VWDiesel.net The IDI, TDI, and mTDI source.
General Information => Upgrades (non engine related ) => Topic started by: hillfolk'r on March 05, 2008, 08:18:33 pm
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ill have to post my "rebuild" pics here
(http://img233.imageshack.us/img233/2687/hpim1057zj0.jpg)
custom firewall for more turbo clearance,and a "kickout" in the fender for either an airbox,or air filter or somethin :wink:
(http://img248.imageshack.us/img248/7148/hpim1068mj7.jpg)
(http://img139.imageshack.us/img139/3520/hpim1053ig3.jpg)
heres almost 30k on my totalseals,they look great
(http://img132.imageshack.us/img132/3796/hpim1046vq0.jpg)
ouch,a paperweight
ill use it for manifold fabrication
(http://img175.imageshack.us/img175/7789/hpim1049yp3.jpg)
heres sort of the idea
(http://img521.imageshack.us/img521/7563/hpim1050uy1.jpg)
im gonna make exh manifold spacers
(http://img521.imageshack.us/img521/6196/hpim1051wl4.jpg)
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sweet :twisted:
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What engine did you get that exhaust manifold form?
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its a us mk1 early 4 into 2 manifold,flipped over
if you bolt a exh manifold on a head upside down,the ports match,BUT....!!
you have a clearance issue with the intake......
mill,grind,cut or chew the outer part of the exh manifold down so the intake clears
basically,look at the clearance notches that are on the exh manifold when its installed correctly,and mimic those notches...
you can even "cheat" and use a old exh manifold gasket flipped over on the manifold to trace the shape
then i ported the manifold nicely so i could get a nice shape for that 1 inch adapter...
it matches the dual port on one side,and matches the t3 on the other all tapered nicely....
i dont have pics but if you have seen one, the dual port round ports are now D shaped basically with the wall thinned/tapered down in between them
we were unsure but we just drilled right into the manifold for the 4 turbo bolts
even though the holes end up drilling away half of some of the orig bolt holes,it wasnt a problem,as all the studs were snapped off anyways:)
you gotta fill the holes before drilling anyways
we took a clean up cut on a milling machine...it can all be done by hand with grinders+stuff,itll just take longer
i got copper .060 sheet and made gaskets using a dremel...
i hope i was clear and didnt confuse you
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I think I get what you are saying about the adapter. Did you see my question to you in the other thread? I'll re-post it here:
Deo, any reason why you have the exhaust manifold flipped? I might have a spare dual-port gasser manifold left over. Interested in that adapter plate you made. :D
Just wondering, as I might need the space above for an intake manifold and I wanted to run the manifold pointed downward.
Any chance you could make another adapter plate? ;)
Thanks,
Brendan
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a coupla reasons i guess.....
easier to plumb the turbo oil drain for one
and general plumbing of boost tubes+intake is easier IMO
i would like to set it (manifold)back like 3/4 of an inch or so for better intake clearance
longer studs and spacers that resemble 3/4 inch thick "gaskets" will do the trick....
yea you get more intake clearance the other way for using a "gasser" style long runner intake,but exhaust routing looks like a headache
(im picturing an older callaway gasser look to an "under" turbo setup...)
heres a few pics
(http://img248.imageshack.us/img248/3185/hpim1067mq6.jpg)
before,sort of,1 patch in there:
(http://img517.imageshack.us/img517/6454/hpim1082lj4.jpg)
its funny,the welds look worse in the pics
:cry: hey i said i could weld,,,,you didnt ask if i was GOOD at it :lol:
(http://img517.imageshack.us/img517/5135/hpim1083cu5.jpg)
after,and im welding seams while im at it too:
(http://img399.imageshack.us/img399/5740/hpim1084em1.jpg)
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i welded a few patches in to get some straight edges to work with
(http://img98.imageshack.us/img98/3710/hpim1085sq2.jpg)
then i made my new cardboard firewall+taped that sumbish in thar
thats good nuff fer us there hillfolk
:lol: :lol:
(http://img87.imageshack.us/img87/9591/hpim1086qy0.jpg)
heres the start of the end or somethin
probably 7-9 hours so far,hard to tell i keep gettin interupted w/people stoppin by:(
(http://img87.imageshack.us/img87/6702/hpim1087ta8.jpg)
i got a side piece trimmed out also,but no pics yet
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she'll be comin round the mountain when she comes
man this is tedious
(http://img258.imageshack.us/img258/4892/hpim1096tp4.jpg)
inside view
(http://img297.imageshack.us/img297/3954/hpim1090yj9.jpg)
(http://img405.imageshack.us/img405/2166/hpim1095uz3.jpg)
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Looking good :D
I wish I had the time and the space....
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:shock: Wow, hardcore!
I like it!!! :)
Brendan
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This build makes me feel very guilty about putting off my motor mount swap due to laziness. :oops:
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Nice, I like the air duct, cold air intake de-luxe :lol:
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this guy....