My Golf Project

L1J · 21 Apr 2007 at 21:36

tonyyeb said:
Common problem on VW's at that age it seems

Agreed!

Last update for today

Downpipe wrapped, will get a jubilee clip for the other end Monday.

Found a place for the oil temp sensor, now only need a T piece for both pressure sensors (arrowed)

Dash half in place, cant attach everything until a speedo cable that's on backorder arrives. High low boost switch in place (circled), I've also used the light within the switch as a shift light that will only come on when high boost is selected

tonyyeb · 21 Apr 2007 at 21:38

Will you be resetting the mileage or is that not wise?

L1J · 21 Apr 2007 at 21:40

tonyyeb said:
Will you be resetting the mileage or is that not wise?

Don't see the need to really, I'm looking forward to seeing it turn to 200k

tonyyeb · 21 Apr 2007 at 21:42

L1J said:
Don't see the need to really, I'm looking forward to seeing it turn to 200k

With that new beast up front 40,000 miles wont take long!

dsb · 21 Apr 2007 at 21:56

dumb quetion, whats witht the heat wrap, why is it needed?

helpimcrap · 21 Apr 2007 at 21:58

dsb said:
dumb quetion, whats witht the heat wrap, why is it needed?

cools the engine bay down as the exhaust wrap shields the heat inside a bit more.

L1J · 21 Apr 2007 at 22:02

dsb said:
dumb quetion, whats witht the heat wrap, why is it needed?

It basically keeps the heat under the bonnet down. As the air filter is situated under the bonnet I'm trying to keep the air intake temps as cool as possible. The heat shield around the filter should help a lot, but no harm in making it's job easier! That reminds me I need to route a cold air feed to the filter somehow!

EDIT helpimcrap got there first!

helpimcrap · 21 Apr 2007 at 22:16

L1J said:
It basically keeps the heat under the bonnet down. As the air filter is situated under the bonnet I'm trying to keep the air intake temps as cool as possible. The heat shield around the filter should help a lot, but no harm in making it's job easier! That reminds me I need to route a cold air feed to the filter somehow!

EDIT helpimcrap got there first!

as ever you were more detailed.

andi · 21 Apr 2007 at 22:33

IIRC, hot exhaust gases also flow faster, so you want the heat kept in.

Or something along those lines..

lozza23_uk · 21 Apr 2007 at 22:49

L1J said:
Carpet is going to be coming out for a jetwash soon

Interior does look a mess at the moment

save up and take it to MJ's for a retrim all inside

p.s. the hazard switch will light up when full boost is on? sounds great.
maybe a custom switch though? just plain red would be nice.

not my car though...and my golf days are long over

L1J · 21 Apr 2007 at 22:50

helpimcrap said:
as ever you were more detailed.

No I wasnt I forgot what andi said!

Yes hotter exhaust gasses have more energy and should flow faster!

lozza23_uk · 21 Apr 2007 at 22:59

L1J said:
No I wasnt I forgot what andi said!

Yes hotter exhaust gasses have more energy and should flow faster!

keeping the exhaust at a high temp but everything else low temp is the key here.

tidy wrap job there mate!

helpimcrap · 21 Apr 2007 at 23:25

L1J said:
No I wasnt I forgot what andi said!

Yes hotter exhaust gasses have more energy and should flow faster!

ah i was just going by the intake temp idea.. ie colder air in = denser = more power.

L1J · 21 Apr 2007 at 23:28

lozza23_uk said:
save up and take it to MJ's for a retrim all inside

p.s. the hazard switch will light up when full boost is on? sounds great.
maybe a custom switch though? just plain red would be nice.

not my car though...and my golf days are long over

tidy wrap job there mate!

The light inside the switch will come on when it's time to change gear when high boost is selected. I'm looking into removing the triangle on the switch, will get a spare and experiment!

Wrap is going to be painted with high temp paint tomorrow to try and seal it so it doesnt absorb as much water when it's wet! I'm not keen on it looking like a steam train!

lozza23_uk · 22 Apr 2007 at 09:51

L1J said:
The light inside the switch will come on when it's time to change gear when high boost is selected. I'm looking into removing the triangle on the switch, will get a spare and experiment!

Wrap is going to be painted with high temp paint tomorrow to try and seal it so it doesnt absorb as much water when it's wet! I'm not keen on it looking like a steam train!

never thought of that. only ever seen manifolds wrapped not the downpipe.

will the paint take to it?

L1J · 22 Apr 2007 at 18:07

lozza23_uk said:
never thought of that. only ever seen manifolds wrapped not the downpipe.

will the paint take to it?

Will post some pics of it painted later, the paint seems to be absorbed quite well.

Quick update

After checking the fuel pump primes, starter turns over etc I installed some security devices this morning. This pic is all you're getting

(black wires are part of the system). I'll feel really sorry for anyone that has to fault find the system if it goes wrong. They are going to spend hours trying to find the units and trace the wiring. I've also installed a few extra measures.

Carried on with some under bonnet plumbing this afternoon. Slimline fan gives much more room for all the pipes. Everything looks so messy at the moment, it will be cleaned before it's finished! I have a new rad on order and the intercooler needs painting.

Tonight I'm going to try and fabricate some pipework for the air filter to the turbo and the turbo to intercooler.

Slight problem with trying to start it, I didnt put the clutch or flywheel in as they need to be lightened and balanced. Firing up date will be May the 8th after the gearbox has been overhauled!

(I really cant believe I expected it to start without a flywheel, MUPPET! :rolleyes:

)

Cupra · 22 Apr 2007 at 18:43

wow its really coming on now... can you see the end yet?

Andybtsn · 22 Apr 2007 at 18:44

Looking good mate

L1J · 22 Apr 2007 at 21:15

paul_64l said:
wow its really coming on now... can you see the end yet?

Lots of fiddly time consuming jobs left. I dont think it's goign to be 100% finished by the RR meet, but it will get there and run! I'm going to be booking the MOT for the 10th of May....

Pic of the exhaust wrap painted, looks like it's sealed it quite well

Needed to make some pipework up from the turbo outlet to the intercooler. Made a template out of some old pipes and hose I had around.

Popped into work (better workshop!) armed with some pipework, everything joined using tape for now to make sure it all fits before it's welded.

Test in place, all ok and fitted first time. It'll be welded up tomorrow. Thanks to Paul for the help

Conanius · 22 Apr 2007 at 22:11

obviously this is just in case it fails the MOT spectacularly, but do you want me to find you some local garages to powerstation that do MOT's? Just if its looking a bit last minute tis all....

.......or if you just want it booked in there if you were to be asked.......ahem......