Hello again guys and girls! I've been away from the forum for a while, well, a long while. The whole time Boris has been sat in my lockup needing some attention. I took him off the road about 5 years ago after I melted a cam, that's what you get for bodging an inlet manifold in a hurry. Turns out engines don't like it when you lose one of the silicone pipes holding the bike cams on!

Anyway, came up with a new plan, spent some time modding the engine bay and then left him in pieces for about 4 years but finally his time has come! 

Current spec is:

AFH head and case 

Balanced AVY crank/controls/pistons/oil pump 

Twin dellorto 40's

Helix 6 paddle clutch 

Honda civic Ali radiator 

Mk1 golf coilys and hubs 

Vauxhall calibra calipers and 256mm disks

22mm passat? Master cylinder 

Got the block assembled tonight 

 

Made a bracket for the engine mount 

 

 

Had one of the blokes at work skim 4mm off the back so it sits flush

 

Starting to look like an engine again now! 

Need to get a new tensioner for the cambelt and pick up a few bolts and what nots from vw.

Will do some more at the weekend if I get a chance, picking up some wheels tonight. 

Edited 6 May, 201610 yr by skapunk1
Added pics

Does anyone know if you can still get big bore exhaust manifolds for the valver lump? I remember someone making them a few years ago but can't find them now. 

Just picked up some new shoes for Boris! Gunna take them to work and cut them up next weekend

Got quite a bit done today! 

Tried the wheels on for size, they're 6j at the moment, going to band them to get 7j on the front and 8 or 8.5 at the rear. Once I've got the rims cut on the lathe at work I'll tack one together at 8j and one at 8.5j and see which one I prefer before welding them up.

 

Got the rear coilovers on. Fronts were fitted a few years ago before the build ground to a halt 

(looks bent in the pic but I assure you it's not!) 

 

Made the radiator brackets and threw some primer on them

 

And because I realised there's no pictures showing Boris in all his glory yet, here he is about 7 years ago when I first got him 

 

And here he is now 

 

Should have a cambelt tensioner and some engine mounts in the next couple of days so I'll be able to drop the engine in, get the head back on and start on the inlet / exhaust manifolds!

 

Edited 8 May, 201610 yr by skapunk1

So, you know I said I was gunna take the wheels to work and cut them up? 

 

Got 2 cut, going to just tack them together for now, 1 8j and 1 8.5j. Will weld them up after I've decided how wide to go at the back. Will cut and weld the fronts at 7j later in the week. 

Wheels thrown together so I can try them on for size (not the finished article, obviously!) 

Does anyone know if these are the right cv joints to go with the golf hubs? 

Look at this on eBay http://www.ebay.co.uk/itm/181887632393

Done a bit more today, got the flywheel bolts torqued up. Might not seem like a major deal but I have no engine stand or fancy tools for locking the flywheel so ended up drilling holes in my bench and bolting the block down to stop it moving, then wedged a big flat head screwdriver against a bolt wound into the hole for the gearbox to lock the flywheel, bit awkward but it does the trick!

6 paddles of joy waiting to go on once I have the bolts for the pressure plate 

Played around with wheel sizes 

8s on the rear

And 8.5s

Decided to go with the 8s as the rim sits quite close to the coilover on the back so I'll need to space it out anyway. 

Got the engine mount painted 

Then went home for dinner. 

Engine mounts should be here this week so need to pop down to vw for a few bolts ready to drop the engine in at the weekend :-D

Banded my wheels yesterday :-D

Also popped into vw and ordered the (hopefully) last bits and pieces for the engine with the exception of the crankshaft oil seal, decided I might as well put a new one in while the engine's out. Does mean I need to take the flywheel back off though. Shame really, could have had the engine fitted this weekend if I'd fitted a new seal first time round! 

Made some castor blocks at work today.

Just need to find some bolts for them