If it's only 2 inches you need(ooer missus!) can't you just cut off the bit of pipe after the cat from your old downpipe?

At least that would be spot on borewise for the rest of the system then(48mm)

Just buy the lot from VW for the oil pressure stuff. Won't be that expensive and it will fit perfectly.

haha

I thought about cutting up my spare downpipe but i haven't got a welder. So i wouldnt be able to join that bit of pipe to the AEE downpipe due to the size being the same (i think)

Carn't be arsed taking the downpipe off again lol

I was just thinking of getting a bit of off cut thats a tight fit over the downpipe and the centre section and just clamping it. lol

Edited 9 August, 200818 yr by carver

Could always go to a tyre and exhaust place and raid their skip for a bit of tube?

Yeah ill have a nose around on monday, or if i get desperate ill go for a blast with a straight through on lol

The car is now alive :-)

Still need to get the exhaust finished and time it up, get it running noice.

Big thanks to 86c for bringing another starter down this one has the beans to turn the beast :-)

I'll get some pics tomorrow, it should be on the road tomorrow!!!!

nice one!

i love it when a plan comes together

I thought i would give my opinion on how this engine actually drives on GT management in a mk3...

Specification

At the moment I'm sub-standard really, I'm still using a polo afm and a rubbish GT exhaust as well as the standard 1.6 cam...

Last night finally saw me venturing out after 86c (Steve, legend) came down and sorted out some ECU stored faults and the timing. I Wondered off down the street like a paranoid learner driver i was so worried something was going to break, not that it should as its had alot of new parts and alot of time but more because i was very close to loosing my patience with it this week. I would fix one problem and then 2 more would crop up, then it would rain, i'd get wet then it would stop then another problem ect . I don't think i could of taken anymore mental abuse from it much longer

Anyway, made it down the street - no bangs, strange noises and it still idled nice :-) took it nice and slow up the bypass, made it to the petrol station (lowest i have ever seen a mk3 fuel gauage ) filled her up, checked the coolant and carried on. Had a nice stable engine temp i gave it a poke in 3'rd gear nice, slowed down to let a blind man across the road, 2'need gear built a few revs and gave it some awesome, the acceleration put a huge smile on my face instantly. Anyone who owns a GT knows about the seconde stage throttle where you get a nice kick in 1'st and 2'need... with this engine its like being pulled by a speeding train.

In comparison to a GT

My old GT was pretty standard bar a chip and dewedged throttle body, but i have been in a few tuned GT's including one with a 1.4 bottom end. The difference is rather then waiting for the engine to pull through the revs before you start moving you get on the power and you get a strong surge of power then you change gear and you get another surge and again until you run out of gears . I still havn't given it any abuse yet as I'm still in the settling in stage but i can safely say all the work has been worth it :-D

In fact it doesnt really compare to a GT its in G40 territory, thats the sort of pull it has. I still havn't been in a GT with enough grunt to really impress me but this does, I'm still on standard GT wheels (165's) and it will spin them in 2nd gear from about 20mph no problem.

Sorry for the essay but i know theres quite a few people who want to know what this setup goes like. If your on a tight'ish budget and don't mind getting your hands dirty and making brackets and various other bits go for it. If you have a big budget go for something else but for what i have spent i think its worth double.

Thanks

I would like to say a huge thanks to Steve (86c) who has answered countless PM's and has taken the time to come down and bring me parts and help me get the engine running sweet :-)

Also Gaz amd Ema, again answered many questions and have been a huge help!

Everyone who i have had parts off too, Pettsy for the GT inlet that i needed a few hours before it needing to be at the machine shop

Thanks for the comments too, its helped me keep motivation

And thanks to anyone else i might have missed :-)

x

good work dude:) glad its all come together for you

Small update, the car has had some testing now

Not had any problems yet, its crying out for a Golf afm i think but still pulls brilliantly.

Just had to fill up again, and to be honest I'm astounded i put 15 litres in and that got me 154 miles (46 MPG)

Thats just town driving, mixed with normal driving and having some fun everynow and then...

This is good news as it gives me room for performance mods whilst retaining good MPG for the commute this year.

Plans are,

Four branch

Golf AFM

GT cam (267 cam later)

Home brew free flow exhaust

Aftermarket panel filter wth cold feed

ECU chip

That should see me with 105 - 110bhp, and when i get a break from uni i shall be looking at mildly porting the head, inlet and throttle body and a vernier pulley. Hopefully getting close to 120bhp

Todays effort, I'm not a fan of the mk4 rocker cover so taking it old school, How it should be.

Need to dremel the tight spaces out and paint it, hopefully tomorrow

Four branch

Golf AFM

GT cam (267 cam later)

Home brew free flow exhaust

Aftermarket panel filter wth cold feed

ECU chip

That should see me with 105 - 110bhp, and when i get a break from uni i shall be looking at mildly porting the head, inlet and throttle body and a vernier pulley. Hopefully getting close to 120bhp

I got 96bhp on my GT before I fitted a Golf AFM and before I had set my cam up properly. With a 1.6 bottom end I would like to think you will be getting more than 110bhp. Throw some porting in the equation and you will be laughing.

http://www.noswizard.com/

We will see at the next rolling road day hopefully :biggrin:

I did think about nitrous but I'm going to be more then happy with 115 - 120bhp, especially as i won't be throwing too much money at the chassis

Gave the rocker cover some 'RUST NOT' mainly as there were some bits i couldn't get too so this should hold it back a few years. I'm going to sand it flat and paint it with some high temp paint.

The GT badge has been taken out of service for a bit whilst i refurb it.

Some pretty deep stone chips in there, i have filled them with super fine filler. It will be getting sanded back for a super smooth finish, masked up and painted!

Looking sweet dude i like it :-D

All the little touches really will finnish it off ..

Whilst digging some spare parts out from under the bed i found a GT fuel filter.. Carnt even remember buying it

Thought it would be worth sticking on as i hadn't done it yet.... 5 minute job, yeah right.

As most will know its like a big clamp that holds the fuel filter to the bracket, you loosen the bolt and the whole thing comes out from the main pump bracket. For some reason mine was in the most impossible position ever, looked like it had been fitted with know back axel/suspension. I had to remove the whole pump bracket and get the hammer out. Job done now and it seems even more free to rev now :-D

Fucking gash!

Yes, that does say 22/02/93 Its now been decommissioned after a long earned break

I replaced a couple of pipes whilst i was down there, next summer might see new injection pipes all the way through the car..

I have been attacking my spare parts bin again, bit of forward planning. The AEE 1.6 has a very deep sump which won't be practical when i lower it. I'm probably going to be changing it for a mk3 sump and different pickup..

Its had some batter but no cracks...

Attacked it with a wire brush

To the paint booth

Decided to go with good old hammerite, what with it being hard as fuck :-)

Then removed the pickup and oil pump.

And got abit carried away...

Anyone want a paper weight?

Just to add...

That shell has seen 140,000 miles the last 5k being hard ones

Looking at this engines internals i would expect it to have sailed past 200,000 miles, respect to VW i think.

Thats from an engine that didn't have any service history too, so oil changes were probably sparse, not any sign of swarf either.

Edited 4 September, 200818 yr by carver

Looking good man, missed the last update. Sounds like its a right blast, wouldn't mind a go! I'm determined to do something N/A to keep up with my G-powered friends. I was cleaning up the exact same rocker last night for a GT for the mk2 :grin: Everytime I see an AEE in the scrappers I start pondering though...

Steve is a real legend eh

Looking good man, missed the last update. Sounds like its a right blast, wouldn't mind a go! I'm determined to do something N/A to keep up with my G-powered friends. I was cleaning up the exact same rocker last night for a GT for the mk2 :grin: Everytime I see an AEE in the scrappers I start pondering though...

Steve is a real legend eh

Do it! I love it, its nice and smooth and unsuspecting around town :-) Then boot it and the passenger shit them selfs. Spesh the missus who things we are going to crash and die

It still gets me in the wet, I'm still on crap tyres and suspension but it torque steers in the wet in 3rd up to about 70 - 80ish which is rather scary I think alot of it is down to the amount of weight shift going to the back with the soft suspension.

Yeah Steve is an utter legend!

Was really tempted to AEE but just built up a 3F for practically nothing so can't complain. (wanting a GT badge like yours actually )

That, and the yard wanted "about £170 mate" for just the engine. Erm yeah I'd rather not! Could try CMS but haven't really got time to fuck about with all the bits inbetween mk1 project and going back to uni soon.

What you doing about tyres & suspension? H&R kits are mighty expensive these days!

Edited 4 September, 200818 yr by TomW

The 3F is alot of fun, revvy bastards. I got my motor from CMS paid £100 for it which was a bargain in my eyes. I wouldn't pay much more then that though but mines only got 30k on it.

I know what you mean about going back to uni, I'm glad its done now. I always do a project in between uni breaks and its always close like last year, christmas holidays a week before going back i did the Gt conversion Only got it running properly 2 days before going back. All good fun. I'll be building some sort of home brew supercharged project this year

Not sure on what chassis setup to go for, i was thinking sub frame but i carn't justify it for what i use the car for. My main priority is renewing all the suspension bushes with powerflex or the like and get it through its MOT in November. That should tighten the whole front up, already have a lower brace i will be either buying or making an uprated gearbox mount like PPP sell with the back brace. I want the HnR kit as it seems to be the best for the monies. As for wheels and tyres, something 14" 195's/185's something good, Yokos or Toyos i should think.

well done mate this is really impressive.

i think videos are in order

haha am making a table out of my old engine

Glass top...pistons used init

well done mate this is really impressive.

i think videos are in order

Thanks mate, i will get some videos up soon. Soon as the roads dry

haha am making a table out of my old engine

Glass top...pistons used init

Haha i have something in mind.

Today, BRAKE FAILURE

I have been meaning to change the master cylinder for well, quite some time now.. I needed to go to GSF today to get some parts for the birds car. I was sitting on the fence wether to get a new MC and braided hoses. Usually i wouldn't think twice about spending money on the car but being very skint at the moment i was being tight.

Obviously i managed to persuade myself by the time i got to GSF, went for Goodridge Stainless Steel Brake Hose's and a 22.2m master cylinder. Should be good with what i already have (VWII calipers and Brembo vented discs and pads), new fluid as well obviously.

Unfortunetly GSF didnt stock the brake lines so il be picking them up tomorrow, fitted the master cylinder it went on easily if not a bit messy. Removed the brake lines ready for the new ones and they are MOT failure for sure.

Luckily i was in town when the cylinder died, all though i had the missus in the car and its not a good situation to be in

What happened was the pedal went to the floor but worked just as well as it does at the top, then it was fine for about 10 minutes. But after leaving sainsburys it was completely dead, only the front left brake was working i could lock the front left wheel if i pushed hard enough but not sufficient even at 10mph...

Looking at the old MC and pushing the piston in only makes one of the brake holes push air out along with it being full of clotted brake fluid, so looks like the seals collapsed.

Anyway should be sorted tomorrow, might not make the polo show if it goes tits up though

Edited 11 September, 200818 yr by carver