yes ledgebar! and its gonnnnnne

Bit more chopping and grinding saw something close

Bit of weldy weldy

Bolted up the charger and alternator so i could put a belt on, tension up the charger and check for belt clearance

that's a no then haha

so with that all mocked up nicely, i set the job of addressing that to another day this week.

next job was boost piping - nothing to change on the outlet side of the intercooler so that was all sweet, so just the charger->intercooler jobbie.

armed with a box full of assorted boost pipes from my cupboard of joy, a handful of head scratching and a hacksaw, twas sorted.

tomorrow I wanna

Make a bracket for the bottom of the intercooler

mount the oil cooler off the lower bracket

mount the rad and make brackets

Job's I still have to do

Finish engine mount and paint

Cambelt - Get

Remove std G40 cam

Fit Schrick 272 cam, replace camshaft oil seals

fit inner timing belt cover

fit waterpump - new seal

fit cambelt

fit outer lower timing belt cover

fit toothed crank aux pulley

mark tdc on outer casings and pulley in tippex

fit outer cambelt cover

fit 51mm throttle body/ported inlet - new gaskets on way

fit g60 injectors into fuel rail and refit

refit fuel lines

fit 4 branch - modify exhaust to suit

fit lambda bosses

regrease driveshafts and refit

refit gearlinkage

refit throttle/clutch/speedo cables

refit water pipes

charger pulley - fit and torque

fit charger feed lines

fit oil gauge sender and t-piece

refit mapped chip into ecu

refit loom

fluids (engine oil/water/gearbox oil)

cant think of anything else so driiiiiiiiive!

Done this eve

Fitted Schrick 272 cam, replaced camshaft oil seal

Swapped over camcovers

fitted inner timing belt cover, water pump with new seal and vernier pulley

fitted knock sensor

Fitted ISV

Wired up starter

fitted ported inlet with new gasket

Fitted g60 injectors

fit 51mm throttle body/ported inlet - new gaskets thanks for Andy (randombadger69) new VW inlet gasket

Mocked up rad with quick bracket, found suitable water hoses

Connected heater matrix hoses

Job's I still have to do this weekend

Cambelt - Get from TPS tomorrow

fit cambelt / fit outer lower timing belt cover / fit toothed crank aux pulley

mark tdc on outer casings and pulley in tippex

fit outer cambelt cover

Find bolts for cam cover and fit

refit fuel lines

refit throttle/clutch/speedo cables

Remove charger and mount

Mount oil cooler

Mount rad

regrease driveshafts and refit, tighten hubnuts

refit gearlinkage

fit 4 branch - modify exhaust to suit

fit lambda sensors

refit water pipes

Finish engine mount

Refit charger

charger pulley - fit and torque

fit charger feed lines

fit oil gauge sender and t-piece

refit mapped chip into ecu

refit loom

fluids (engine oil/water/gearbox oil)

Got a few hours in on Saturday

regreased driveshafts and refitted

refitted gearlinkage

Spent the rest of the time trying to separate the centre section of the exhaust and removing the lambda. Everything was mega seized. Got well annoyed with everything and gave up in favour of drinks in town and a meat feast at bem brasil. So awesome.

Got over about 3 today

fitted cambelt / outer lower timing belt cover / toothed crank aux pulley / outer cambelt cover

Found bolts for Mk2 cam cover, they a different from mk3 and mk4 bolts, thankfully found 3 that came with the g40

turbo's blue cam cover

Started playing about with places to mount the oil cooler, it's going to go next to the fan on the rad

Modified the engine mount again, better but still touching - need to look into fitting a relay roller from a later engine on there to navigate the belt away from the mount

Cut out the seized lambda and welded in a plate. Cut out a couple of bosses out of another exhaust to weld in and left it there for the day

Finish engine mount

refit fuel lines

refit throttle/clutch/speedo cables

Remove charger and mount

Mount oil cooler

Mount rad

fit lambda sensors

refit water pipes

Refit charger

charger pulley - fit and torque

fit charger feed lines

fit oil gauge sender and t-piece

refit mapped chip into ecu

refit loom

fluids (engine oil/water/gearbox oil)

Torque hub nuts, driveshafts

Here is what I was thinking for the mount using a tension roller from a Lupo GTI

But now thinking of just using the polo mount, as we have a cut up mk3 polo and even if I run a non supercharged mk1 lump I'll still be able to use the original polo mount. Good news for my unit mate as he wants the old engine mount

Edited 8 April, 201313 yr by grungeisdead

A couple of mates mentioned cast iron being something a diy'er can't do in a garage for various reasons, So cracked on this evening spurred on by last nights research

So I set about with this

Which lead me to this

Then I got bored and set out for destruction

About 20 smacks with a mini sledgehammer saw it crack

Back on the Golf - chopped chassis leg and trialling/measuring

Here's where I finished up tonight

I shifted the engine the furthest to the left as he mounts would allow so plenty of room to move the engine to the right if necessary, but I'm pretty happy so far.

Engine out again, only needed driveshafts off, gear linkage and engine mounts so quick job

Cleaned up the mount and surrounding area, tack welded in a couple of places before I took the engine out and started to plate it up using 1.5mm zintec sheet

Only got a couple of hours on it an my lift came , Got the day off tomorrow so should hopefully be productive :)

Decided to tax the Beemer and throw in some steel seal stuff to prolong it for a week or two as I've got errands to run that need a car!

Did some more on the mount today but ran out of gas no long after I started, knew I was running low so the Beemer will take my ass and das gas bottle to work tomorrow for an exchange.

Nowt worse than no gas on a weekend/days off next week!

Planning on a late one tomorrow night, I wanna get it finished up and in a coat of epoxy mastic, while I've got some mixed i'll give the comets newly welded panels a coat too, ready for the outer sill to go on :) bust out the seam sealer on Saturday and drop the engine back in

Edited 11 April, 201313 yr by grungeisdead

looks good

I'm about out of gas too hate it when it happens as its such a farse and I know it will run out right in the middle of something important especially when I've got loads I plan to do but always the way

charger mount done - far better

4 branch extended and lambda bosses welded in

rad, oil cooler, lines and fan fitted

finished up most of little jobs off this evening

few minor jobs tomorrow

swap ecu/chip

wiring - fan / thermoswitch / alternator / starter

exhaust rubbers

and hopefully all being well it'll fire up and I can rejoice and take it into work on Tuesday :)

then theres a few jobs in the near future i wanna do, tidy up some of the wiring, get a load of grommets to replace the missing ones on the bulkhead, refit the front cage door bars, replace the centre box for a straight through

Lovely work saf!

well highs and lows in the golf saga since my last update.

that monday night I smashed it out to get the car ready to crank over and found a leak or two. one from the oil pump alloy cover and another from the block to rear water pipe, and another from various points on the sump.

turns out the previous owner decided to negate the need for gaskets in certain parts of his rebuild =/ amongst other things *sigh*

anyway oil pump cover off

turns out the gasket is obsolete and the jebends at elring wont reply to my query as i found their respective part number to see if they supply it, so i just used some black silicone gasket maker and sealed it that way - refitted it all

and left it at that for the day.

then we saw bye bye to another unit friend

removed the inlet manifold to get decent access to the water pipe, glad i did, as one of the bolts had been hero tightened and mangled so was a mare to get out. anyway refitted with a gasket and some sealant for good measure

left that to cure and then took a sabbatical from the cars whilst me and a few friends went on an epic 1400 man paintball battle.

got back on it tonight, soldered up the fan and thermo switch, and proper vw plug for the starter motor/alternator harness, tightened up the hubnuts, topped up the fluids and cranked the engine to build up oil pressure.

all good, no leaks, went to fire it up - no go.

fuel check

air - DOH - reattached boost pipe that was removed when i was fitting new copper washers

went to fire it up - no go

fuel - still check

air - check

spark - ok from the coil, no go to the plugs. scratch head - take off dizzy cap - no rotor arm - deuchebag i am!

went to fire it up - it liiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiives! so good to hear that supercharger whine again.

then sorted out the headlight wiring and went for a kfc with the boys and called it a night.

going to mess with the exhaust tomo and make this straight thru

also got these coming for the golf, as its done its time on 14 inch alloys and I've now sold the borbets

just need to get hold of some 195/45s now

You can still buy them gaskets for the ally pump cover from ECP mate I was going to get a new cover and gasket from them but then bought new genuine ones from someone on here instead cheaper

Original VW ones had a metal gasket

But the ECP ones use a thick paper gasket just like the sump one but a bit waxier

Straight thru done, needs some tweaking to maintain an idle long enough while I time it up, fingers crossed for tomorrows session

You're mad man. Have loved reading the last few updates whilst I can't sleep!

That collar's in the post this morning Saf, got it bagged up in the glovebox with two bolts (third has been butchered in the past).

This is gonna be a monster.

You can still buy them gaskets for the ally pump cover from ECP mate I was going to get a new cover and gasket from them but then bought new genuine ones from someone on here instead cheaper

Original VW ones had a metal gasket

But the ECP ones use a thick paper gasket just like the sump one but a bit waxier

Cheers dude, pretty sure you can't and I tried all the usual suspects including elring as I found the original part number foe them. I think the cover differs for the 16v blocks. However if you have a part number from ecp , ill go check it in branch.

Mikey - thank you very much sir. I kept my three bolts but thanks always pays to have spares :)

il have a look at my bits for you and see what I can find mate

Got that sleeve Mikey, cheers matey.

bobbed over to unit tonight with a few jobs in mind.

Redo earthing point to charger

Replace hosing to aav

check spark plugs

Swapped out dizzy and coil

Reset co pot to 650ohms and idle screw all the way in then 2 1/2 turns out.

Refused to idle still argh.

just stuck on a spare ecu that had a ko3 chip in and that idled fine, so swapped the chips over and it seems to have solved it.

Cold and hungry by then I gave up. So tomorrow gonna swap over some wheels, run it up to temp, set timing, co on the gas analyser and the idle and take it for a spin :)

its lives, it drives =D

poly engine bushes - bad idea - my roof vibrates now haha

belts have slackened off slightly in my drive, think the engine mount bolts may be slightly loose =/ safffronnnnnnnn!

BTS didnt seem to make any difference when i unplugged it while it was warming up, so probably not a good sign! need to get my multimeter out tomorrow.

so 50 mile round trip to work tomorrow, bit of a tweak in the evening and then I will give the cars a full wash, polish and wax on friday ready for all types.

then its time to crack on with the comet blue as theres only a couple of weeks worth left on it. If i could get by the first week in June i would be very happy, and being half way through the year my target of getting every car working and drivable will be half way complete, with two cars left to go.

good times

Safe

I love your bish bash bosh approach on cars, Just crack on and get it done !!

Top job mate !!..

done around 250 miles now, cars running well. engine mount bolts were loose, all 4 had removed themselves on my drive to my missuses. Her dad was less than pleased hahaha.

All tightened up and torqued appropriately now. Sorted the issue with the belt slackening, just needed more torque on the top charger bolt, now it whines like a toothied G-lader should.

Stuck my head under the car on monday to work out where the exhaust is blowing - its on both joins, so i need to whip the exhaust off and get some exhaust paste on the joins before sticking it all back together - hoping to get on that tonight.

bar that buzzing to be back in the Golf!

after some 195/45/15 tyres if anyone has anything, and I'm also thinking of parting with the E21, I am after a small turbo diesel or something interesting but new and reliable. hit me up with any offers though, old or new.

Looking clean as fuck that! My mrs lived in the warehouse opposite UDP for a little while funnily enough!

fuckinghell saf it looks cracking! top job

Sweet.

unfortunatly i have a bizarre problem of having more cars, than I have wheels, so been doing a bit of swapping around whilst I swap over tyres and what not

i need 1 10mm non hubcentric spacer or a set of 15mm non hubcentric or hubcentric spacers, if anyones got any,

Cheers!