VWDiesel.net The IDI, TDI, and mTDI source.
General Information => Upgrades (non engine related ) => Topic started by: regcheeseman on April 27, 2010, 06:45:35 pm
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Seeing as I'm detailing other bitts of this project elsewhere on here, some may be interested in the intended recipient...
Started out as a 1983 1300cc mk1 Golf Driver
(http://i492.photobucket.com/albums/rr281/regcheeseman/golf5.jpg)
Taken home and stripped out
(http://img83.imageshack.us/img83/5553/project001we1.jpg)
Rolled and bits restored
(http://i492.photobucket.com/albums/rr281/regcheeseman/Golf%20in%20progress/Progress006.jpg)
(http://i492.photobucket.com/albums/rr281/regcheeseman/Golf%20in%20progress/golf003.jpg)
Notched chassis rails to slam it.
(http://i492.photobucket.com/albums/rr281/regcheeseman/Golf%20in%20progress/Maysprogress008.jpg)
Vinegar soaked and 'rustbuster' epoxy masticed
(http://i492.photobucket.com/albums/rr281/regcheeseman/Golf%20in%20progress/rustbusted.jpg)
Starting to remove seam sealer and attack rust
(http://i492.photobucket.com/albums/rr281/regcheeseman/Golf%20in%20progress/P1010059.jpg)
Get 'em started young
(http://i492.photobucket.com/albums/rr281/regcheeseman/turbo002.jpg)
lots and lots and lots of holes welded up, seams welded paint stripped
(http://i492.photobucket.com/albums/rr281/regcheeseman/Golf%20in%20progress/Enginebaysmoothing002.jpg)
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Nothing cleans like a lot of paint!
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Big hole cut out
(http://i492.photobucket.com/albums/rr281/regcheeseman/Golf%20in%20progress/Enginebayweldingandholes004.jpg)
Big hole filled - note RHD car now has direct action brake servo (a big one too)
(http://i492.photobucket.com/albums/rr281/regcheeseman/Golf%20in%20progress/Brakeservomod007.jpg)
More epoxy mastic
(http://i492.photobucket.com/albums/rr281/regcheeseman/Golf%20in%20progress/July-grindertime009.jpg)
Filler
(http://i492.photobucket.com/albums/rr281/regcheeseman/Golf%20in%20progress/Fillerinenginebay002.jpg)
more paint
(http://i492.photobucket.com/albums/rr281/regcheeseman/Golf%20in%20progress/nearlydone010.jpg)
Not happy with the slam panel - so plated that as well.
(http://i492.photobucket.com/albums/rr281/regcheeseman/Golf%20in%20progress/slampanel001.jpg)
All wiring hidden under wing
(http://i492.photobucket.com/albums/rr281/regcheeseman/Golf%20in%20progress/wiring001.jpg)
Tidied
(http://i492.photobucket.com/albums/rr281/regcheeseman/Golf%20in%20progress/wiring004.jpg)
Modified my ebay cheapy IC with a simple stencil ;)
(http://i492.photobucket.com/albums/rr281/regcheeseman/Golf%20in%20progress/P1010750.jpg)
Breaks cover for a quick photocall
(http://i492.photobucket.com/albums/rr281/regcheeseman/Golf%20in%20progress/P1010810.jpg)
Home made wheels - spot the mistake? :-[
(http://i492.photobucket.com/albums/rr281/regcheeseman/Golf%20in%20progress/P1010850.jpg)
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I've gotta get me a Rabbit. I'm jealous of your build.
As for the wheels, is the channel too far in the centre of the barrel? Would that make it difficult to get the tire on?
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Wow that's nice :o, how long did it take to get to that point?
What coilovers are those?
I like the wiring job, it always bugged me how they run right across the engine bay.
What's that bottle under the left fender?
Nice work, keep it up ;D
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As for the wheels, is the channel too far in the centre of the barrel? Would that make it difficult to get the tire on?
Difficult? - No, impossible. ::)
What coilovers are those?
Ebay cheapys that came still wrapped in a box in the back of the car.
What's that bottle under the left fender?
I could lie and say water injection - but in reality, I messed up. :-[
It was due to be an expansion/overflow for the radiator - I'd assumed the top fill rad had an overflow at atmospheric pressure like a motorbike setup - it doesn't so the bottle is now removed and sat in the garage cupboard.
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Few more pictures of progress
Rear end
(http://i492.photobucket.com/albums/rr281/regcheeseman/Golf%20in%20progress/Maystatus003.jpg)
Front end, my IC fun wasn't completely wasted. ;) Shame about the dog poo bags!
(http://i492.photobucket.com/albums/rr281/regcheeseman/Golf%20in%20progress/Maystatus002.jpg)
One manky gearbox tidied up
(http://i492.photobucket.com/albums/rr281/regcheeseman/Golf%20in%20progress/Engineandgearboxinpaint002.jpg)
Block well on the way (WAITING FOR GIRDLE!!!!!)
(http://i492.photobucket.com/albums/rr281/regcheeseman/Golf%20in%20progress/Engineandgearboxinpaint001.jpg)
Marked up the manifolds for some port matching and a bit of flow work.
(http://i492.photobucket.com/albums/rr281/regcheeseman/Golf%20in%20progress/Engineandgearboxinpaint004.jpg)
Finally - toys. mmmmwahahahahahahahahahahaha!
(http://i492.photobucket.com/albums/rr281/regcheeseman/Golf%20in%20progress/Engineandgearboxinpaint005.jpg)
1Y/AAZ head, 1Y manifold, MK4 VNT turbo, MLS gasket, ARP studs
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Wonder how long that's all going to stay white.... ;D
Lookin good!
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Ok, I'd forgotten the thread so by way of a little update....
Wonder how long that's all going to stay white....
Not long....
(http://i492.photobucket.com/albums/rr281/regcheeseman/Golf%20in%20progress/P1010997.jpg)
The more I looked at the white and black the more I disliked it.
knocked myself a pump together out of a few old pumps, few hours of swearing, and fiddly assembly.
(http://i492.photobucket.com/albums/rr281/regcheeseman/Golf%20in%20progress/pump002.jpg)
Lot's of cleaning, rubbing down, spraying, polishing to get to this stage
It's AAZ based, got a 10mm head from a TDI (up from 8mm), running on the AAZ camplate and set up with 1.10 mm lift.
It's got a GTD boost pin and spring, gov mod and aaz limiter blanked off.
Started to put he headlining in, ignored advice and did it my usual way, fitted the back, pulled the front taut and glued that, held nicely by bulldog clips bought from staples. Then did the side, I'm well happy, no creases or sags.
(http://i492.photobucket.com/albums/rr281/regcheeseman/headlining2.jpg)
made some custom rear 'door' cards
(http://i492.photobucket.com/albums/rr281/regcheeseman/Golf%20in%20progress/doorpods.jpg)
painted my inlet manifold.
(http://i492.photobucket.com/albums/rr281/regcheeseman/Golf%20in%20progress/manifold.jpg)
Got dish?
(http://i492.photobucket.com/albums/rr281/regcheeseman/rearwheels003sml.jpg)
Had to push the Golf out into the sun, the calipers are on, maybe a bit 'barry' but I like them
(http://i492.photobucket.com/albums/rr281/regcheeseman/noengine005sml.jpg)
My boy was straight in it, cool kid.
(http://i492.photobucket.com/albums/rr281/regcheeseman/noengine002sml.jpg)
And the rear end just gets better with fat rubber to beef it up
(http://i492.photobucket.com/albums/rr281/regcheeseman/noengine003sml.jpg)
Engine going in next week ;D
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A few more hours work and the motor is off the stand and ready to go in.
(http://i492.photobucket.com/albums/rr281/regcheeseman/engine.jpg)
Red clutch should give me at least another 20 brake.
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My sketchy 20 year old engine hoist got put into use, this was bought by my cheapskate parents from god knows where (£1 shop?) and is actually sold as an engine hoist. It consists of a a few tiny pulleys and some worn looking thin cord.
However, as it's done many times before, it lifted a motor and gearbox in.
(http://i492.photobucket.com/albums/rr281/regcheeseman/enginegoingin001.jpg)
After a few minutes faffing the first mounting bolt slipped home and the gearbox mount temporarily made with some webbing. The hoist can be removed
(http://i492.photobucket.com/albums/rr281/regcheeseman/enginegoingin002.jpg)
All is not sweetness and light, the oh so easy gearbox mount is 55mm away from where it should be so it's back to plan A - make it from worthing caddy's pattern.
(http://i492.photobucket.com/albums/rr281/regcheeseman/enginegoingin004.jpg)
And the alt fouls the oil cooler by about 3mm. so that has to be cut out. >:(
(http://i492.photobucket.com/albums/rr281/regcheeseman/enginegoingin005.jpg)
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WOW, that engine bay looks good!!!!!! eh, scrap good, it look amazing!!
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Looks great.
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My turbo VNT linkage has been modified to suit the bowden cable operation.
(http://i492.photobucket.com/albums/rr281/regcheeseman/Enginegoingin012.jpg)
Not happy with the arrangement for the sensors, so I went and bought some decent tees in the right size.
Finished the first stage of the exhaust, just got to add the hangers and tidy it up a bit.
(http://i492.photobucket.com/albums/rr281/regcheeseman/Exhaust.jpg)
2.5" from turbo to rear beam (and potential for a straight through side exit pipe ;))
And then a 2" system and token silencer box and discreet turndown exit
All in stainless, the manky bit is an pre-used section cut from an old downpipe but it'll clean up like the rest
Bored of waiting for bits to turn up and needing to get into the loft I had to take the car off the stack of blocks it's sat on for 2 weeks and get it out of the garage.
Certainly sits a bit better with some weight in the front
(http://i492.photobucket.com/albums/rr281/regcheeseman/out.jpg)
With the loft sorted and rain threatening I tried to push the car away again. (here's where I start collecting scene points by the bucketload)
(http://i492.photobucket.com/albums/rr281/regcheeseman/sump.jpg)
It wont go back in the garage, the less than 2" tall step up is whacking the sump, I ended up fashioning ramps to put it away.
Exhaust is finished and wrapped, had to make a bracket to keep the gearchange cables out the way.
Wired the turbo sensors, made the cables for the VNT
Fitted the spangly new clutch hose - thanks to http://www.helcarkits.co.uk/ (http://"http://www.helcarkits.co.uk/")
(http://i492.photobucket.com/albums/rr281/regcheeseman/pipewrapped.jpg)
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I love it all!
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great work!'
how much time on that all
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How much time? Far too much, the turbo controller alone owes me 100's of hours and it's still not right, I had the laptop plugged into it last night to try and set the servo up.
Re-birthing my tired looking seats
If you remember, I bought some seats...
(http://i492.photobucket.com/albums/rr281/regcheeseman/Golf%20in%20progress/tombstones.jpg)
Started off by trying to rejuvenate what I had already but I wasn't 100% on the results,
(http://i492.photobucket.com/albums/rr281/regcheeseman/seats.jpg)
also the back bench wouldn't fit and the fronts needed the centre rail changing on the runners
I annoyed Andy (ART1234) some more and came away with a hanging mk1 rear bench and front seats, they got stripped and cut up for bits, the rear frame was rusty and needed plates welding on.
Then I dismantled the rocco seats and was left with a large pile of various seat components.
I tried various combinations of parts to see what might fit or be made to fit before coming up with a plan....
After I unpicked the worn and faded center panels from all my 'rocco covers I took them to a local upholsterer, he made up new centres and sewed them in, and then he replaced another section with a small fag burn - and as he had some vinyl left, he replaced the side sections on the rear seat back because they had holes in them for the (now defunct) scirocco mounting hardware. The holes were not visible with the seats fitted but you 'know' they are there and he obviously takes pride in his work.
To cap it all, he was doing them for a good price but 'in between jobs' and had told me they would take about four weeks, so I figured six before I started to nag him.
He phoned me within 3 weeks to come and collect them.
The rear seat I've built is a hybrid, the foam is mk1 golf, the frame is mostly mk1 golf with a few mods to allow the 'rocco covers to fit, I could have used the rocco foams, but they are really thin with no density - the Golf ones are about 6" thicker and slightly smaller - the upshot of this is the 'rocco covers need some stretching to fit but eventually they were coaxed into place.
The clips are holding the cover in place while the glue dries, not normally glued but the cover was threatening to ping off as it's only just tucked in.
(http://i492.photobucket.com/albums/rr281/regcheeseman/seatsdone2.jpg)
Quite often the seat backs on a mk1 are covered in a bubbly shrunk scruffy vinyl, I freshened mine up with a layer of carpet left over from trimming the boot area.
The fronts very pretty straightforward to recover and were soon back together
(http://i492.photobucket.com/albums/rr281/regcheeseman/seatsdone.jpg)
Not sure if the blue one will fit though.
The rear bench went back in no bother and I'm proper chuffed, even the missus was impressed.
(http://i492.photobucket.com/albums/rr281/regcheeseman/seatsdone3.jpg)
I also hooked up the alt, the oil cooler and the radiator was sat in place to measure up for a bracket.... getting there!
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What's your oil pressure while running two turbos?
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I'm not running two turbos - just the one. ???
Anyway, an update is due and it seems that for the last few weeks I have mostly been lying in puddles of brake fluid swearing.
the rear o/s had three hard lines made up, before a REALLY sketchy double bubble flare managed to seal.
It was so sketchy that I couldn't leave it like that and ordered extra long rear lines to do away with the hard lines that run along the rear beam.
However having disturbed the fitting on the hard line to the chassis, they were both now leaking. They'd appear fine until the pressurised bleeder was fitted and they'd start to drip
Whilst this was going on I discovered the clutch master had also seized, I bought another that was full of rust and knackered seals , using bits from both I've made a usable unit, once bleed I find that the thick plate it is bolted to is flexing nicely and needs bracing
Made up a bracing plate from 4mm stainless and then welded a bracing bar back to the column.
(http://i492.photobucket.com/albums/rr281/regcheeseman/nearly003.jpg)
two nights ago I fitted the rear lines (having to drop the rear beam AGAIN.) cutting off the old fittings and re-flaring the pipe. When the bleeder was fitted they held fluid but now the front offside is dripping.
I had to put the back end together before working on the front, which thankfully was a simply case of re-flaring the line and changing the nipple - never use TTE (thread-to-end) fittings with concave female fittings.
Finally the system is sealed and I can bleed it up.
Bear in mind the car has no front wheel and the front O/S is up on the jack so the rear N/S is tight to the wall. I start to bleed the rear and when I finally squeeze between wall and car - I find a new puddle of brake fluid.
Turns out the fitting wasn't tight, easy fix.:)
Finally I have the brakes bled and they are absolutely rock solid
To relieve the pain of all this hassle, I've added a few carbon bits to the engine bay and the body.....
(http://i492.photobucket.com/albums/rr281/regcheeseman/nearly001.jpg)
(http://i492.photobucket.com/albums/rr281/regcheeseman/nearly002.jpg)
Hopefully I can get the bonnet/tailgate and a couple of spots painted this weekend. And take it for a quick spin.
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Finally, three year have passed and I finally get to drive my golf.
Engine off, with the brace in place on the clutch master cyl, the action is short and all the ratios seem to engage, precisely - no hit or miss sloppy rod linkage here.
The engine fires instantly and I let it warm for a bit. Bear in mind I have two bolt in each wheel and none have been torqued. The front camber is obviously a mile out as the front end resembles the sort of broke look normally found on air-cooled VWs.
I snick into first and lurch out of the garage.
The engine seems noisy - not helped by the lack of bonnet, whiff of throttle and short shift into second and up the drive.
I do a few gentle runs up and down our drive and all seems fine so I return to the garage.
Walking back to the house I'm disappointed by the noise and the fact it seems quite slow - the turbo is fixed into it's most laggy position where it also has the potential for the most boost - maybe that's to blame???
A few hours later and I cant resist a quick spin again, I pull out of the garage and leave it sat on the drive idling whilst I check all is ok - the vac pump is wobbling and spewing oil, just a loose clamp.
I go for another quick spin, the motor seems quieter this time.
Temptation gets the better of me and I floor it in second, it starts to accelerate then sweet baby jesus! everything goes a bit mental fast forward. I back off and coast to a halt.
In the mirror I can see a sizeable cloud which clears to reveal a thick black line, odd because I never felt any wheelspin but it did all happen a bit quick.
I turn around and go back, as I approach the line, it's obvious why I felt no wheelspin. :D
(http://i492.photobucket.com/albums/rr281/regcheeseman/blacklines.jpg)
I'm laying darkies with soot. 8)
I appreciate I've been driving a poxy 1300 polo for 12 months but this Golf is quick, quicker than my caddy was, and that would rape a mk1 GTI