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#75
by
RabbitGTDguy
on 02 May, 2006 03:46
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Good thought... but with the amount of material that has to be removed from the non-TDI counterflow manifold (in my case, the Corrado G60 one) it would be as thin at one end as the other...it could be possible to center the manifold a bit more by doing eccentrics, even out the amount of material from both the top side and the bottom side instead of taking more from one area but then you'd almost need some sort of spacer or bushing IMO to keep the manifold from moving on the port with the vibration of the diesel motor and just the heating/cooling cycles of the motor. Its a thought though...could work.
There is def. alot of material on the 8v and 5 cyl counterflow manifolds...however, not quite enough where needed at top as I mentioned above. Its going to get out there, but we'll see how it does. I think I'll still build up the top portion next winter and plane it back out to really make things nice
It'll be done soon. I have lots of new pics and the motor is pretty much done. Had to ditch the t belt backing plate for using the MKIV style adjustable pulley but everything else has come together pretty nicely and the motor is pretty much out of the 79 ready to swap in the TDI. It'll be most impressive
Just working on the details at this point before swapping in.
Joe
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#76
by
TDForNow
on 02 May, 2006 09:24
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...it could be possible to center the manifold a bit more by doing eccentrics, even out the amount of material from both the top side and the bottom side instead of taking more from one area but then you'd almost need some sort of spacer or bushing IMO to keep the manifold from moving on the port with the vibration of the diesel motor and just the heating/cooling cycles of the motor.
Joe
That's why I suggested fab-ing locating pins, possibly three of them. Wouldn't they address this?
Can't wait to see the rest! You're almost there!!
Alain
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#77
by
RabbitGTDguy
on 04 May, 2006 18:53
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Its begun...the old 1.5 is almost out of the 79...haven't had time to get the pesky exhaust bolt holding the motor in at the moment yet this week as my 72 Westy kinda had to take over commuter duty and its not gas friendly so I've been biking to work and staying over in the area between shifts...hoping to get the TDI in at least this weekend...
But....some pics of progress... thought I had a few of my 4 hr ripping session over the weekend of removing the old motor, but appears I only took one of the car...
Finishing the head...
Found a helper at work that loves to work on motors who helped hand lap in the valves again and installed the cam and lifters ...
Head installed...
The nozzles for now until Race 520's come into my budget...
thanks to Karl...
Marking and aligning the MKIV style adjustable inection pump pulley hub and setting initial timing marks for easy reference down the road...
Attempt to work with the timing belt backing plate so I could use the upper cover. It worked, modfied, fit, etc. However, once the hub was pressed to the pump and the pump pulley installed and tightened...the assembly rubbed...so scratched the upper timing belt cover and backing plate...
Current status of engine...almost ready, only a few things to do and install the exhaust manifold w/ turbo (retapped for larger studs) as well as the intake manifold once in the car.
The MKIV injection pump pulley will be so sweet. It adjusts very easily and will make "on the fly" timing advance/retard a snap with the dial indicator.
Thats all for now...
Joe
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#78
by
malone
on 04 May, 2006 21:23
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Nice seeing progress
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#79
by
TDForNow
on 05 May, 2006 10:17
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Very Nice!
How tight do you have to tie the wife up to get your parts on the kitchen counter?!! LOL !!
Alain
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#80
by
RabbitGTDguy
on 05 May, 2006 16:42
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Well...fiancee... close enough though.
She is actually very accomodating to it, as long as I clean up my mess. Though, the suggestion has been made to get a part washer for the basement.
Should've seen the bathtub last fall when I first cleaned the cylinder head...that was fun...
Joe[/quote]
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#81
by
hillfolk'r
on 05 May, 2006 20:52
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mine does get a little testy when i wash parts in the dishwasher,like consoles,etc,but hey,it works awesome,its like a hot tank in your kitchen!!! :shock:
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#82
by
TDForNow
on 06 May, 2006 22:34
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Sorry folks, I tempted fate 20 yrs ago and I got a 5'2"- red-headed- irish-italian- French- cherokee- german- woman to show for it :shock: :shock: !! I KNOW my limits (now) :roll: !!
Alain
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#83
by
RabbitGTDguy
on 11 May, 2006 07:23
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More progress...the old 1.5 is out in the mTDI is sitting in the engine bay. Decided that I needed a day off yesterday and just stayed home, took the sick time and made major progress on things with the mTDI. I had alot of debating to do about the engine compartment, whether to paint it or not since the car is going in this winter for a complete paintjob, etc. in the original Inari color. I couldn't see painting up the engine bay for about 5 months of driving and the work involved in removing all the paint after...so, i gave it a good cleaning and went with that.
As far as transmission selection, I had a few here to chose from. I've got a 4 speed GC, an FN from the GTD, an FO which is the one that was on the 1.5 that I just pulled as well as a 2y 16v tranny. I decided to use the FN because it was in the GTD and if anything it is the one that would "go" first as far as grenading. The FO must have been very lightly used as it shifts like a dream and I'd like to use it as part of a base for the tranny I'll be building this winter to better suit the car since an LSD, etc. wasn't in the works $$$ wise this year. It'll be the FO gearset with a 3.67 final from the 2y with all new syncs, gaskets, LSD, etc. I didn't detail the tranny either...once again, couldn't see the sense in it when it could go or just be removed come fall again.
So....some pictures... the motor is sitting in the bay now waiting for everything to be hooked up. I'm waiting for an inlet weld flange to come for the T3 that I can use as a spacer as I was having a slight issue when fitting everything together with the ATP manifold and the G60 intake manifold hitting the compressor housing on the turbo once mounted. The spacer flange will give me the clearance I need. It seems that accounting for the fact when I did the GTD with the IDI TD before and its downpipe and knowing I wanted to go TDI in the future paid off as the downpipe fits perfectly to the slightly taller block, etc. Hooking everything up, etc. shouldn't take too long now and I look to maybe here it run this weekend possibly depending on when that flange gets here, and the weather which isn't looking too great...
So... last weekend...
Yesterday... and don't worry, that FRAM filter is only on there to keep it on there for the initial start/warmup...then I'll be changing the oil right away and moving to my Mann filter and Amsoil =)
Its a weird feeling that the motor isn't going into the GTD but it'll be nice to have the feel back. Never intended on the 79 being so rock solid and that it would be receiving this as it first started out a easy transpo solution for $100 last fall...
Joe
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#84
by
TDForNow
on 11 May, 2006 10:34
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Actually, if you've seen the video of that insane Finnish Mk1 '77 gasser, you'll probably be enjoying nearly the same "OMFG" responses! Early Mk1's are hard to come by now. To have one with a$$-kicking super-powers brings it to a new level. Nice going so far!
Man, THAT car IS clean!! Just a little skin cancer around the battery tray and rad support! That's awesome considering our climes!!
Alain
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#85
by
RabbitGTDguy
on 13 May, 2006 13:31
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More progress...if things keep moving I might be able to start it for the first time tomorrow... that'd be nice.
Got quite a bit done here today... started to ran so I had to come inside for now...
So...here we go...
Finished G60 intake manifold with modified boost return section to serve as inlet...
Installed...
Preparing this summer's Snail for action... next it'll be a holset !
Installed w/ boost return on intake manifold as well as oil return line...
Looks like its going to clear up...out to do some more...
Joe
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#86
by
RabbitGTDguy
on 15 May, 2006 02:47
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Its' AlIvE.....IT'S ALIVE!!!
Yeap, I got it running this weekend. Only for a really short burst and it took forever to get the fuel system primed but it did come to life yesterday...no exhaust, no intake plumbing, etc. So I need to work on solutions there before I can start it and let it go on its own to warmup, etc. It was exiting to hear it start though
Joe
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#87
by
lord_verminaard
on 15 May, 2006 15:40
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Giggity-Giggity!
When will we have a video?
I'm really anxious to hear how it runs once everything is all broken in!
Brendan
84 Scirocco 8v
00 Camaro L36 M49
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#88
by
hillfolk'r
on 15 May, 2006 16:08
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yea good deal!!!!!!!,,,,wait till you drive it!! it aint no lil na,,itll run!!!!! i dont know the deal,but mine took for ever to prime,and ive got the pump(lift),,,i had to keep all the lines loose,and tighten like 2 at a time,,i tightened 2 down,,and was cranking it more to prime the other 2,and it started !! so i went with it,and tightened the lines down,,but it ran on 2 cyls,till i recracked those 2 lines loose,then it cleared right up,,,,,,and it seems like anytime you have a line loose,for service,etc,it seems to take some time to get that air out again before it starts hittin on all cyls.........
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#89
by
dubCanuck1
on 15 May, 2006 22:43
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Hey, where did you source your oil feed and return lines? I need some customs for my TDI project.