Billet Recirc Bung I've made for a few people now

it fits mk2 golf and jetta diesel engines think they are GTD ones

IMG_3537 by pjdirtjumper, on Flickr

IMG_3538 by pjdirtjumper, on Flickr

finished clocking the turbo tonight and its all back together ready for trial fitting on the engine in the bay to make the manifold. Before I modify it further

IMG_3541 by pjdirtjumper, on Flickr

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Jenolite is a pre treatment before paint Jim it converts the rust there and then and turns it black so you can see its sorted.

you then rub it back a little and primer over it.

always worked for me I've used it for years the jelly stuff is better than the liquid imo it applies a lot better and easier

Edited 17 September, 201312 yr by StinkyPete

_{This is no longer a Polo..... its a crazy mad engineers idea of what a Polo should be. I Love it. keep it up pal. good work.}

few more things have turned up

presents

IMG_3557 by pjdirtjumper, on Flickr

New exhaust silencers proper slimline 4" diameter 12" long body 16" overall with the pipe ends

IMG_3558 by pjdirtjumper, on Flickr

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aluminium sheet 2.5m x 1.25m x 1mm thick 2 sheets of it

its so light its unbelievable this is the new roof, some of the non structural flooring and interior panels

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more to come hopefully cracking on this weekend

some more pictures from yesterdays progress

managed to get the car the right way round now

IMG_3563 by pjdirtjumper, on Flickr

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and the floorpan from the inside of the car now rather than just underneath

IMG_3566 by pjdirtjumper, on Flickr

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bit more progress today

more floorpan sheets being made up for the rear

IMG_3606 by pjdirtjumper, on Flickr
IMG_3607 by pjdirtjumper, on Flickr

then finished off the rear X Brace for strengthening and also seperating the fuel tank from the cabin

IMG_3608 by pjdirtjumper, on Flickr

IMG_3609 by pjdirtjumper, on Flickr

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welded some of the new rear floor in too

IMG_3612 by pjdirtjumper, on Flickr

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getting the rear floorpanel ready for welding in

IMG_3615 by pjdirtjumper, on Flickr

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managed to get some more time in the garage last weekend and heres the progress.

first off i used an old bust dizzy to start making a dizzy blank as a friend has requested one as they will be using aftermarket management and i also want one too so after finding about 6 old dizzies in my boxes that i honestly cant recall getting I'm making them into dizzy blanks. heres a pic of the first so far its not completely finished but only need to make a press in bung for the centre.

These are basically OE dizzy blanks

started like this

IMG_3643 by pjdirtjumper, on Flickr

ended like this

IMG_3645 by pjdirtjumper, on Flickr

IMG_3646 by pjdirtjumper, on Flickr

IMG_3648 by pjdirtjumper, on Flickr

anyway back onto my car as I'm sure thats what you want to see.

i got the rear vertical turret braces notched and welded into place

IMG_3649 by pjdirtjumper, on Flickr

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Started on the front tunnel roof this is where the template sheets start getting complicated from here on.

but it turned out alright

IMG_3653 by pjdirtjumper, on Flickr

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IMG_3655 by pjdirtjumper, on Flickr

all welded in

IMG_3656 by pjdirtjumper, on Flickr

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looking down the tunnel now

IMG_3658 by pjdirtjumper, on Flickr

looking at the rear from inside

IMG_3659 by pjdirtjumper, on Flickr

Wow, this gets more crazy by the minute!

started plating up the bulkhead

IMG_3660 by pjdirtjumper, on Flickr

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inside passenegers footwell

IMG_3673 by pjdirtjumper, on Flickr

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tunnel top inside the car

IMG_3675 by pjdirtjumper, on Flickr

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inside view of tunnel and footwells

IMG_3677 by pjdirtjumper, on Flickr

better rear pics of rear bulkhead separator

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Omex 600 ECU finally

IMG_3698 by pjdirtjumper, on Flickr

Omex 600 Loom with auxiliary wiring for extra functions

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new arch to try and see if I can get it to work

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trial fitting of the arch

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front wing on the car

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pedal box, steering column and steering rack all fitted back in to check clearance and fitting

IMG_3711 by pjdirtjumper, on Flickr

clearance :)

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more bulkhead progress

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turret top

IMG_3724 by pjdirtjumper, on Flickr

Keep going mate, looking spot on!!

This build is like nothing else I've seen, it should have gone viral by now. Can't wait to see the hardware going in.

Every short block 16v twin belt engine, so around the 99-07 era, has two dizzy blanks fitted to the cylinder head as standard. I've been throwing them away. Shoulda said lol

got the drivers side wheel well bulkhead plated and welded up at the weekend

so its coming along just the main top and front to do now and then the bulkhead is finished

IMG_3755 by pjdirtjumper, on Flickr

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need to grind the welds down and clean it all up but I'm going to hit all that up at once on the whole car and do it in a oner

finished passenger side top under turret too

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My intercooler also arrived its bigger than I thought (shit) lol

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Looking awesome Pete, by far the most serious engineering project on the forum. Keep it up dude!

P.s did you find that Boss Rubber thingy?

intercooler modding began pretty soon after

180 degree 2.5" alloy pipe

IMG_3771 by pjdirtjumper, on Flickr

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intercooler end before

IMG_3773 by pjdirtjumper, on Flickr

during

IMG_3774 by pjdirtjumper, on Flickr

after

IMG_3775 by pjdirtjumper, on Flickr

ready for the new 90 degree ends

IMG_3778 by pjdirtjumper, on Flickr

drilled the new dog bone mount arm

its aluminium extruded U section so more than strong enough for the job and less than half the weight of the old steel 25mm box section I was using

IMG_3779 by pjdirtjumper, on Flickr

IMG_3781 by pjdirtjumper, on Flickr

started sorting the new turbo exhaust manifold so ordered a T3 lasercut flange for the exhaust inlet which is what I was told it was to find out it doesn't fit.

so ordered a T2 lasercut flange to find out this was too small so it was bloody in between in the end after £15 spent I just made one which I could have done from the start was just being lazy and trying to save my time to do other bits.

so correct flange

IMG_3746 by pjdirtjumper, on Flickr

in the middle of the T2 and T3 flanges

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and fitted to the turbo

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the intercooler will be welded up tomorrow when I nip down to welding at college to play on the a/c Tig machines

also modifying my radiator so it works better with how I want to route things

Etches I haven't found it yet its definitely around somewhere I just cant remember where I put it but il be having the shed out tomorrow night anyway as long as its dry as I need to find something else anyways

parts have started arriving for my Cam Chain conversion not seen this done on the AFH before but will hopefully be a benefit over cambelt I'm definitely sure of this

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new sprocket versus old

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Cheers Pete, I've personally never even heard of converting a head to a chain set up, whats the benefit? Sprockets look boss though, custom expensivo?

They do it on race engines from what I've been told and have seen.

It gets rid of belt failure basically and will help with the extra torque

It also minimises stuff on that side as I can run smaller items

It's actually cheaper than people would think