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#45 by TurboJ on 11 Nov, 2008 12:58
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I think MJF should answer the questions about the girdle.
As for the head studs, I can ask when I next meet the guy who made mine.
I'll post info about that then. -
#46 by TurboJ on 13 Nov, 2008 15:46
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At this point I still haven't got price info on the camshafts and head studs, but I will let you guys know when I get the change.
As for now, I'm still busy with bodywork repairs. It's taking a lot more time than I had planned, and the deadline at the end of the year even seems threathened now.
There's still one day of welding left before we can get to filling and sanding pre-paint. A quick calculation tells me there are now 24 patches welded into the bodywork! And I originally thought it was a rather good starting point...
Anyway, I will post new pictures when I can, and I'll post the parts info as well, as soon as possible. -
#47 by RabbitJockey on 13 Nov, 2008 17:30
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just so everyone knows, those girdles are available, but they cost 500 dollars
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#48 by TurboJ on 13 Nov, 2008 20:20
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Quote from: "Trev0rbr"
just so everyone knows, those girdles are available, but they cost 500 dollars
Yeah, that's what they cost in a speed shop...
I'll see still if I can find a way to have a series of them made. It seems like there is a lot of interest about them. -
#49 by truckinwagen on 13 Nov, 2008 20:44
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even just a CAD drawing of one so we could make them ourselves would be good,
I feel confident that I could build one, but if all the measurements were already made it would be way easier -
#50 by TurboJ on 14 Nov, 2008 14:26
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Quote from: "truckinwagen"
first off awesome project, you are a inspiration to us all.
do you have the cad file on that girdle?
if so would it be possible to get it so a local machine shop could make one for me?
how thick is the girdle and what kind of steel is it(mild/alloy)
I am working on a sequential turbo setup, and that girdle looks like the solution I have been looking for to hold the bottom end together,
I also have a few buddies with gassers that are interested in the girdle design to make their high HP motors more reliable.
Sorry I didn't see your post right away.
Thanks a lot for the nice feedback!
The girdle is approximately 10 mm thick and it's precision machined, plasma cut mild steel. I don't have the exact material info right here though..
No CAD drawings I'm afraid, as the girdles weren't made by me (MJF had them made ).
I will try and see if some could be made still. No promises though. -
#51 by Jetman on 14 Nov, 2008 14:43
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Quote from: "Trev0rbr"
just so everyone knows, those girdles are available, but they cost 500 dollars
If I remember right, in Finland those girdles costs about 40-50€.. -
#52 by TurboJ on 14 Nov, 2008 14:52
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Quote from: "Jetman"Quote from: "Trev0rbr"
just so everyone knows, those girdles are available, but they cost 500 dollars
If I remember right, in Finland those girdles costs about 40-50€..
Last time I saw one for sale for 80 €, but they're very rarely available. -
#53 by truckinwagen on 14 Nov, 2008 15:13
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oh well, I might have to bust out the calipers and autocad and do it myself.
which is fine, I had already planned on it, I just thought that if it was already designed I could save some time.
good luck with your project, it looks like it will low the rest of us out of the water big time! -
#54 by 53 willys on 14 Nov, 2008 15:23
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Quote from: "truckinwagen"
oh well, I might have to bust out the calipers and autocad and do it myself.
which is fine, I had already planned on it, I just thought that if it was already designed I could save some time.
good luck with your project, it looks like it will low the rest of us out of the water big time!
post your CAD when your done!!!
:wink: -
#55 by truckinwagen on 14 Nov, 2008 15:24
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will do, I will be putting up a thread of my own when my compound daily driver project gets off the ground.
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#56 by 53 willys on 14 Nov, 2008 16:04
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Quote from: "truckinwagen"
will do, I will be putting up a thread of my own when my compound daily driver project gets off the ground.
sweet!! sounds like a great project!!! I wanna do compounds after I get mine running for a bit....
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#57 by zukgod1 on 14 Nov, 2008 16:43
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Quote from: "53 willys"Quote from: "truckinwagen"
will do, I will be putting up a thread of my own when my compound daily driver project gets off the ground.
sweet!! sounds like a great project!!! I wanna do compounds after I get mine running for a bit....
Ya, you better just get yours running there Mr!! :evil: -
#58 by truckinwagen on 14 Nov, 2008 16:48
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seems top be a common problem, mine has been sitting dead 240 miles away at my parents house with air/fuel issues for three months!
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#59 by TurboJ on 06 Dec, 2008 14:34
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I apologize for not updating this topic for a while.
I've been busy with other stuff lately, and the last time I was working on the car I forgot to bring the camera.
The bodywork is beginning to get ready as far as the rust repairs are concerned. We are now contemplating on doing some body reinforcement - spot welding and perhaps longitudinal fender well supports to go along with the strut braces that I have decided to order. I will be getting front upper and lower braces and also a rear brace. With that and extra spot welding of the body, I think the little Jetta should be more than driveable!
The engine has progressed some as well. Everything is going smoothly apart from the fact that the connecting rods have quite a lot of wear on their upper ends. New rings will go on there.
I opted for not ordering the discussed H-profile rods yet, since there are strong OE rods also available, namely the 1.9 N/A ones. So, in case my rods go, I will just switch to a 1.9 block.
The block has now been honed and washed, and everything apart from the rods is bolted together.
Here you can see our guest master mechanic performing the honing task.
This is Aki applying glue to the block's lower sealing surface.
We won't be using a gasket between the block and the main girdle, to make sure they are torqued to eachother as strongly as possible.
Between the girlde and the sump a normal paper gasket will go.
Tightening sockets, main girdle and the special main bearing bolts and nuts fitted together to stay. Just the rods to go and then it's on to the head work...
Test fitting the engine ancillaries.
As you can see, I have colour coded all the little parts and fittings.
I thing with the black/silver combination it will look good and not too 'ricey'. And knowing Aki's skills in building engines, I have confidence that the performance aspect will be every bit as good.
I will also pay attention to the engine room appearance with a new coat of paint and some overall clean-up with wires, fittings etc.
Now I'm just anxious to get putting the car back together!
Building of the twin-plenum intake manifold.
The log than connects to the original manifold's plenum needs to have an opening of exactly right dimensions to provide equal air flow for each inlet port. The twin plenum design works really well when done right, which is why race and rally cars have used them extensively since the '80s.
The formidable Group B Audi S1, for example, has a very similar inlet manifold design.
I only hope that I'll be able to squeeze the front upper strut brace in there with the new inlet manifold.
More will follow soon as I will have to speed things up to get the car finished before february.
Again, comments and questions are all welcome!
