haha

Yeah ill be up for that mate, give us a pm and ill come up and have a chat with you.

sounds like you've got everything cooking nicely now chick.

As you know, I've just sold my 1.6gt. the lad that bought it wanted the gt box putting back in. God it felt like a monster driving it for a week with it in. personally i preferred my mk4 box, still had good acceleration and a better top end but it wasnt as harsh. if you want it for raping everything at the lights then go for gt box, but fuel wise, it'll drink it. definately not an economical box

you'll have to take me for a spin when its sorted

emaxx

Yeah things are moving again, going to cut and shut an ABU inlet...

I'm going to see how i go with this box, i will more then likely change the clutch before i go back to uni so might go for a different box then.

What mk4 box was it Em? And arnt they dodgey strength wise?

Hopefully have it running this week

Oh! Emma, how was yours plumbed? I'm using the AEE thermostat housing, I havnt looked yet to see if the coolant pipes will reach. How did you get round yours?

We used a gt thermortat. Drilled and tapped the head.

sweet work dude keep it up !!!

Sounds like I'm going to be having fun with the plumbing seeing as nobody else seems to have used the AEE housing.... lol

Just to update, i found a local engineering company up for cutting, skimming and welding the inlet. I have sourced an ABU inlet and will be cutting and shutting it with my G40 inlet.

Might have a few pics tomorrow, just been cleaning the inlets up so they have a clean surface for welding. I will be attempting the plumbing tomorrow, I'm expecting problems lol

Shall try to get the drivers drive shaft on and the exhaust too, theres fair few more things that need doing. The inlet is getting started on Friday but might not get finished till monday/tuesday so the plan is to get EVERYTHING finished ready for the inlet so i can get it off the 'kin drive and go for a drive!!

What mk4 box was it Em? And arnt they dodgey strength wise?

They work much better in the lighter Mk 3 shells, they are the same as the G40 boxes, bar the ratios

I'll keep an eye out for one, whats the engine code and which engine they usualy paired with?

Thanks

Ash

have you spoken to 86c (uncle steve) with regards to the plumbing. hes local (in notts) and has done this conversion on his yellow mk2, he might be able to sort you some words of wisdom or have the bits you need!

Yeah spoke to steve many times about this, he used the Gt thermohousing and drilled new holes for it.

Ill see what i can knock up with my hoard of pipes!

Not much to update, the cooling system is now in. Had to do some pikey hose extension. Silicone hoses are damn exspensive, as are the flexi radiator hose's so this will do for now.

All the other pipes fitted fine, just had to cut them down an inch. Was much much easier then i expected. :-)

The plastic bit i have used to extend the hose is part of the water pump pipe on a 1.3 cl engine so it wont have any trouble with melting

As for the bottom hose i had to be a bit clever about, i used the origional hose, cut the top as it goes to a corner and then use a right angle hose from a 1.3 cl engine.

fits well enough. This is all because the GT thermostat housing doesnt fit and the AEE housing is set further back hence the hoses not reaching.

Should get the modded inlet back tomorrow, so might have it running tomorrow :-D

Long time coming.

Jobs to do:

Drivers drive shaft still

Drive shaft heat sheild

Downpipe and manifold

fit rest of the exhaust

Fill cooling system and hope it doesnt leak

Brake fluid

Torque engine mounts

Go for a drive :-)

Quick trip to GSF this morning to pick up the parts i ordered, they actually ordered the right parts too :-)

Had to make a shelter as the sky was looking miserable

Picked this up as the mk3 downpipe doesnt clear the block with this engine.

New gasket, couple of studs and new nuts with copper grease.

I had to get the hammer out to give the downpipe some more clearance on the ARB, fits well now

I had to make up a bracket to support the exhaust as the cat has been lobbed off on this down pipe. I havn't checked yet but i might need a bit of pipe so the rest of the exhaust reaches.

Got most things done today,

Drivers drive shaft finally on, managed to get the nut off with minimum effort as it had been copper greased at some point :-)

Fan belt on and tensioned

Filled with coolant, checked for leaks - damn thermostat housing leaked so i had to apply some water gasket sealent

Cleaned and re-attched drive shaft heat sheild

Hoovered the battery tray (full of dry soil for some reason) but no corrosion

Fitted new number plate lights

Time seemed to fly today but I'm happy with what i got done, i didnt want to rush as i have all day tomorrow to play.

So far I'm very impressed with the actual car, i havn't came across a seized bolt even the bottom ball joint bolt came out easily.

More pics tomorrow.

This has been entertaining! I've been on the edge of my seat,waiting to hear how things go with the starter motor..

Yeah,whilst i said at the time 'its a nightmare,nothing fits' i didnt remember all the little problems. They've been worse for you,though it took ages for me to make a bracket out of billet steel for the front engine mount. Coolant pipes were easy though - i just used 6n items

Dont worry about the alternator belt fouling the cambelt cover either,it'll burn through a couple of mm after a few miles,then be fine.

I never did manage to scrape the sump,but i tried,with some big air on hump-back bridges..

I need to correct you on something though. I didnt go 1.4 for economy reasons - contrary,it sipped fuel with impressive economy. I was just sick of breaking gearboxes.

Just come in for a break, damn hot out.

I'll be using 6n pipes at a later date when i see one at a scrappers.

I'm using a mk4 starter motor from an AEE engine so no problems there.. i think i managed to shave enough off the tensionor nut to clear the alt belt...

I'v done the same, made a bracket for the third hole going down towards a hole lower down the block, might change the two bolts for high tension allen key ones later.

I carn't remember commenting about you changing to 1.4 for that reason If i did i must of just assumed so lol

Anyways just to update,

The inlet is on!!!!! The engineering company did a really good job on it for pennys as well :biggrin:

Just going to knock up a quick bracket for the back of the inlet to take some strain off the welds.

Theres a few more problems i came across which i will talk about later seeing as this is turning in to a bit of a 'how to'

I just need to put the injectors on and the intake system and cross my fingers...

nice work mate, was going to do this just before the summer but as my engine went kaput i oppted for a cheep run about instead. Keep us updated with this mate, its a great thread because the question gets asked all the time. :thumbsup:

Bit of an update..

Picked up the inlet from the engineering house, well pleased with it. Had to clean it out as it was full of bits of ali.

I filled it with degreaser and blasted vasts amount of water through it

You can see where its been welded with the ABU flange.

About time!!!

Inlet and throttle body on,

Exciting :-)

Thats how it stands now, i need a different starter motor but not much to do now.

Updates soon, I'm feeling some polished money shots too

Thanks for the comments guys.

Edited 8 August, 200818 yr by carver

What air flow meter have you opted for?

The Golf GTi one or will you be trying to use the standard GT item?

Wha's the flow rate of your injectors too?

I'm using the standard afm for a week or so till i pick up a golf gti item.

I'm using Golf gti 8v injectors the flow rate is slightly more then GT injectors 190cc off the top of my head? Slight chance it might run slightly reacher then it needs to but i might look at different injectors later on and a chip/remap

Edited 8 August, 200818 yr by carver

Can't understand how I missed this thread until now, doh!

Got it fired up yet now you have the correct starter? :-D

Well the correct starter is on now (many thanks, steve!) went to fire it up but the battery was tatered

Got the fooker on charge so hopefully it will be running tomorrow, i got absoloutly soaked putting the starter on

I carnt see why it shouldn't fire up with a good battery on though.

Just need to find some steel tubing to extend the exhaust slightly as it doesnt fit.

The pain and effort is worth it though.

Once it's running, you'll find something else that needs altering or modding slightly, but I wouldn't have it any other way now

You have my number if you get stumped by something

Just so you're aware for future reference, if you do decide to change the sump for the earlier shallow Mk.3 item, you will have to cut and shut the oil pump pick up pipe by an inch or so, as it's too long to fit inside the shallow sump.

ABU conversions don't have this issue as the oil pump/pick up pipe is same design as the GT(and they're not interchangeable with AEE parts)

Yeah theres quite a few things that i want to change already, i'll iron out the niggly bits later on.

I'm glad i have gone for this engine now, after being in your mk2. I love how it eats hills :-)

I havn't decided if I'm going to lower it 60mm or 40mm yet but that sump is soo low to the ground its something i will have to do later on..

Where did you get your oil pressure adapter from? Can you pick them up from gsf or ebay?

Dealer only part for the G40(PY code) engine, although some later Mk.2 Polo Formel E engines(HB code) also had them.

Mine was off a G40 engine I have.

cool, managed to get the part number from ETKA. I might buy the union from VW and just buy a banjo bolt from my local car place.

Where can i buy some bog standard steel tubing for the exhaust, do you know any places that off cuts in notts?