more odds n sods

new wishbones with polys fitted, accidently ordered the wrong ball joints so they are getting swapped today or tomorrow

also passat 4 port mc and gearbox bushes

polybushes

got a few duplicates i dont need, steering rack bushes, rear top mounts, rear beam bushes and front wishbone bushes, gimme a shout if anyone wants em

got the shift rod linkages all painted up and sorted, just awaiting a goodie pack from missing linkz with a teflon accelerator pedal push, shift rod bush, headlight wiring relay and weighted shift rod that just takes the place

Shift rod linkages painted, all new bushes and tsr linkage

The top golden bar is being replaced with a weighted shift rod from missing linkz, also coming is a teflon shift rod bush and accelerator pedal bushing, and an uprated headlight wiring loom.

some shiney bits - top radiator cover, coil cover and brand new fuel pump (it wont be used on the engine but will just look nice and shiney on the block)

Some odds n sods, service related parts (all new bar the leads - coil, 22.2 passat mc, sparks, gaskets, tie rod ends and belts)

new water pump and 90a alternator (needs cleaning up)

Stuff to do

Stuft to get - Pre MOT

* Backbox

Brakes - Pre MOT

* Enlarge Bulkhead Hole

* Fit 22.2mm Master Cylinder

* Plumb Brake lines and brake switch

* Bleed Brakes

Other Pre MOT Jobs to fit

* Refit Gearlinkage

* Fit Coil/Sparks/Belts/Leads

* Plug Expansion Tank Hole

* Fit Facet Pump & Filter

* Fit new mech pump and block off outlets

* Fit Inlet Manifold

* Fit Carbs

* Plumb fuel lines

* Fit throttle linkages

* Mount Oil Cooler

* Change Oil

* Fit Front Splitter

turns out the new master cylinder isnt really suitable for my application and without a servo will make it harder to stamp on the brakes so teh std one just went back on.

re-fitted the gear linkage, but its super stiff now, too stiff for my liking, its coming off again, gotta do a few tweeks and rebuild teh shifter base and drill out the rivits that hold the shift rod bush in place

fitted new sparks, leads, dizzy cap, rotor arm, clutch cable, and chucked 3 litres of fresh oil in there (previously put half a litre in the new filter when that was fitted and drained the oil the other day

chopped down some manifold studs to mount the inlet manifold but two were bent and by that time i was bored so gonna chop some more up and test fit on the head in the house and have the carbs on for tuesday/wednesday. need to get some aluminium sheeting cos i want to make a bracket mounts the bulkhead where the coil resides to mount the pump/reg and coil

and the recaros came, subframes are gettin welded in the next week or so, gotta pass them on to a mate

Edited 19 April, 200818 yr by grungeisdead

dizzy looks soo odd on the side of the engine lol

i too have bodged....i mean got some welded recaro subframes!

make sure they dont wobble about like mine did...till i craftily modified them

Looking pimp my friend

dizzy looks soo odd on the side of the engine lol

hahah i said that when i first saw an olop engine as it was coming out the side of the head haha!

Looking pimp my friend

nice one my brother from another mother

got pally with mr hacksaw again today and cut down some more manifold bolts that werent bent this time fookers

bolted it up to the head in the house to check it all fitted ok, jobs a good un

you can just see to the right that I've blocked off the vacuum take off, ill be pluggin two vacuum lines into this for the vacuum guage in the car and one to the dizzy

stuck the carbs on so i could get the fuel lines measured up, the one of the left is a bit short so ill be sorting that oot.

spent a while working out where i wanted to mount the filter king for neatness of the plumbing in the bay and noticed too coincedentally placed holes, so ill be cutting the mounting plate that came with it and drilling some new holes in it to mount it to the carb, should look pretty cool when its all fitted.

means i can also retain the original coils placement and just mount the fuel pump on the bulkhead next to it.

when i get round to doing the bay I'm either going to chop out the rain tray completely or thinking of louvering the panel so its open in front of the carbs, and incorate vents in the sides of the wings to vent air into the rain tray and into the path of the carbs. not sure out much air would be sucked in from the vents being placed so far up the wing (right next to the doors/windscreen) but will be interesting anyway if i do it

looks nice man

get those carbs on and running

Looks a nice project, always liked mk1 golfs and this is a niice example.

looks nice man

get those carbs on and running

hoping to have them signing by the end of the week and in for mot at the start of next week fingers crossed, but dont worry a video shall be made when i fire them into life

Looks a nice project, always liked mk1 golfs and this is a niice example.

cheers dude and welcome to the club

hoping to have them signing by the end of the week and in for mot at the start of next week fingers crossed, but dont worry a video shall be made when i fire them into life

awesome

got my angle grinder today happy days

first to get chopped up was the throttle pedal for fit the 2-1 adaptor

sytec one fitted, got a weber one coming instead cos it uses grub screws instead of this one which i think uses the solderless nipples but either way its shite

broom broooom

drilled out the rivits for the shift rod bush

painted up the new rear ally caliper i got

whipped some bits off beena and painted them up, rear wishbone mounts with arb brackets and the rear arb and all those brackets

few bits to fit tomorrow :-

refit all the gear linkage

plug expansion tank hole

fit uprated wiring loom and smoked indis

also gotta get angle grinder happy on the short shift adaptor to shave a few mm off the edges to clear the block.

got a sheet of metal to make a bracket for the throttle cable holders, will cut that out tomorrow and drill holes for the throttle cable adjusters.

might mount the filter king and pump if i get round to it.

ordered a few more bits to finish the carb assembly, alot more bits were needed than i first anticipated but better doing it all now that fannying around later.

anyway quick list of those bits

fuel pump inertia switch

weber pedal block

heatwrap and stainless ties

2ms of overbraided fuel lines

and need to find a relay in the house to wire up the pump from the igntion, big thanks for mk1nath on the mk1 owners club for loads of advice and pictures and stuff while I've been gettin me head round this all.

woohoo

Nice continued progress dude :-)

Yay for the anglay grinday purchase, you`ll be hooked now hehehehe

twas raining on and off today but got a fair few odds n sods done

made up the bracket for the throttle cables and had to file a wee bit of the throttle cable hole so it fitted properly

you can just see it fitted in the far left

oil cooler fitted and a few wires tidied out the way, fitted the headlight loom

fitted the front wishbone mounts from the gti for the arb mounts, refitted the gearlinkage and shift rod bush housing, cleaned up and flushed rad, fitted new lower hose as the old one was cracked and blocked off the expansion tank hole

oh also fitted smoked indis

tomorrow i gotta

set the shift finger stop gap and fit weighted shift rod

wrap the 4 branch in heatwrap

fit pump, reg, relay and then get the inlet manifold and carbs on if all goes well

oh and chin splitter woot

still waiting on an inertia switch which should be here tomorrow hopefully.

woopagio

picture of the throttle bracket

made a bracket to hold the pump and reg

fitted that and new coil/holder

heat wrap on

chin splittay on

and the oz routes came woot, me mams picking up some brand new yoko a539 195/45/14s for me at the weekend so i need to try and blag her into coming up to manchester to drop em off haha

tried to mount the inlet manifold but it was catching against the 4 branch, took a bit off with a grinding disc but more needs to come off tomorrow, once they are on i can get the carbs on and plumbed in, also gotta find somewhere to mount the inertia switch and then wire up the electrics for it all but thats how shes gonna sleep till wednesday after the next 2 exams

Edited 25 April, 200818 yr by grungeisdead

well exams are nearly over 1 left wooop.

sun has been out in force this week but instead of playing with the car i've been immersed in gta 4 haha.

anyway messed about with the inlet manifold again took some more off it with the angle grinder and it'll almost go on fully, but got bored at that job so started with the wheels

got a few more coats to do over the week, not sure if I'm going to detail the inner bits black now cos I'm liking them all white but i'll see when I'm done

Looking cool man

lok good man, dont forget what i said about flatting them back :p good luck dude.

Looking cool man

FFBM

lok good man, dont forget what i said about flatting them back :p good luck dude.

aye will do you country bumpkin mofo, cheers for teh advice

I want those wheels for my little Mk1 variant!!!!

Nice work fella I have to say.

When will I see it on my driveway??????

hopefully soon mincerella

made up the wiring loom for the fuelling system last night, and finally managed to mount the inlet manifold today hurrrrrrrrrrah

just gonna chillax with a smoke then I'm off down to the motor factors to get a solid brake line made up and some more white paint, then tomorrow i can get the carbivores on wired up, plumbed in and hopefully roaring

swapped over the brakes and got a new brake line made up from the master cylinder to the drivers side wheel so i could bend it out of the path of the carbs without kinking it

239mm jobbies back on

angle grinded the flexi pipe and fitted the centre section, needs a larger sized tube placing over ideally and welding, will get the pat the mot'r to do that for me woot

finally got the inlet manifold after much fannying about with an angle grinder

pressure gauge (I've got a blanking screw for after I've set the pressure

carbs all fitted and plumbed in, just got to fit the pedal back on, connect the throttle cables and wire up the fuelling loom

and got a couple more coats done on the wheels too woopagio

off to stanford hall show tomorrow with my mate rob and picking up my yokos woo

well updates

managed to get the carbs spitting and stuttering but not firing up, fuel pressure guage was broken and i didnt have a balancer for hand but new FPG is on the way and a friend is letting me try out his balancer that he picked up for setting up his twin 45s on a 2L 16v.

also will check timing is correct by whipping spark number one out, turning the head by hand and checking teh piston height with a screwdriver.

fuel pressure was at 2psi before the gauge broke so i dont want to mess about adjusting the fuel pressure without a working gauge to check and i dont want too much fuel pressure in the carbs. also got some fresh petrol today cos the car was left garaged for the last year so the petrol probably lost all its octane level

and went down to my local tyre fitters and got the yokos on the routays, got them balanced then stuck em on the car, bled the brakes while i changed the wheels for ease of convenience so i finally have a brake pedal that works woo!

some piccies cos the day was still warm (check out my 3.75 bhp grass cutting skillz)

so all that needs doing pre mot is getting the carbs up and running and once thats done i can set the gear linkage ensuring all gears are correctly selecting, refit backbox and get it down to pat the friendly mot man

Looks funking ruuuuuuuuude in the flesh with routays

Nice project mate, those new wheels look the nuts i wasn't too convinced how good they'd look when you were spraying them but now they're on the car they look swish go so well against the Pastel Green

Could have sworn id posted in this thread, obviously not!!! Looks awesome on those wheels, bloody good call that was. Can't wait to see it in the flesh safmeister!

hahahaha you have you spoon theres just one in polo chat that was the lisa left eye lopez replacement thread that had loads of replies in so for some reason i keep updating them both :-/

cheers dude, i was looking for pics of yours on the smoors, send me some on msn you gaypher