hey Hillfolk,whatcha doin? - Upgrades (non engine related ) - VWDiesel.net The IDI, TDI, and mTDI source.

• hey Hillfolk,whatcha doin? by hillfolk'r on 05 Mar, 2008 20:18
• ill have to post my "rebuild" pics here
  
  
  custom firewall for more turbo clearance,and a "kickout" in the fender for either an airbox,or  air filter or somethin :wink:
  
  
  heres almost 30k on my totalseals,they look great
  
  ouch,a paperweight
  ill use it for manifold fabrication
  
  heres sort of the idea
  
  im gonna make exh manifold spacers
  
• #1 by AdAm84 on 06 Mar, 2008 08:01
• sweet  :twisted:
• #2 by andy2 on 06 Mar, 2008 14:44
• What engine did you get that exhaust manifold form?
• #3 by hillfolk'r on 07 Mar, 2008 20:00
• 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
• #4 by lord_verminaard on 11 Mar, 2008 13:51
• 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.  
  
  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
• #5 by hillfolk'r on 13 Mar, 2008 18:50
• 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
  
  
  before,sort of,1 patch in there:
  
  
  
  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:
  
  
  
  after,and im welding seams while im at it too:
  
• #6 by hillfolk'r on 15 Mar, 2008 20:22
• i welded a few patches in to get some straight edges to work with
  
  then i made my new cardboard firewall+taped that sumbish in thar
  thats good nuff fer us there hillfolk
   :lol:  :lol:
  
  
  
  
  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:(
  
  
  i got a side piece trimmed out also,but no pics yet
• #7 by hillfolk'r on 26 Mar, 2008 17:53
• she'll be comin round the mountain when she comes
  man this is tedious
  
  
  inside view
  
  
  
• #8 by burn_your_money on 26 Mar, 2008 18:16
• Looking good
  
  I wish I had the time and the space....
• #9 by lord_verminaard on 27 Mar, 2008 08:24
• :shock: Wow, hardcore!
  
  I like it!!!  
  
  Brendan
• #10 by fastvicar on 28 Mar, 2008 05:37
• This build makes me feel very guilty about putting off my motor mount swap due to laziness.   :oops:
• #11 by nokivasara on 30 Apr, 2008 06:37
• Nice, I like the air duct, cold air intake de-luxe  :lol:
• #12 by RabbitJockey on 06 May, 2008 19:14
• this guy....