Post by: lord_verminaard on May 05, 2009, 02:16:43 pm
Quote from: "arb"
Looking good. Do you have the baffle for under your valve cover ? It will reduce oil looses through the breather.


No I dont, actually.  On my list of things to get.  Thanks for the reminder!  :)

Updates with pictures!!!!!!!!!

Yay piktars!!!

Pistons, freshly coated:
(http://lh4.ggpht.com/_mDxOuTI25gI/SgBrfK1LmSI/AAAAAAAACSs/O07hHpL-puE/s800/IMG_2805.JPG)

(http://lh3.ggpht.com/_mDxOuTI25gI/SgBrnruAn7I/AAAAAAAACS8/8YtgJbYpabQ/s800/IMG_2807.JPG)

(http://lh5.ggpht.com/_mDxOuTI25gI/SgBrjkxelzI/AAAAAAAACS0/_6aeArWvpN4/s800/IMG_2806.JPG)

Yeah, I still gotta clean some carbon out of the ring lands.   :rolleyes:

Engine on my new stand:
(http://lh3.ggpht.com/_mDxOuTI25gI/SgBr0u_UQJI/AAAAAAAACTM/HPFFY82QH9E/s800/IMG_2812.JPG)

Crank in place:
(http://lh4.ggpht.com/_mDxOuTI25gI/SgBr5-H0ZQI/AAAAAAAACTU/LZtQcQiH0-g/s800/IMG_2813.JPG)

(http://lh3.ggpht.com/_mDxOuTI25gI/SgBr_N8KUFI/AAAAAAAACTc/pxs3Z2TQNOs/s800/IMG_2814.JPG)

Intermediate shaft and front seal:
(http://lh5.ggpht.com/_mDxOuTI25gI/SgBsKt8aiMI/AAAAAAAACTw/qJffZ37zDRY/s800/IMG_2816.JPG)

Me looking way too serious- it was a joy to assemble this engine so far:
(http://lh4.ggpht.com/_mDxOuTI25gI/SgBsPRtWZkI/AAAAAAAACT4/CBQxwsKdYNE/s800/IMG_2817.JPG)

Now, the powerwashing.  Engine bay before:  Gross!!!
(http://lh6.ggpht.com/_mDxOuTI25gI/SeKHpv1lE7I/AAAAAAAACIs/EHF5i5Mealw/s800/IMG_2467.JPG)

After:  Yay!  I have not even scrubbed anything yet, just washed.  Tools of choice were Simple green and a neighbor's powerwasher.  I also used some Gunk engine brite but it really didn't do much besides smell everything up (simple green smells much better) and leave a nasty residue all over the driveway.
(http://lh3.ggpht.com/_mDxOuTI25gI/SgBsUj-YScI/AAAAAAAACUA/T-688w2avGE/s800/IMG_2818.JPG)

(http://lh4.ggpht.com/_mDxOuTI25gI/SgBsaaSiGhI/AAAAAAAACUI/cSvrcMsfvQM/s800/IMG_2819.JPG)

Woah, the steering rack was blue??
(http://lh5.ggpht.com/_mDxOuTI25gI/SgBsgRbLDHI/AAAAAAAACUQ/4kWBQAOIbaQ/s800/IMG_2820.JPG)

(http://lh3.ggpht.com/_mDxOuTI25gI/SgBslENi3VI/AAAAAAAACUY/FY74lf6S2cg/s800/IMG_2821.JPG)

Battery tray rust.  No big deal.
(http://lh6.ggpht.com/_mDxOuTI25gI/SgBsqmJ3B-I/AAAAAAAACUg/8P3XD3b8uMw/s800/IMG_2822.JPG)

That's it!  Head is at the machine shop right now, getting a full valve job with new seals, so in the meantime, I'll be cleaning carbon out of the pistons and awaiting those circlips, and possibly cleaning up the bay a little more and prepping those bad areas for a little bit of paint.

Brendan
Title: Wife's Project: 86 Golf NA (maybe TD?)
Post by: arb on May 05, 2009, 02:38:35 pm
Are you using assembly oil ? I use 50/50 of 10w-40 and STP oil treatment. Its very thick and will stick to the bearings for months, in case its months before you start.
Title: Wife's Project: 86 Golf NA (maybe TD?)
Post by: lord_verminaard on May 05, 2009, 02:55:47 pm
Quote from: "arb"
Are you using assembly oil ? I use 50/50 of 10w-40 and STP oil treatment. Its very thick and will stick to the bearings for months, in case its months before you start.


Yep, using this stuff:
(http://www.carshopinc.com/images/PEX/81950.jpg)

It's about the consistency of cold maple syrup.  Really sticky too.  Working real well so far.  Also using 15W-40 in a little oil can for lubing up bolts and seals and stuff.

Brendan
Title: Wife's Project: 86 Golf NA (maybe TD?)
Post by: arb on May 05, 2009, 03:33:17 pm
Quote from: "lord_verminaard"
Quote from: "arb"
Are you using assembly oil ? I use 50/50 of 10w-40 and STP oil treatment. Its very thick and will stick to the bearings for months, in case its months before you start.


Yep, using this stuff:
(http://www.carshopinc.com/images/PEX/81950.jpg)

It's about the consistency of cold maple syrup.  Really sticky too.  Working real well so far.  Also using 15W-40 in a little oil can for lubing up bolts and seals and stuff.

Brendan


Great. Its about the same thing as my mix, but it has a dye to show you're using the special stuff. The proof is to dip a standard screw driver business end in the stuff and try to hold it between your finger and thumb. It will slip right out every time. Very thick, sticky, and slippery.
Title: Wife's Project: 86 Golf NA (maybe TD?)
Post by: lord_verminaard on May 07, 2009, 10:14:39 am
Snuck home from work a little early yesterday, got cracking on some other things. I wire-brushed out the rusty parts in the engine compartment in preparation for paint. I also spent most of the time beating on a single-round core support to make it fit properly. One thing that bugs the hell out of me on just about every A2 that I see is the grille being zip-tied on. I hate that. Not on this car. I spent the time to "massage" the core support the right way so it all fits. Doing this now before I paint. The result:

(http://lh4.ggpht.com/_mDxOuTI25gI/SgLVNM8lAZI/AAAAAAAACVY/sABtN_HN9xA/s800/0506092307.jpg)

Yay, no zip ties! The passenger fender is a little wanged, though all the mounting points are still where they are supposed to be. We already have two straight replacement fenders (in red), but those won't get put on until the whole car gets painted. The core support was used and traded owners about a dozen times so it's been tweaked a few times, but a little time with a hammer and a dolly and it's perfect now.

If it's as slow today at work as it was yesterday, I'll be going home early again to work some more.

Brendan
Title: Re: Wife's Project: 86 Golf NA (maybe TD?)
Post by: lord_verminaard on June 23, 2009, 11:11:08 am
Let's dig this back up!!!  Some updates:  Transmission is cleaned, re-sealed and ready to go.  Got some of the rusty parts under the hood cleaned up and coated with rust-bullet.  Last weekend, I finished up the bottom-end and got the pistons installed.  Everything dropped right in, and the only issue I had was a rod that was in backwards.  That, and those damn piston pin circlips.  Those are a royal pain to install.  Some pics:


(http://lh3.ggpht.com/_mDxOuTI25gI/SkDQ3fxJnsI/AAAAAAAACn4/BQG7VbsQ8rU/s800/IMG_3418.JPG)

(http://lh6.ggpht.com/_mDxOuTI25gI/SkDQ9Nq5NpI/AAAAAAAACoA/-mz-dsTfbtk/s800/IMG_3419.JPG)

(http://lh4.ggpht.com/_mDxOuTI25gI/SkDRBdUmtVI/AAAAAAAACoE/b9dSpuEr6Ys/s800/IMG_3420.JPG)

(http://lh4.ggpht.com/_mDxOuTI25gI/SkDRG_cQ7pI/AAAAAAAACoI/KAcHhzOG41U/s800/IMG_3421.JPG)

Yay!  Also, I've been spending some time at the machine shop after work- mostly cleaning up the head to save me some money.  I wasn't happy with the transition area from the intake runners to  the valve throat area.  Cylinders 2 and 3 especially had very large casting steps on them.  Guessing that is because it's an aftermarket head.  So before the valve job is going to be done, I ported out those casting steps, and wend ahead and ported the rest of the head too.  It just would have bugged me to put it back in the car the way it was after all of this work.  :)  The valve job should be done today, and after work I'm going back to set the valve clearance and it should be done!  Pics to come.  Maybe, just maybe, the engine will be assembled this weekend!!!  Getting close now!!!

Brendan
Title: Re: Wife's Project: 86 Golf NA (maybe TD?)
Post by: arb on June 23, 2009, 12:38:16 pm
Great job Brendan ! Keep at it, don't hurry, it'll be worth it. More photos please.
Title: Re: Wife's Project: 86 Golf NA (maybe TD?)
Post by: lord_verminaard on June 24, 2009, 10:53:49 am
Thanks!  :)

Anyway- the valve job is finished, everything is cleaned and ready to be re-assembled.  Today the cam journals and "bearing" surfaces in the head need to be polished, they were scored up pretty good.  The bearing caps on this head are way more flimsy than an OEM VW ones, I guess that is what you get with aftermarket.  Other than that and the bad port casting flaws, the head seems pretty good and my machine shop guy confirmed that, so that makes me feel better.

Cellphone pics:

Oh hai:
 (http://lh3.ggpht.com/_mDxOuTI25gI/SkIZncGnF0I/AAAAAAAACrA/eRND9x2P3N4/s800/0623091546a.jpg)

  (http://lh3.ggpht.com/_mDxOuTI25gI/SkIZvYHzABI/AAAAAAAACrI/0V5MfBnGe88/s800/0623091547_01.jpg)

This was after porting, before the valve job.

Brendan
Title: Re: Wife's Project: 86 Golf NA (maybe TD?)
Post by: theman53 on June 24, 2009, 06:41:19 pm
When you say a rod was backwards which way do they go? Or just the piston that was attached was backwards? I didn't know that there was a front and back to the rods...good to know.
Title: Re: Wife's Project: 86 Golf NA (maybe TD?)
Post by: lord_verminaard on June 25, 2009, 09:22:01 am
Yeah, it might not matter much, but I didn't want to risk it, so I put the rods back in the same way they came out.  :)  I know that if you are re-using rods, if you swap the rod or main caps, it will sometimes not work.

The head is finished!  I stayed out at the machine shop late last night, until 9:30, but we got it done.  It's a masterpiece too.  :)  I've got probably the best VW machinist in the midwest, no joke.  He used to work at a VW/Audi/Porsche shop in the late 70's/mid-80's.  You should have seen him do the valve adjustment.  It was like magic.  It would have taken me hours!  :)  I've only checked the valve adjustment on a VW solid-lifter head, I've never had to adjust anything before.

Brendan
Title: Re: Wife's Project: 86 Golf NA (maybe TD?)
Post by: theman53 on June 25, 2009, 06:28:43 pm
So as I am ready to assemble the bottom of my engine I need to know which way they came out...it was october when it was torn down. Let me know what you did. I need to get the thing in so I can measure for a headgasket.
Title: Re: Wife's Project: 86 Golf NA (maybe TD?)
Post by: lord_verminaard on June 29, 2009, 09:12:18 am
Heh, I marked each one with what cylinder it came from and which direction it was pointing as I took them out.  It was also back in early November when I took this one apart.  Probably doesn't help you though!  I'm not sure how you would figure out which way they go if you didn't mark them.

Brendan
Title: Re: Wife's Project: 86 Golf NA (maybe TD?)
Post by: theman53 on June 29, 2009, 10:49:13 am
I have the bearing caps marked I just didn't remember which way they went. I know which rod goes in which hole and if I remember the bearing groves go toward the IP side of the engine, that is the way they are going anyway.
Title: Re: Wife's Project: 86 Golf NA (maybe TD?)
Post by: arb on June 29, 2009, 10:59:10 am
I have the bearing caps marked I just didn't remember which way they went. I know which rod goes in which hole and if I remember the bearing groves go toward the IP side of the engine, that is the way they are going anyway.

I try to mark the mains and the rod at the same time and from the same side of the block - the main's only go one way so you'll know which way the rods go. Post mortem for this case, but many it will help someone. I don't remember who taught me this trick. Getting old is hell (my dad taught me that ;-)
Title: Re: Wife's Project: 86 Golf NA (maybe TD?)
Post by: lord_verminaard on July 21, 2009, 11:11:00 am
Time for a double-dose of updates!  I actually had accomplished about two weekends in a row of work so I'll add them both.

First, more of the engine is assembled:
 (http://lh6.ggpht.com/_mDxOuTI25gI/SmMqC42L-nI/AAAAAAAAC3E/ufQuR_HtQlQ/s800/IMG_3634.JPG)

Laura helped by pulling up the pictures of the disassembly so I could remember what goes where.  :P
(http://lh5.ggpht.com/_mDxOuTI25gI/SmMp2rKnESI/AAAAAAAAC28/HA7COV_BNJ4/s800/IMG_3632.JPG)

Got the injection pump mounted, ready to put on the timing belt, but didn't have the tensioner stud.  FAIL.  It's different from the gas cars so I might have to special order one- GAP didn't have it either.
(http://lh3.ggpht.com/_mDxOuTI25gI/SmMqeqyVsiI/AAAAAAAAC3U/b0Ye-e6tszU/s800/IMG_3639.JPG)

Notice lack of TDC locating devices.  There isn't a single mark on ANYTHING on this engine to designate TDC.  Oh well.  :P

Went to assemble the water pump halves and install that, but one bolt broke when I removed it and was stuck in the water pump housing.  I used all versions of heat, force, and chemicals that I was capable of, and it didn't come out.  FAIL.  I even drilled all the way through the broken bolt, and used an easy-out, but it broke the easy-out!!!  EPIC FAIL. 

So I got pissed and wanted to see some real progress so I pulled all of the studs on the head and swapped them for the proper studs for a rubber valve cover gasket, and temporarily threw the valve cover on there so I could see what it will look like.  WIN.
(http://lh4.ggpht.com/_mDxOuTI25gI/SmMqWWN_tLI/AAAAAAAAC3Q/S4Iokm7xtZU/s800/IMG_3638.JPG)

I also tested all of the glow plugs before I re-installed them.  So that was the weekend before last.  The injectors are re-built and awaiting pickup, so this week it looks like I'll be ordering more parts.  Timing this thing without any reference marks is going to be a beeyoch.

2nd update to follow.  :)

Brendan

Title: Re: Wife's Project: 86 Golf NA (maybe TD?)
Post by: lord_verminaard on July 21, 2009, 11:12:54 am
2nd update, not a lot of details since most of the work was boring.  Painted the engine bay- a pretty rough and dirty job but it looks a zillion times better than it did.  Note this picture from the last update of the bay:
(http://lh5.ggpht.com/_mDxOuTI25gI/SmMp2rKnESI/AAAAAAAAC28/HA7COV_BNJ4/s800/IMG_3632.JPG)

The silver areas is the Rust Bullet.  I'm happy with the way that stuff worked.  First, I pulled all of the wiring out of the holders and wrapped it up.  Then I scuffed everything I could reach with scotch-brite, then washed everything down with Denatured Alcohol.  Then some tape and newspaper, then some paint!  Here's how it turned out:
(http://lh5.ggpht.com/_mDxOuTI25gI/SmMqkECNPLI/AAAAAAAAC3Y/368IB69gSbg/s800/IMG_3669.JPG)

(http://lh6.ggpht.com/_mDxOuTI25gI/SmMqpps8QnI/AAAAAAAAC3c/uRCRFnkPbpw/s800/IMG_3670.JPG)

(http://lh4.ggpht.com/_mDxOuTI25gI/SmMqu-LhPzI/AAAAAAAAC3g/K2MmCpTL6RM/s800/IMG_3671.JPG)

Getting excited about how it looked, I went ahead and fitted the apron, then quickly cleaned and painted the subframes, threw them on there, and blacked out the lower part of the core support and put it on.  Also fitted the chin spoiler and trim piece too.  How's this for inspiration?

(http://lh5.ggpht.com/_mDxOuTI25gI/SmMq1vffG9I/AAAAAAAAC3k/mYgvZiDeEoA/s800/IMG_3672.JPG)

(http://lh3.ggpht.com/_mDxOuTI25gI/SmMq8OnXByI/AAAAAAAAC3o/r5f0iVDPcb8/s800/IMG_3673.JPG)

(http://lh4.ggpht.com/_mDxOuTI25gI/SmMrCdQf3ZI/AAAAAAAAC3w/bW8NURfRUG0/s800/IMG_3674.JPG)

(http://lh4.ggpht.com/_mDxOuTI25gI/SmMrH2298TI/AAAAAAAAC30/OiIbBqfPRrw/s800/IMG_3675.JPG)


Not bad, eh?  :)

Brendan
Title: Re: Wife's Project: 86 Golf NA (maybe TD?)
Post by: andyztoy on July 21, 2009, 02:09:33 pm
wow great work
that things gunna run great
i like the idea of the block heater, deff going to look into putting on of those on my aaz

after u get her all back together u will have to address that rain tray
Title: Re: Wife's Project: 86 Golf NA (maybe TD?)
Post by: lord_verminaard on July 22, 2009, 10:19:09 am
Yeah, I know.  Though that's the only rust on the whole car.  We've got it in the budget for a complete re-spray too.  Helps that I have a full Porsche restoration shop at my disposal when it comes time for paint.  :)

Brendan
Title: Re: Wife's Project: 86 Golf NA (maybe TD?)
Post by: arb on July 22, 2009, 11:26:21 am
2nd update to follow.  :)

Brendan


Excellent progress Brendan !!  Always better if your wife is helping ;-)  Questions:  Are you going to "pimp your GP" ? Good time to install the wires. Also, are you going to use a VAC pump? Mine dumps its air into the crank for extra ventilation and a clean solution to the vent.
Title: Re: Wife's Project: 86 Golf NA (maybe TD?)
Post by: catlin_cava on July 22, 2009, 11:30:00 pm
hehe I see your like me and drag the laptop next to you in the shop while working lol
Title: Re: Wife's Project: 86 Golf NA (maybe TD?)
Post by: BlueMule on July 26, 2009, 04:27:22 pm
Brendan, outstanding work. Painting the engine compartment is always a very nice touch. I also applaud the lack of Orange/Red Silicone slathered and dripping out of every joint of the engine, the build looks very clean and professional.  ;) Also the wrinkle finish on the V/C is really "Old School", like you were reading my mind. If you are going to Turbo the engine I would like to suggest a "Catch Can" similar to this one, http://www.racinglab.com/weapon-r-oil-tank-826-113-101.html it helps keep any blowby oil out of the compressor. All in all a very nice start  8)

BlueMule
 
Title: Re: Wife's Project: 86 Golf NA (maybe TD?)
Post by: lord_verminaard on August 11, 2009, 09:47:06 am
Update time.  About two more weekends of work here.  Some fail, but mostly win.  :)

Got it timed:  WIN.
(http://lh3.ggpht.com/_mDxOuTI25gI/SoC2nzlX3BI/AAAAAAAAC88/pgxXQlXTXdg/s800/IMG_3861.JPG)

Waterpump, cam oil baffle, flanges:  WIN.  Flanges on the wrong way, waterpump on before the big-assed accessory bracket, forgetting to install the cam seal:  FAIL.
(http://lh5.ggpht.com/_mDxOuTI25gI/SoC2zeQrkmI/AAAAAAAAC9E/1q7akLkebuY/s800/IMG_3863.JPG)

The biggest FAIL of all so far:  Fitting the stupid intake/exhaust manifolds.  Some of the grinding on the intake that I did:
(http://lh6.ggpht.com/_mDxOuTI25gI/SoC3Aj0HFoI/AAAAAAAAC9M/GeKqJhOKNVA/s800/IMG_3865.JPG)

And on the exhaust manifold... AFTER I had already grinded away a lot of material and painted it...
(http://lh3.ggpht.com/_mDxOuTI25gI/SoC3HrdUuVI/AAAAAAAAC_I/U08RN0mgEvM/s800/IMG_3866.JPG)

And the studs that NAPA had were too short too.   :banghead:
(http://lh6.ggpht.com/_mDxOuTI25gI/SoC3ONWVyEI/AAAAAAAAC9U/XK48pJi1Xm0/s800/IMG_3867.JPG)

Now for some more WIN:

Got all of the stupid accessory brackets and crap figured out.  After going through ETKA finding all of the bolt sizes, then spending $60 on hardware.....  Finally it's together.  I got the engine off of the stand and on the hoist so I could put together the rear seal/clutch/etc...

(http://lh3.ggpht.com/_mDxOuTI25gI/SoC3UEHuAJI/AAAAAAAAC9Y/81PUV2vcACY/s800/IMG_3944.JPG)

(http://lh4.ggpht.com/_mDxOuTI25gI/SoC3aij9cZI/AAAAAAAAC9c/3xDsqZDjXXQ/s800/IMG_3945.JPG)

Gasser clutch/pp/flywheel:
(http://lh5.ggpht.com/_mDxOuTI25gI/SoC3g8uhLDI/AAAAAAAAC9g/jDVGl7Xyc3s/s800/IMG_3946.JPG)

Flanges on the correct way this time...   :rolleyes:
(http://lh4.ggpht.com/_mDxOuTI25gI/SoC3m21s72I/AAAAAAAAC9k/2aYNmdq0E5k/s800/IMG_3947.JPG)

Marked a new TDC spot on the flywheel....
(http://lh5.ggpht.com/_mDxOuTI25gI/SoC38TuXZNI/AAAAAAAAC94/pT_x2b05aOY/s800/IMG_3951.JPG)

More things to go on the car...
(http://lh3.ggpht.com/_mDxOuTI25gI/SoC32iEULeI/AAAAAAAAC90/B3jq6qWoEHI/s800/IMG_3950.JPG)
 :laugh:

(http://lh3.ggpht.com/_mDxOuTI25gI/SoFYrsknQYI/AAAAAAAAC-k/ZC7hxmFXeRg/s800/IMG_3956.JPG)

Shown here:  Missing Linkz complete hardware kit, oil-pan baffle/gasket, and the gauges above:  (oil pan was temporarily installed for the other pics to catch drippings)
(http://lh5.ggpht.com/_mDxOuTI25gI/SoC3sFfYJQI/AAAAAAAAC9s/SrRWQyKMtF0/s800/IMG_3948.JPG)

Money shot!
(http://lh6.ggpht.com/_mDxOuTI25gI/SoC3xWOUNfI/AAAAAAAAC9w/TPKz1mqgrLo/s800/IMG_3949.JPG)


Won't be long now!!!  Turbo should be coming this week, along with oil lines and a new T3 8v manifold.  Could realistically have the engine ready to put in the car this weekend.  Probably won't happen though.  Still a fair amount of things to do...

Some wiring- for the gauges, also need all of the senders and sensors figured out, still need a boost gauge, I would like to have a tach cluster too.  Also going to run a small fuel lift-pump, so I have to do a circuit for that and figure out how to mount it, re-doing the glowplug circuit to a better design, relaying the headlights, etc....

Mechanicals:  Build the downpipe and exhaust, fabricate caps/block-offs for the manifold, run all new vac/boost tubing, fabricate the turbo intake/intercooler piping, hook up a manual boost controller,  :laugh:
mount the intercooler somewhere, still need a damn oil cooler........

Lot of work ahead but most of the hard stuff is over.

Brendan
Title: Re: Wife's Project: 86 Golf NA (maybe TD?)
Post by: lord_verminaard on August 11, 2009, 12:26:08 pm
Hmm, maybe.  I don't really have a complete turbo, just a junk turbine housing.  With the manifold flipped, the turbine housing is about 2 inches away from the rear mount- pointing directly toward it.  I don't see there being any possible way to get a downpipe on there with it that way, unless a new rear mount is fabricated to allow clearance.

Brendan
Title: Re: Wife's Project: 86 Golf NA (maybe TD?)
Post by: lord_verminaard on August 11, 2009, 03:48:11 pm
Hehe, went home for lunch and found a big box on the porch... turbo came today!  :D

Brendan
Title: Re: Wife's Project: 86 Golf NA (maybe TD?)
Post by: Rabbit on Roids on August 12, 2009, 01:37:23 pm
lucky...
im so jealous.
Title: Re: Wife's Project: 86 Golf NA (maybe TD?)
Post by: lord_verminaard on September 01, 2009, 09:52:38 am
More updates to keep this out of the archives.  :D

We are really close now, engine is together, tranny is attached, just ordered about $500 worth of stuff to finish everything up.  Here's what's been going on over the past few weeks:

First, worked on the turbo oil system some.

Drilled and tapped oil flange:
(http://lh3.ggpht.com/_mDxOuTI25gI/Spm0I6-GNwI/AAAAAAAADAA/d6Xx-GYVXDg/s800/IMG_4000.JPG)

Various oil lines for feed and drain- cheap ebay kit.  :D
(http://lh3.ggpht.com/_mDxOuTI25gI/Spm0OS7U2cI/AAAAAAAADAE/fnLPCAAk8pU/s800/IMG_4001.JPG)

Steel -AN fitting I got at a local hydraulic store- I filed it down so it would enter the pan at a bit of an angle.
(http://lh6.ggpht.com/_mDxOuTI25gI/Spm0RNy4IuI/AAAAAAAADAI/_TeIbg3VH8k/s800/IMG_4002.JPG)

Drilled the spot on the pan and got it ready to weld.
(http://lh3.ggpht.com/_mDxOuTI25gI/Spm0WN7p4yI/AAAAAAAADAM/3i_3oXSP-M4/s800/IMG_4003.JPG)

No pics of the welding, it was HOT that day.  By the way, non-auto darkening welding helmets suck.  I should have spent the extra $20 on an auto version.   :banghead:

Later, I figured out the maddening puzzle that was some crazy German's wet dream, the accessory drive belt system.  :what: Got it, I think!!!
(http://lh4.ggpht.com/_mDxOuTI25gI/Spm0bQYtyFI/AAAAAAAADAQ/uDUGvxMOfDc/s800/IMG_4076.JPG)

Oil pump, gasket/windage tray, and drilled pan, cleaned up, welded fitting, and a fresh coat of paint:
(http://lh4.ggpht.com/_mDxOuTI25gI/Spm0gErevtI/AAAAAAAADAU/8Z28myBs2U4/s800/IMG_4077.JPG)

Tossed the tranny on there while I was at it:
(http://lh3.ggpht.com/_mDxOuTI25gI/Spm0u1Iy8KI/AAAAAAAADAg/1Gb2M3xCwlc/s800/IMG_4080.JPG)

So close now!!!
(http://lh6.ggpht.com/_mDxOuTI25gI/Spm01SDXpPI/AAAAAAAADAo/aGAcbR3U9Pc/s800/IMG_4081.JPG)

The oil flange is a busy place now.  Shown here, in back, the feed line for the turbo, which fits in the drilled/tapped 1/8 NPT spot, I put an angled fitting on there for clearance.  In front, an M10 "T", so I can run the factory oil temp sensor, and the dual-post VDO sender from 42DD to run a pressure gauge and have a terminal for the factory low pressure warning light.
(http://lh3.ggpht.com/_mDxOuTI25gI/Spm06_rm79I/AAAAAAAADAs/xdo6stfiGuM/s800/IMG_4082.JPG)

Dipstick in too!  That's when you KNOW you are almost finished.  :thumbup:
(http://lh3.ggpht.com/_mDxOuTI25gI/Spm1CMJlPrI/AAAAAAAADAw/PlXrjpG8LiE/s800/IMG_4083.JPG)

Coming in the mail soon:
-bunch of mandrel bends and exhaust tubing and a muffler so I can build an exhaust system,
-EGT gauge and probe, which I just found out is backordered :banghead:
-Ebay intercooler pipe kit

Still left to do:
-Wire up relays for headlights
-"pimp" the glowplug system.  (yes, more relays!)
-Add electric diesel lift pump and wiring for that
-Need new Power steering pressure hose
-Need new A/C o-rings and such
-Intake tube/air filter
-Wire in all gauges, which include:  Oil pressure, temp, volts, boost, EGT.  Also need to figure out where to put them.  :P
-Clean up the starter and hope it works, it's FUGLY.
-De-grease alternator and AC compressor, they look pretty nasty compared to everything else
-Turbo Drama....

About the turbo, the Mercedes T3 '45' trim came in damaged.  The compressor wheel had some really weird damage, all of the high fins were bent over backwards.  How that happened without the turbo grenading is beyond me.  Bummed, I took it to my machine shop guy yesterday, he happened to have a spare Volvo T3 laying around that has the same .42 compressor housing, so voila, new compressor wheel.  :)  He also had a rebuild kit for it so I don't need to order that either.  So that should be done next week.  Hopefully that EGT gauge comes in soon, I need to drill and tap the turbo manifold but I don't know what size!!

Oh yeah, I happened to "stumble upon" about a gallon of white Dupont Imron paint, so this project won't be done until she comes out with a new paintjob.  :D  Can we finish it before winter?  Stay tuned!

Brendan
Title: Re: Wife's Project: 86 Golf NA (maybe TD?)
Post by: lord_verminaard on October 02, 2009, 10:31:59 am
Wow, been a long time, with sadly, not a lot of updates.  My Wife and I are probably in some of the worst possible financial trouble we have been in, after the state board of Unemployment made her pay back six months worth of unemployment benefits.  Then my check card number got stolen and my account drained.  Now we are trying to sell Laura's house, and she's upside-down on it so we will have to come up with the money just to be rid of it.  We are working through it, but it's really taken a hit on what we can do with this project.

First, a BIG box from Summit with the last batch of parts ordered about a month ago:
(http://lh3.ggpht.com/_mDxOuTI25gI/SsX3DmsnLqI/AAAAAAAADFE/Yg3fSCUIzlE/s800/IMG_4200.JPG)

Also not shown, an ATP turbine outlet flange for a T-3, and a 2"-2 1/2" silicone elbow.

Drilled and taped the EGT port on the manifold- that was a ***, since the runners would interfere with the T-handle wrench I was using on the tap- I had to inch it about an 1/8th of a turn, reposition the wrench, do another 1/8th of a turn, then carefully use a pipe wrench about 1/4 of a turn, then back to the T-handle again.  Took forever.
(http://lh5.ggpht.com/_mDxOuTI25gI/SsX3KGNPGaI/AAAAAAAADFI/16fvH1z76yI/s800/IMG_4201.JPG)

I've been farting around with manifolds too, and I won't be able to use the gasser intake, it just won't fit.  Since I have a TDI manifold here, I'm going to use that.  Of course, the head has round intake ports and the manifold has D-shaped ports, so I have to fix that.  Here's a pic, though from the angle you can hardly tell I did anything.
(http://lh4.ggpht.com/_mDxOuTI25gI/SsX3O7TPjVI/AAAAAAAADFM/9aT4q0fVUjA/s800/IMG_4206.JPG)

I stuffed some rags in the ports, and used a shop-vac while I was porting, kept all of the shavings out.

Here's the turbo installed, painted, and ready to go. 

(http://lh4.ggpht.com/_mDxOuTI25gI/SsX3S2O7jUI/AAAAAAAADFQ/aaPYXLY_sgc/s800/IMG_4207.JPG)

I have NO IDEA if it will fit.  I've read some bad things on the A2 board on VWVortex that the ATP manifolds will not clear the firewall.  I guess it depends on the turbo, this T3 is a little on the small side but bigger than the stock T3, so who knows.  I've taken some measurements, I can't tell where it's gonna be but if it clears, it will be close. 

EGT and block heater wires can be tucked away together.
(http://lh5.ggpht.com/_mDxOuTI25gI/SsX3XMwrAcI/AAAAAAAADFU/wY3_mxH45tA/s800/IMG_4208.JPG)

Oil drain line, which is more than likely going to interfere with the axle.  Might have to find a 90* -AN fitting from the oil pan then run the line to that.  Won't know until it's all bolted up though.  Looks pretty I guess.  :P
(http://lh4.ggpht.com/_mDxOuTI25gI/SsX3biDgRKI/AAAAAAAADFY/T231ylJ38o0/s800/IMG_4209.JPG)

My oil cooler, FINALLY, after buying from three different people online, someone finally actually sends me one.  :(  It was a mess, I cleaned it up good before taking this picture:
(http://lh4.ggpht.com/_mDxOuTI25gI/SsX3gOhiN2I/AAAAAAAADFc/-wVbcIolWFY/s800/IMG_4210.JPG)

Installed:
(http://lh4.ggpht.com/_mDxOuTI25gI/SsX3kTX5Y2I/AAAAAAAADFg/vL4UPYb-YEk/s800/IMG_4211.JPG)

The lines probably aren't going to work, depends on where I will mount the cooler I guess.  I'll cross that bridge when I get there. 

So that's it for now.  The goal is to have it running now, by the end of the month.  Most of what is left is little crap- not a lot to buy really.  I'll probably have to forget about having a tach right now, and I'll probably only have the vital gauges hooked up, I need the sockets for the OEM Audi gauges but they are $8 each not including bulbs, almost $25 just for gauge lighting is nuts. 

It seems the suspension is in good shape, I have rack boots to replace and a power steering line, which I will do while the engine is still out.  I know the rear wheel bearings are toast, but at least those are cheap and easy.  If all goes well, the engine will be in the car this weekend, that of course depends on what sort of chores I'll end up getting suckered in to between now and then.  :P

The next update should be with the engine in the car getting ready for it's first fire up. :D

Brendan
Title: Re: Wife's Project: 86 Golf NA (maybe TD?)
Post by: drrtybyl on October 02, 2009, 04:58:39 pm
Everything looks very fancy -- sorry to hear about your setbacks.
Title: Re: Wife's Project: 86 Golf NA (maybe TD?)
Post by: lord_verminaard on October 05, 2009, 10:30:17 am
The Eagle has landed.  Pics coming soon.  :)

Brendan

Title: Re: Wife's Project: 86 Golf NA (maybe TD?)
Post by: gilligan5000 on October 06, 2009, 08:13:07 am
c'mon.........work is draggin and I really need some movitation!

Title: Re: Wife's Project: 86 Golf NA (maybe TD?)
Post by: lord_verminaard on October 06, 2009, 01:58:26 pm
Ok, as promised, here are the pics from this weekend.  Took a day off on Sunday to work on the car so I got a lot done.

Saturday:
Fitting the TDI intake manifold, and getting ready to drop the engine in.  I managed to pop out to the Porsche shop last week and fab up a "race pipe" for the manifold- my intercooler tubing is 2.5" and the inlet of the TDI manifold is roughly 2", so to use a 2.5" to 2.25" reducer, I had to open up the TDI inlet a bit more.  So that was first:
(http://lh3.ggpht.com/_mDxOuTI25gI/Sst2-gqVLUI/AAAAAAAADGc/C_xuVfxdfzI/s800/IMG_4214.JPG)

And the "race pipe":
(http://lh6.ggpht.com/_mDxOuTI25gI/Sst3BurM-LI/AAAAAAAADGg/7nmIXVHBnhM/s800/IMG_4215.JPG)

Low and behold, the TDI manifold also DID NOT FIT so I had to once again file away at the flange side so it would slide into place.  Counter-flow VW heads are a PITA.

Anywho, that done, I installed a new pressure hose for the power steering, which was not quite as bad as I thought it would be.  Also loosely dropped on a new front mount. (which I later learned you should attach to the engine, not the subframe first)
(http://lh6.ggpht.com/_mDxOuTI25gI/Sst3G2z_A1I/AAAAAAAADGk/t6iGe4KuEkM/s800/IMG_4216.JPG)

And popped on the new speedo gear for the ACN tranny:
(http://lh4.ggpht.com/_mDxOuTI25gI/Sst3Ky8thDI/AAAAAAAADGo/wm4d59TwoRQ/s800/IMG_4218.JPG)

Finally, the rest of the 4-crawler bushing/linkage kit:
(http://lh3.ggpht.com/_mDxOuTI25gI/Sst3PcU6JCI/AAAAAAAADGs/RgVrwTHRfeg/s800/IMG_4219.JPG)

(also learned that it's better to leave that upper linkage arm OFF while lowering the engine into place  :rolleyes: )

All systems go!
(http://lh4.ggpht.com/_mDxOuTI25gI/Sst3X41NBVI/AAAAAAAADG4/84yWrs6Vvf8/s800/IMG_4221.JPG)

(http://lh6.ggpht.com/_mDxOuTI25gI/Sst3cg5EcaI/AAAAAAAADG8/UYdR3cO31ug/s800/IMG_4222.JPG)

(yeah, I had to loose the silicone connectors too)

On Sunday, it started with me replacing the rack boots.  HOLY HELL what a pain.  Of course, both tie-rod ends were seized to gorilla-tight proportions, and reaching the drivers side boot to put it in place, while trying to carefully feed the invisible vent tube, was about enough to try my patience to the end.  Thankfully I managed to get it done.  If I have to do it again, I'm dropping the whole damn subframe.

IT FITS!!!
(http://lh4.ggpht.com/_mDxOuTI25gI/Sst3m4_ZU5I/AAAAAAAADHE/54IgrqtUvQQ/s800/IMG_4224.JPG)

It's close...
(http://lh5.ggpht.com/_mDxOuTI25gI/Sst3r78eFYI/AAAAAAAADHI/t3mVynkf8gY/s800/IMG_4225.JPG)

Really close....
(http://lh3.ggpht.com/_mDxOuTI25gI/Sst3wEQPBgI/AAAAAAAADHM/nI0XRqu9HVA/s800/IMG_4226.JPG)

Like.. super-OMGWTF close....
(http://lh5.ggpht.com/_mDxOuTI25gI/Sst30BzZRlI/AAAAAAAADHQ/t-Yk_HQPVx0/s800/IMG_4227.JPG)

Gonna be fun getting the downpipe around all that junk...
(http://lh6.ggpht.com/_mDxOuTI25gI/Sst34WBxMmI/AAAAAAAADHU/XDXgsTyeXdc/s800/IMG_4228.JPG)

Also gonna be fun getting the inlet hose in there.... Probably will require another piece of expensive silicone.  :(
(http://lh6.ggpht.com/_mDxOuTI25gI/Sst36_iTuHI/AAAAAAAADHY/ruQqWlDI6Es/s800/IMG_4229.JPG)

One major epic fail:
(http://lh4.ggpht.com/_mDxOuTI25gI/Sst3hzgFu0I/AAAAAAAADHA/sjt9d1lRRwY/s800/IMG_4223.JPG)

Shouldn't be hard finding another one, but the question is, will it be clean enough that I can actually remove the receiver dryer without twisting the lines off like this?

And, to finish it all off, a final shot of the day, I loosely put the grille and headlights in and it all lines up pretty good.  Still gotta paint the lower trim strip.
(http://lh4.ggpht.com/_mDxOuTI25gI/Sst3_0MdndI/AAAAAAAADHc/RZL60xpiigA/s800/IMG_4230.JPG)

So, punch list looks like this right now:
-Need both upper radiator supports, mine are MIA.
-Find good used condenser.
-Route the wiring where it's supposed to go, run additional wires.
-Fabricate downpipe/exhaust.
-Fit the intercooler.
-Fit the air/oil cooler, possibly fab new lines.
-Fit the boost tubing.
-Install electric lift pump.
-Install additional relays for headlights and glowplugs.
-Buy new coolant distribution pipe
-Need a new coolant hose or two and clamps
-Coolant
-Oil
-Battery
-Prime oil and fuel
-FIRE IT UP!

Wife and I are going over money issues tonight, we might dip into our emergency savings to finish this up.....

Stay tuned.  If I don't keep getting swamped with side-work and misc. errand running every day this week like I have been for the past month, I might get started on the downpipe.  I've already got everything I need to do that.


Brendan
Title: Re: Wife's Project: 86 Golf NA (maybe TD?)
Post by: lord_verminaard on October 07, 2009, 04:39:41 pm
Wow, I guess nobody cares anymore.  :P

Brendan
Title: Re: Wife's Project: 86 Golf NA (maybe TD?)
Post by: theman53 on October 07, 2009, 06:18:29 pm
I had the exact fail on my a/c. I decided to wait until next spring to deal with that.
Did you get copper nuts for the downpipe? If so tell me about that as they would probably take heat better than my stainless ones.
Title: Re: Wife's Project: 86 Golf NA (maybe TD?)
Post by: lord_verminaard on October 08, 2009, 09:45:17 am
Yep, same nuts that are used on the exhaust manifold.  Long story, but I ended up not using studs/nuts on the exhaust manifold since I couldn't find the right studs, so I had a bunch of left-over nuts.  (I think 2 or three sets I've come upon in the years) I could in-fact use the incorrect studs I bought to replace the studs on the turbo so that's what I did.  :)  Nothing is going to waste in this build.  :D

Brendan
Title: Re: Wife's Project: 86 Golf NA (maybe TD?)
Post by: booneylander on October 08, 2009, 03:49:47 pm
In for more pics and updates!
Title: Re: Wife's Project: 86 Golf NA (maybe TD?)
Post by: clarkrep on October 08, 2009, 09:32:50 pm
I've got rad mounts and the ac components you need if you want them. IM me.
Aaron
Title: Re: Wife's Project: 86 Golf NA (maybe TD?)
Post by: lord_verminaard on October 12, 2009, 11:11:03 am
Aaron- thanks for that, I may have a local source, if not, I'll hit you up.  :)

-Built my first turbo downpipe this weekend.  It turned out GOOD!  I'll post pictures soon.

Brendan
Title: Re: Wife's Project: 86 Golf NA (maybe TD?)
Post by: lord_verminaard on October 12, 2009, 01:48:28 pm
...And here they are.

I didn't get much time to work on the car this weekend, and when I did finally get some time on Sunday, I spent about three hours looking for crap and about 2 hours of actual work, followed by about an hour of fixing my welder.   :banghead:   But here it is, this is the first real welding project I have done, having probably a total of about 20 minutes of welding experience under my belt before I started.  Only made one real small mistake, (and thankfully, it was about halfway done when I realized it too!) on the first bend I didn't allow enough of the bend in the first cut, so the shifter arm hit the downpipe going in 5th.  I cut it and added a small slice, fits perfect after that.  I'll let the pics do the talking.

(http://lh5.ggpht.com/_mDxOuTI25gI/StNZ0J5VUiI/AAAAAAAADH8/5rTywQjY0Iw/s800/IMG_4294.JPG)

(http://lh3.ggpht.com/_mDxOuTI25gI/StNZ6aOaXmI/AAAAAAAADIA/rbr9Q0Q-IKg/s800/IMG_4295.JPG)

(http://lh6.ggpht.com/_mDxOuTI25gI/StNaABYWG_I/AAAAAAAADIE/bMXoPIZFIIM/s800/IMG_4297.JPG)

Under the car:
(http://lh5.ggpht.com/_mDxOuTI25gI/StNaEy1OZlI/AAAAAAAADII/PJA5jn4V6bg/s800/IMG_4298.JPG)

(http://lh3.ggpht.com/_mDxOuTI25gI/StNaLBD_OgI/AAAAAAAADIM/ABJ-kpZwG5I/s800/IMG_4299.JPG)

Miles of room!
(http://lh3.ggpht.com/_mDxOuTI25gI/StNaQmU58MI/AAAAAAAADIQ/e11ODTWEAAo/s800/IMG_4300.JPG)

How's it look?

Brendan
Title: Re: Wife's Project: 86 Golf NA (maybe TD?)
Post by: booneylander on October 12, 2009, 01:52:37 pm
Nice! Keep up the good work!
Title: Re: Wife's Project: 86 Golf NA (maybe TD?)
Post by: clarkrep on October 12, 2009, 03:20:20 pm
Looks nice, way better than my first welds!
Title: Re: Wife's Project: 86 Golf NA (maybe TD?)
Post by: macka on October 12, 2009, 04:19:41 pm
so whats the dealio on the intake? Sillycone or a stock rubber piece? If you are junkyard searching, I think the Merkur turbo models had some tight intake angles and some nifty rubber parts to go with it.
Title: Re: Wife's Project: 86 Golf NA (maybe TD?)
Post by: theman53 on October 12, 2009, 05:46:32 pm
That is really good for your first welds. Is that 2.5 or 3 inch pipe. It looks like it was supposed to be there.
Title: Re: Wife's Project: 86 Golf NA (maybe TD?)
Post by: 1outof5 on October 13, 2009, 03:53:16 am
those welds don't look like you only have 20 minutes experience so I guess congratulations are in order: well done  8)
the exhaust does look right where it needs to be.
Title: Re: Wife's Project: 86 Golf NA (maybe TD?)
Post by: lord_verminaard on October 13, 2009, 09:56:32 am
so whats the dealio on the intake? Sillycone or a stock rubber piece? If you are junkyard searching, I think the Merkur turbo models had some tight intake angles and some nifty rubber parts to go with it.

LOL Merkur turbos.  I've only seen like 3 of those in my whole life.  :)  Doubt I'd find any in the junkyards around here.  I think the rice section at AutoStoned has some stuff I can use.

Title: Re: Wife's Project: 86 Golf NA (maybe TD?)
Post by: lord_verminaard on October 13, 2009, 09:58:33 am
That is really good for your first welds. Is that 2.5 or 3 inch pipe. It looks like it was supposed to be there.

Thanks!  It's 2.5" pipe, all from Summit.  Good quality stuff and cheap.  Before I fixed the mistake, I clamped it in the vice and hung from it with all of my weight thinking I could tweak it a bit, that was a fail.  :)  Good way to test your welds though.  :D  The rest of the exhaust should go smoothly I hope.

Brendan
Title: Re: Wife's Project: 86 Golf NA (maybe TD?)
Post by: Rabbit TD on October 13, 2009, 09:44:04 pm
That is about as good as it could possibly get in my opinion.  Excellent fit too, I cant imagine how you got everything so precise that it fits like that.  If I had ordered one from a professional fabricator I really wouldn't expect it to come out that good today.  I've been welding for about the same time also but we're obviously not in the same league from your pictures, you're way better ;D  I got an auto-darkening helmet when I got my mig welder last year, Northern tools $49.  It works great but even on it's brightest setting (9) it is still a little too dark for a beginner like me to really see good, even outside on sunny day when doing something as light gauge as exhaust tubing.  I can't imagine what a fixed shade must be like unless they make some lighter than 9 in a fixed version.  They probably do but since I'm no welder I have no idea.  I know you are gonna get some "can you make one for me" posts ;D
Title: Re: Wife's Project: 86 Golf NA (maybe TD?)
Post by: Possum79 on October 13, 2009, 09:55:57 pm
I can't imagine what a fixed shade must be like unless they make some lighter than 9 in a fixed version.  They probably do but since I'm no welder I have no idea.  I know you are gonna get some "can you make one for me" posts ;D

Trust me you don't want flash burn. When I was in welding classes I thought they said OSHA requires at least a shade of 10 for welding and a 5 for oxy acet. Some guys in my shop class back in high school "forgot" their helmet. They never forgot it again after a day or two of severe eye ache/ head ache. Lucky they didn't go blind.  A 9 probably wouldnt be bad for only welding once in a while though. Its not a lot lighter. And yes they are avaliable at welding supply shops.

Just thought I would add that. Also I agree for 20 mins of weld time those aren't half bad. Welding on pipe is hard enough let alone thin pipe.
Title: Re: Wife's Project: 86 Golf NA (maybe TD?)
Post by: Rabbit TD on October 13, 2009, 11:29:09 pm
I can't imagine what a fixed shade must be like unless they make some lighter than 9 in a fixed version.  They probably do but since I'm no welder I have no idea.  I know you are gonna get some "can you make one for me" posts ;D

Trust me you don't want flash burn. When I was in welding classes I thought they said OSHA requires at least a shade of 10 for welding and a 5 for oxy acet. Some guys in my shop class back in high school "forgot" their helmet. They never forgot it again after a day or two of severe eye ache/ head ache. Lucky they didn't go blind.  A 9 probably wouldnt be bad for only welding once in a while though. Its not a lot lighter. And yes they are avaliable at welding supply shops.

Just thought I would add that. Also I agree for 20 mins of weld time those aren't half bad. Welding on pipe is hard enough let alone thin pipe.
Yes that was my problem, on the light gauge pipe you have to have the heat setting down to 2 I think it was with the .030 solid core and using gas I was getting very good welds, the problem was they weren't where I thought they were because it was too dark with the light flash of the low heat setting to see what I was doing.  I'll have to do some lighting experimenting with a halogen light or somethng to see better I guess ???
Title: Re: Wife's Project: 86 Golf NA (maybe TD?)
Post by: lord_verminaard on October 14, 2009, 09:08:27 am
Heh, thanks guys, I actually thought about building a jig so I can replicate these, but I don't have time for that right now, and I really didn't expect it to fit this good either, since a handful of the angles were "eyeball and guess" at best. 

I was an idiot and bought a non-auto darkening helmet a while back, that was a mistake.  I borrowed an auto-darkening one for this job, and will probably buy one at Harbor Freight the next time I have $50 in my pocket.  I also used a chain-type exhaust cutter to make all of the cuts.  It took a little while, but with a cutter like that, the only way you can cut pipe is squarely, so all of your inner diameters are consistent.  I might buy a new one instead of a chop saw.  I don't have air in my garage so cleaning up the rough cuts of a chopsaw would take a lot more time than it took me to wire-brush the cuts I made with the chain cutter.  :)

Believe it or not, the old guy I work with at the Porsche shop does not use a welding helmet at all.  He's been doing it that way for 40 years so who am I to question.  One of the first couple times I came out there to help, I had on the helmet, but had a short-sleeve shirt on, my arms got cooked.  I have no idea how his eyes (or face!) can handle that.

I'll add that I was using a 30-year old Snap-on welder.  I've only used about 3 or 4 welders, most of them newer, in my life (and obviously none of them for more than about 5 minutes) but this one welds so nice.  I actually have two of these same models, a YA-205, I'd eventually like to set up the other one for stainless.  It's cost me enough already just for the stupid small bottle of C25 and running the 220 to the garage.  :P

Brendan
Title: Re: Wife's Project: 86 Golf NA (maybe TD?)
Post by: macka on October 14, 2009, 09:18:37 am
if you buy an auto shield, spend the extra $$ and get a good one. Your eyes are worth it.
Title: Re: Wife's Project: 86 Golf NA (maybe TD?)
Post by: lord_verminaard on November 02, 2009, 09:46:01 am
Bringing this back up...

A few updates, but not much.  I was hoping to have the car fired up this weekend, but it didn't happen.  Hopefully I'll be able to put some time into it this week in the 40 minutes of daylight I have after work.

From last week, the lift pump is installed and works:
(http://lh5.ggpht.com/_mDxOuTI25gI/Su4aIq_wKbI/AAAAAAAADLg/5EzU8NkmyRM/s800/IMG_4471.JPG)

Wires are run into the passenger compartment but not to the fuse panel yet.  I did test it with a battery I had laying around, it pumps fuel!  Filled the fuel filter and had fuel coming out the return so it works.  No leaks either and it's a nice clean setup.  I originally had kept the water separator back here and installed the pump with it, but like an idiot I turned the valve on the water separator to see if it still worked, and the valve broke off instantly and splashed diesel everywhere.  I later found out that since most fuel filters have water separators built-in to them, and our fuel is better now than it was in 1986, the rear separator isn't needed anymore.  Oh well.

Here's the pump I used:
(http://lh6.ggpht.com/_mDxOuTI25gI/Su4aPL4rJQI/AAAAAAAADLk/DKGSlMQLOhs/s800/IMG_4473.JPG)

And yesterday, I got the console out and modified for gauges:
(http://lh5.ggpht.com/_mDxOuTI25gI/Su4aY8lbYDI/AAAAAAAADLo/wGnlpAasfAc/s800/IMG_4525.JPG)

(http://lh3.ggpht.com/_mDxOuTI25gI/Su4ag5IZOiI/AAAAAAAADLs/SM298q5eBTg/s800/IMG_4530.JPG)

I have most of the wiring done for the gauges, still need to run the wires into the car.  I also had to scavenge the backlights from the gauges in my Scirocco since these Audi gauges didn't have the sockets with them.  I think it looks good though, and it passed the Wife Test.  :)  I like it because the lower cubby is still usable, and the radio will be in the stock location.

That's about it really.  I noodled around under the hood some, got most of the stuff in order, cobbled together a working vaccum system, tucked some wires, arranged the harnesses, and managed to somehow break the ground stud that is on the driver's inner fender.   :banghead: 

I'm going to fabricate two upper radiator supports and attempt to push in the radiator about 2", I think that will give me just enough room to fit the intercooler in there with a little trimming to the core support.  But I think once the wiring is done, I will fire it up without the intercooler anyway just to get it warmed up for the re-torque before we break it in properly.    :laugh:

So, next week she should be running.  We'll see.

Brendan
Title: Re: Wife's Project: 86 Golf NA (maybe TD?)
Post by: clarkrep on November 02, 2009, 11:40:25 pm
Looks nice, I like how the gauges look kinda factory.  I have a lift pump like that on my mk1 gti and it works well(7psi at the IP inlet) One thing i would do though is mount it with a rubber mount cause they make the whole floor pan vibrate when mounted solid. I used one of the cis fuel pump mounts that was there already.
Aaron
Title: Re: Wife's Project: 86 Golf NA (maybe TD?)
Post by: GEE-BEE on November 03, 2009, 12:11:11 am
I removed the cis pump in my caddy...

Do i need to install a pump, It seems to get plenty of fuel from the gravity feed ?

Gee-Bee

Need a gasket made let me know ?

I do silicone only...
Title: Re: Wife's Project: 86 Golf NA (maybe TD?)
Post by: twardnw on November 05, 2009, 12:00:38 am
Do i need to install a pump, It seems to get plenty of fuel from the gravity feed ?

The pump isn't required, it does help if you for some reason small amounts of air are making it into the lines, or fuel is draining back toward the tank when the pump is off. And it will REALLY help if you ever run out of fuel, makes priming the pump an almost non-issue.
Title: Re: Wife's Project: 86 Golf NA (maybe TD?)
Post by: lord_verminaard on November 05, 2009, 10:44:15 am
Hey Tyler, welcome.  :)

Brendan
Title: Re: Wife's Project: 86 Golf NA (maybe TD?)
Post by: theman53 on November 05, 2009, 06:59:59 pm
I love the way your center consol looks. I was going to head to summit racing today to get some gauge mounting holes, but didn't make it. The purpose was to make my consol look like yours here and the summit is the cheapest route I could find. Where did you get your gauge mounting stuff? Looks great I would love to see it in person someday, let me know when you get it done and if that would be ok.
Title: Re: Wife's Project: 86 Golf NA (maybe TD?)
Post by: lord_verminaard on November 08, 2009, 08:03:17 am
Thanks!

The Audi triple-gauge setup already came with the plastic bezel, I'm guessing it was the original Audi one.  My Scirocco had 5 gauges in it, so someone else had made up the panels for that.  I trimmed the Audi one to fit, and cut one of the holes off of the triple one that was in the Scirocco for the two-gauge pod.  I just made a couple L-brackets from some flat stock to mount the lower one, and the upper one is held in place by one of the "u"-brackets that hold the gauge to the bezel and with a quick homemade bracket on the other side.  The two screws on the top piece are just to cover up existing holes that were already there.  :)

Brendan
Title: Re: Wife's Project: 86 Golf NA (maybe TD?)
Post by: lord_verminaard on November 08, 2009, 08:04:36 am
Update: 


IT RUNS!!!!!!!!!!!    :laugh:  :beer:  :thumbup:

Fired it up right as it got dark last night.  Took about 20 sec. of cranking before I could hear one cylinder firing, then about 10 sec. more before two of them were firing, then about 5 more sec. of that and it roared to life!  Man, I was a happy camper.  It managed to start on only 2 glow plugs too, as I was trying to hurry and couldn't reach the two on the passenger side.  (my 8mm wrench vanished somewhere!!!)

2 issues, like an idiot, I forgot to tighten down the power steering pressure hose at the pump, so it sprayed PS-foam everywhere.  Also had a fuel leak at the return line, so I shut the car down, and fixed those issues before starting it back up again.  Fired up immediately the 2nd time.

I have a few issues to solve.  The first major one, that I need to fix before I start it up again, is that none of my aux. gauges are reading correctly.  (at least I hope not)  The oil temp gauge maxes out immediately as soon as it gets power, the volt and oil pressure gauges move slightly from 0 but neither one of them do anything after that.  I am not really comfortable running this engine without oil pressure.  The idiot-light works when you turn the key, then goes off as soon as the car starts, so I am assuming that is working correctly.  I have spare oil pressure and oil temp gauges from the Scirocco, after I verify correct voltage at the gauge I will swap them out to see if they are malfunctioning.

I also need an insulator on the fuel pump, it's kinda loud reverberating on the body.  Aaron was right about needing one.  It doesn't vibrate so much but it's louder than I'd like it.

Still gotta build the intake and fit the intercooler.  Gonna try to tackle that today.  I also temporarily wired up the glow plugs so I need to finalize that today too. 

Exciting!!!!

Brendan
Title: Re: Wife's Project: 86 Golf NA (maybe TD?)
Post by: theman53 on November 08, 2009, 08:09:29 am
I bet a peice of tire tube would work for that pump. Great to hear that it works, but weird about the gauges.
Title: Re: Wife's Project: 86 Golf NA (maybe TD?)
Post by: lord_verminaard on November 09, 2009, 10:21:59 am
Remainder of the weekend was full of beating my head against the wall but at least I have some peace of mind.
So I started to troubleshoot the gauge issue. The Audi volt gauge was bad.   Replaced it with a spare Scirocco gauge, works great now. I was using my digital multimeter to test things, when all of a sudden it just went all retarded on me.   Thankfully, I had a very old analog spare meter, it actually worked really well.

Next was the oil temp gauge, it pegs all the way right as soon as it get's voltage. I swapped it out with a rabbit oil temp gauge, and it does the same thing.   The temp sender is a new one I bought at GAP. Have not figured out that one yet.

Oil pressure: It moves up to 0 when it get's power, but goes nowhere after that, even when the car is running. I swapped out the gauge (for yet another spare) and it does the same thing. The oil pressure warning light comes on after the car is revved up. So not wanting to take any chances, I went to the parts store and bought a cheap mechanical oil pressure gauge to hook up temporarily. Getting the fittings and adapters was a nightmare. It's amazing to me that you can go to every parts store in town and nobody has a M10x1 to 1/8th compression adapter anywhere. I hooked it up and though it leaked everywhere, I got 75 PSI cold at idle, so that's good.

Next, I replaced the low pressure switch on the side of the head with the VDO dual-post sender I was using, this one to be exact: http://www.egauges.com/vdo_ind...0-006 (http://www.egauges.com/vdo_ind...0-006) and I get the oil light at ignition, and it goes out after it starts. Good. Still no pressure on the gauge.   Put the high-pressure stock switch back in the oil flange, and no more oil light after 2000 rpms, so that's a WIN too.

At least I know the oil pressure is good. I let it run for about a half hour, the cooling fan kicks on when it is supposed to, though the oil temp never got high enough to open the thermostat in the oil cooler. Also, while blipping the throttle, the turbo spins up really well.   I was afraid it was too big, but if it's spinning up without any load on it, I'm sure it will do fine. The timing is off some, as there is a bit of white fuel smoke while it's running, but that will be easy enough to fix once Andrew gets his timing kit sorted.  :)

I have an exxon-valdez style oil leak somewhere, I think from the front oil flange fitting when I re-threaded the high pressure switch back in. The wiring is still a mess, and most of the interior is out of the car. But it's coming along! At least 3 nights this week are booked after work but the remaining 2 I'll try to tie up some loose ends and finalize the wiring, then maybe next weekend we can drive this thing. 

Brendan
Title: Re: Wife's Project: 86 Golf NA (maybe TD?)
Post by: lord_verminaard on November 24, 2009, 07:09:29 pm
Well here we go.  Another update, I've actually been working on it pretty steadily, but it seems that some days I'll spend the whole day and nothing really ends up getting done.  But there is some real progress to report.

First up, the wiring is all finished and the interior is back together except for the passenger seat.  I had ripped all the seats out, most of the carpet, and vaccumed everything while I was doing the wiring.  Got all of the gauges sorted and working, and got the glow plug "pimping" done.  I was figuring out where to mount all of the electrical additions with the glow plug system and relaying the headlights and didn't like the idea of just plopping it in the engine bay somewhere.  So I had a spare ECU bracket from a digi car, and low and behold, the Golf has the mounting pins for it in the raintray.  So I decided to put all my crap on that.
(http://lh3.ggpht.com/_mDxOuTI25gI/SwxprDWy5bI/AAAAAAAADOc/-eUHrojNPvw/s800/IMG_4647.JPG)

(http://lh5.ggpht.com/_mDxOuTI25gI/Swxpwy2dGmI/AAAAAAAADOg/Vlq_k2xp_8k/s800/IMG_4648.JPG)

I especially like the solenoid underneath like that away from stray tools and wires and whatnot as opposed to being in the engine bay directly. 

Here it is all wired up and installed:
(http://lh3.ggpht.com/_mDxOuTI25gI/SwxqmibwTxI/AAAAAAAADPI/8S9mFVfJ_nc/s800/IMG_4689.JPG)

(http://lh6.ggpht.com/_mDxOuTI25gI/SwxqroUnYsI/AAAAAAAADPM/OT0UsnOkHFI/s800/IMG_4690.JPG)

I spent a lot of time wiping down everything inside the car to clean it up before I put it together.  Here's the results of that effort:
(http://lh6.ggpht.com/_mDxOuTI25gI/Swxqbu03dGI/AAAAAAAADPA/56tyedm9LgY/s800/IMG_4687.JPG)

(http://lh3.ggpht.com/_mDxOuTI25gI/SwxqhWWBHQI/AAAAAAAADPE/h-qSrBT_-ds/s800/IMG_4688.JPG)

On order are all new seat sliders and a new switch blank to cover that hole.  Stereo coming eventually.  :P

Next up, the god damn intercooler.  For the record, the SAAB intercooler is not the best for this application, there just isn't a good place for it.  I spent most of a day modding the AC condenser from my Corrado to make it fit since it was a little bit smaller, and when I was putting all of the AC lines back in, (with new o-rings) I twisted off the end of one of the fittings, and it was the last freaking line before the system was done.  DAMMIT!   So I yanked all of it except the compressor out.  No AC for this car for now, maybe later.  That gave me more space to mount the intercooler but it was still a bastard, I had to cut one of the mounting posts off of the intercooler, and nip one of the mounting bosses off of the radiator, and cut a lot of the core support away completely.  But it fits!
(http://lh3.ggpht.com/_mDxOuTI25gI/SwxqEInSBII/AAAAAAAADOs/FrZrN_cccr8/s800/IMG_4683.JPG)

Also tucked away on the right side is the oil cooler with a simple L-bracket to hold it in place.  

The intercooler piping was a pain too.  I had some left over exhaust bends, so I had to fabricate some pipes to go along with the cxracing.com aluminum pipe kit.  I had to dimple one of the pipes with a hammer to clear the Alt. pulley:
(http://lh6.ggpht.com/_mDxOuTI25gI/SwxqOkkTlFI/AAAAAAAADO4/2Iez_ZnoDhE/s800/IMG_4685.JPG)

It's a TIGHT fit.  But I think it will work.  Here are the rest of the pics that I took tonight:

The bay as it sits right now:
(http://lh3.ggpht.com/_mDxOuTI25gI/Swxp3XmR4AI/AAAAAAAADOk/l1w5rAmJ9Yk/s800/IMG_4681.JPG)

Still a few wires to clean up when I get around to it.
(http://lh4.ggpht.com/_mDxOuTI25gI/Swxp-gwt-TI/AAAAAAAADOo/QUOWnfeh8Xg/s800/IMG_4682.JPG)

Yes, I'll put the upper timing cover back on.  Didn't feel like doing it tonight.
(http://lh4.ggpht.com/_mDxOuTI25gI/SwxqKKyn4kI/AAAAAAAADOw/r7Y3IZR0Z44/s800/IMG_4684.JPG)

The "Spectre" air filter and intake pipe kit from the rice section at AutoStoned.  PITA to work with and the pipes are plastic, but unless you can bend and weld aluminum, it will have to do.  It actually fits pretty nicely after I got it all together.
(http://lh4.ggpht.com/_mDxOuTI25gI/SwxqULw_PdI/AAAAAAAADO8/oQx--mT7Jn4/s800/IMG_4686.JPG)

Whew.  I had a bit of drama as some of you might know, I had to remove the injection pump to fix a coolant leak that I could not reach, and apparently when it put it back together, I got the timing off a bit and she wouldn't start.  I went out and fixed that tonight and she starts right up, and no sign of the leak either.  I think the timing is still advanced a bit too much as the "diesel clatter" is a bit louder than I think it should be, but it's about time to drive this thing.

I need to un-stick the parking brake, slap on the axles, (still have no idea if the turbo oil drain line will clear!!!) and get it on the ground for a trial run.  Hopefully I can get that done this weekend.  Wish me luck!!!

Brendan
Title: Re: Wife's Project: 86 Golf NA (maybe TD?)
Post by: theman53 on November 24, 2009, 09:18:15 pm
If you need to use my dial indicator let me know. My car is down and will be probably all winter as I have nowhere to work on it warm. So let me know and I can let you borrow it for a time. I am in MT Vernon about once a week ... Free delivery :D
Title: Re: Wife's Project: 86 Golf NA (maybe TD?)
Post by: truckinwagen on November 24, 2009, 09:21:47 pm
I actually kinda like the Spectre intake parts, they are reusable, and even seal with an O-ring.

for those of us who don't have access to all the tooling required for aluminum or stainless fabrication, they make for a very usable and affordable alternative.

good looking car by the way!

-Owen
Title: Re: Wife's Project: 86 Golf NA (maybe TD?)
Post by: lord_verminaard on November 25, 2009, 10:02:37 am
If you need to use my dial indicator let me know. My car is down and will be probably all winter as I have nowhere to work on it warm. So let me know and I can let you borrow it for a time. I am in MT Vernon about once a week ... Free delivery :D

Thanks man, that would be great!  :)

Brendan
Title: Re: Wife's Project: 86 Golf NA (maybe TD?)
Post by: lord_verminaard on November 25, 2009, 10:05:30 am
I actually kinda like the Spectre intake parts, they are reusable, and even seal with an O-ring.

for those of us who don't have access to all the tooling required for aluminum or stainless fabrication, they make for a very usable and affordable alternative.

good looking car by the way!

-Owen

Thanks!  Yeah, I'd be pretty much screwed without the Spectre stuff, when you are trying to make an intake for a car that is using a non-standard... well.. everything, it really helps.  I just wish that for what you payed for the stuff, it would at least be thin-walled aluminum.  :P  I had trouble with the o-rings falling out while trying to loosen the clamps enough to get the pipes together without dropping the little clamp screw.  Eventually I'll probably get more of the stuff for my Corrado since it just has a cheesy filter at the end of the MAF.

Brendan
Title: Re: Wife's Project: 86 Golf NA (maybe TD?)
Post by: GEE-BEE on November 25, 2009, 12:19:33 pm
The silicone tape ( blue or black )might work for you on your wires, I purchased two rolls in black for my compartment
boostcontroller.com

item :Samco-sst-30-bk  19.86 per roll

Looking good !
Title: Re: Wife's Project: 86 Golf NA (maybe TD?)
Post by: arsenicpants on April 06, 2010, 01:55:51 pm
any updates on this car?
I'm doing a mk1 Jetta with the same intercooler, and was hoping to do the same piping setup, since running it completely around the motor seems like a big waste
is there any heat soak from the hot pipe to the cool pipes? is that even an issue?

it seems like the hot air would rise up from the hot air pipe and re-warm the air in the cold side pipe
Title: Re: Wife's Project: 86 Golf NA (maybe TD?)
Post by: theman53 on April 06, 2010, 06:40:25 pm
I saw it a couple weeks ago. Runs good from what I could see. He needed an oil fitting and I gave him mine, but it didn't work *wrong size* Hopefully he will comment too.
Title: Re: Wife's Project: 86 Golf NA (maybe TD?)
Post by: lord_verminaard on April 07, 2010, 10:11:56 am
Sorry, I have not updated in a while.  I didn't have the time to update two forums at the same time, but I'll post what I've got.

I'm not running an intercooler anymore, I blew the end tank off of the old one.  Not completely off, but it split the seam in the plastic.  So I'm looking for another FMIC to use instead, since I hated the way the pipes were routed for that one anyway.  Here's the most recent post from the Vortex:
______________________________

Well, this has probably fallen out of everyone's watched topics, and probably out of most people's memories. Time to bump this back up and give some updates.
I have some pictures not yet uploaded that I'll include a little later as well.

It's been a rough ride for this little car the past few months. But in true VW style, (and true VW ownership insanity) we have overcome and the car is really coming together.

So, the car got put into service rather quickly, there was not really any "shakedown" time before Laura needed to drive to work every day, so we had to work on things as they came, with usually a very limited time frame, plus there was the Ohio-winter weather thing to contend with.

The first order of business was the head gasket re-do back in December. I basically had a weekend allocated to do this, in a very cold garage. So Sunday rolls around, and I'm getting ready to drop the head back on. What I did when I initially assembled the engine to align the gasket and head/block, was put a small, deepwell socket in two of the head bolt locations to act as dowels, so after I got the head on and a couple of the bolts hand-threaded in, I used a magnet to pull out the sockets and bolt down the head. Simple enough, right? So I got my "alignment sockets" and dropped one in the front corner hole, and went to drop the other in the rear and- being cold and tired on Sunday night- accidentally dropped it in the oil drain hole instead. I heard it go all the way down the engine. I "assumed" that it made it all the way to the pan, I can fish it out later. I was wrong. The socket fell in to the windage tray instead. After getting it back together, I started it up, no noises, everything was fine. Took it for a test drive, and heard a loud clank. Again, everything was fine. Car was running, no smoke, all gauges were normal. Drove it about 3 miles or so, came back to the house, and popped the hood to check if the coolant leak was finally fixed and then I saw it: The end of the socket sticking out of the side of the block. It looked like a dart stuck through a piece of cardboard. Oil mist was all over the place. (though I didn't really loose that much) My heart sank. I thought it was done.

I looked at Bentley diagrams, and pictures of the block when it was apart, and I got some hope. There was a chance it didn't hit anything. So we made arrangements for Laura to get to work, and I took a day off to start tearing into it again. Pulled out the socket, drained the oil, dropped the pan, (in about 10* F high temp/snow that day!!) and had a look. There was a very small nick on one of the crank counterweights, a dent in the windage tray, and two small pieces of piston- I cracked off a piece of the bottom of the #3 skirt, about 2mm wide, 4mm long, which then broke in half. The bore in the block was fine. The socket made a near perfectly round 1/2" hole in the block. It missed the intermediate shaft and did not hit any oil galleries. I got lucky.

I cleaned the pan, (though managed to break the plastic baffle around the pump pickup- no time to replace it now!!) and contemplated how to handle the hole. I thought patch and JB weld, but then had a better idea. Drill and tap and use a plug. I had a 1/2" NPT pipe tap, and bought an iron square-head NPT plug, and borrowed a big-assed drill from my neighbor. Took the core support of the car off, moved the radiator out of the way, and carefully drilled out the hole. I then proceeded to tap, (by using a socket and ratchet instead of a proper tap wrench which would not fit in the space!!!) and carefully cleaned the hole and both sides of the block surface, and using a bit of sealant, tightened down the plug in the hole. It was perfect, almost like it was supposed to go there. Buttoned the car back up and it's holding fine.



After that incident, Laura decided to name the car "Lucky". I think it's fitting. 

Cathy happened to take a pic of the repair when we saw her at Daun's a while back, but otherwise I'll have to take a few pictures of it.

Edit: Here's the pic, thanks Cathy:
(http://i153.photobucket.com/albums/s221/starfighter53/Trippin%202010/IMG_7722small.jpg)

Many more updates since then, but I'll leave you all with that for now. I was actually very embarrassed about it, and even thought about not posting it at all, but from the few people I've told about it, it makes a great story so why not. Plus, I have something for the "Carnage Award" this year. 

Enjoy. More to come.

Brendan
Title: Re: Wife's Project: 86 Golf NA (maybe TD?)
Post by: theman53 on April 07, 2010, 11:23:47 am
Yeah Lord V you're the man when it comes to fixes of the unknown kind. Glad you got it going. Let me know if you need a hand in the future I would love to help someone that knows what they are doing...so I can learn.
Title: Re: Wife's Project: 86 Golf NA (maybe TD?)
Post by: truckinwagen on April 07, 2010, 11:46:31 am
dont feel bad about it at all, we all drop something in somewhere sometime, I dropped a woodruff key in the valve cover on my last build, it sounded like a bad rod bearing bouncing around in the head.
but I found it, and the miraculous lack of damage it caused.

good for you not giving up on that block!
Title: Re: Wife's Project: 86 Golf NA (maybe TD?)
Post by: vanbcguy on April 07, 2010, 12:38:37 pm
I lost one of my glowplug nuts down an injector hole once... Thankfully aluminum is NOT magnetic, while glowplug nuts ARE - I was able to fish it out ok.  I was having visions of having to pull my head until that.
Title: Re: Wife's Project: 86 Golf NA (maybe TD?)
Post by: Rabbit on Roids on April 07, 2010, 12:41:56 pm
I lost one of my glowplug nuts down an injector hole once... Thankfully aluminum is NOT magnetic, while glowplug nuts ARE - I was able to fish it out ok.  I was having visions of having to pull my head until that.

eh, just pick the car up, turn it upside down, and shake the nut out of the injector hole. no big deal... lol
Title: Re: Wife's Project: 86 Golf NA (maybe TD?)
Post by: Smokey Eddy on April 26, 2010, 02:01:07 pm
I must say i absolutely love your downpipe, glow plug wiring - very clean, and centre console with gauges! zomg so nice! WISH i had done that instead of drilling huge holes in my dash.
I've fubar'd this car up so much i sort of want to get a new dash and different gauges that match...
Title: Re: Wife's Project: 86 Golf NA (maybe TD?)
Post by: theman53 on June 16, 2010, 09:29:13 pm
Is it running well with no leaks yet? I hope so.
Title: Re: Wife's Project: 86 Golf NA (maybe TD?)
Post by: lord_verminaard on June 17, 2010, 10:44:34 am
Nope.  :(

Installed a catch-can, but it was too much restriction and blew the o-ring out of the dipstick tube.  Ended up threading a barb fitting into the hole in the block, and ran that to the can.  Helped a little, but I still have the valve cover open to atmosphere.  Need a better catch can than that cheap e-bay one. 

I finally swapped the stripped out fitting on the drain line to a new one with a barb (push-loc) but damn it is really hard to get a -10 hose on one of those things, especially doing it upside-down and covered in oil.  It only went on about half-way but I added a hose clamp to be sure it doesn't come off.  I still have a nasty, nasty oil leak somewhere, looses about a quart every 100 miles or so and makes a mess all over the driveway.  Not sure where it is coming from- back of the engine somewhere.  The Audi is currently in "service position" on my ramps so I don't have any space to work on it, so we'll just have to keep feeding it until I can get it done.

It's not running too bad right now.  We actually cleaned the car up, and shined the paint up as best as we could in preparation for our annual "Cincy" Scirocco gathering the first weekend in June down near Wilmington.  I had turned the fuel up a good amount (remember, EGT's are still high, boost is still very very late) so that I could keep up with the Sciroccos during the cruise, strangely enough EGT's didn't go up at all during highway driving.  They will climb very quickly when your foot is on it and not in the boost.  But the boost comes on a little earlier now, (but with a lot of smoke) and peaks at about 15 psi.  Not great but not too bad.

We estimated about 54 MPG during the 350-ish miles during the trip.  (speedo-odometer still not working) and the car got a lot of attention at Cincy for being a "kia".  (at Cincy, anything that isn't a Scirocco is a Kia and has to park in the Kia section)

A pic, after I blew a boost tube on I-71 on the way down:
(http://lh4.ggpht.com/_mDxOuTI25gI/TA2O465DCPI/AAAAAAAADd4/JWCa4NY4Zvs/s800/IMG_6077.JPG)


Still lots of work to do on it.  I'm not happy but at least my Wife can drive to work.  :P

Brendan