I know there are issues with the throttle linkages fouling on the manifold, and i have cut off the necessary parts. however i have noticed that the replacement adapter plate doesnt have holes to mount the throttle cable holder, unlike the weber part designed for the standard manifold.

My question is: Can i scrap the insulating plate, which is around 3mm thick, and instead use some gasket paper in between the new adapter and the one for the weber? This will allow me to use the throttle cable bracket holes on the weber adapter, and also fit the correct GK inlet adapter. It also raises the carb up enough to stop it fouling on the manifold.

So in order: GK inlet, GK adapter plate, standard weber adaptor plate, carb. With gasket paper in between each layer of course!

If i can't do that, then i dont know how I'm going to attach the throttle mount bit. Sorry to bother you all, and thanks!

Edited 10 December, 200718 yr by demolover

Aslong as its secure and isnt going to leak air its gonna be cool

so gasket paper or blue silicone between the layers to seal them will be fine

Wicked cheers dude, I'm here with him but I've never played wth carbs before, its all a new form of magic to me! Looks like we will try that method then.

Any other advice would be welcome hehe!

It's because you have two adaptor plates which you are going to sandwich together, I only had the Aldon adaptor plate.

Banana.

What jets are you going to be using in your carb?

F4 Phantoms I dont know anything about setting the carb up, I'm leaving that to him.

I think we can get it all sorted to be honest. The two adaptors together allows much more clearance, and should make life much easier.

How did you get on with this and the whole webber conversion? Just interested after reading and appreciating your info on the webber thread :)

Are you going to put picks up in that thread?

Cheers Dunc

Big thanks to Sam (skatty01) for his help this weekend, was good to have someone there to work it through with as i am sure on my own i would have made some pretty crappy mistakes. Plus he even cleaned my engine bay whilst i was dremeling!! :-) Great guy!!

Time for a little update on the progress that was made this weekend made this weekend.

We removed the old pierburg and inlet manifold which was easy as pie. Then the pierburg throttle arm was removed from the old carb and the weber throttle arm removed from the new carb. The cutting and fitting of this is mush easier to see with both the throttle arms in front of you as you can attempt to fit them and see where they foul each other and then cut off the relevant parts to make them fit. Time consuming and tedious but does help to go slow as not to remove too much material. A dremel is a must here and is a tool that i think everyone should own. Dremel work took up most of my weekend, as with using both adaptor plates i didn't want them to restrict each other so i cut, and grinded them to match... pretty rough but close enough.

I have used both the adaptor plates that i had. The one from aldon automotive and also the adaptor that came with the weber carb which is specific to the polos standard inlet manifold with the rubber block. We looked at both plates and came to the conclusion that removing the thread from the correct holes we could mount both adaptor plate on top of each other with a homemade gasket in between and some instant gasket to make sure its an air tight seal. We therefor left out the insulator gasket as clearance of the GK manifold was no longer an issue. We then mounted the manifold and tightened everything up with locktite to hold it all in place. Choke cable was easy two rubber grommets to pass the cable through and then just fit in the panel under the steering wheel which is held on by a small cross head screw which is a bitch to get at. Once removed this is the perfect place to mount the choke. Haven't attached the choke cable to the carb yet but i am sure it is a case of trial and error to get it to the correct length.....

I have a problem though. By using both of the adapter plates the throttle retaining bracket does not line up with the throttle arm on the carb. When the accel pedel is depressed the cable barely moves the throttle arm at all and is very slack. This means a really short pedal travel and would not be possible to drive as you would not be able to get any power. With someone holding the rubber bung type thing further from the throttle arm on the carb we were able to get full movement of the throttle arm and also the pedal felt much better. So i am going to have to make the bracket hold the throttle in the correct place which means it has to move further out and further back..... can this be bent or am i best trying to make one or have one made?? Any suggestions regards the throttle??? I have pictures of the full setup and will write all this up soon with all the correct diagrams. So all that is left is to attach the thottle cable and the choke cable and attach the fuel lines and the swirl pot and then i am ready to give her a go.....

Regards jets..... what is the ideal setup on a GK weber DMTR?? Anyone got any advice?? At the moment the only jets i have are what came with the carb. Not sure what they are off the top of my head but i know that they are meant for the mk2 1.3 polo. Maybe ok for now but what is ideal?? They are cheap so i am not bothered about trying a few set ups??

I will get pics up soon!! Car is not running right now though so suggestions would be mint!! :-)

Make a new throttle cable support bracket i cant imagine it will be too hard, but if needed I'm guessing the one there could be bent easy enough

Sounds like once you put all the fuel lines in place it should be near enough ready to roll, may need the idle mixture and idle speed tweaking before setting off but should be fine

get it all running with the current jets once all the little bits have been sorted then muck around with new jets

I was thinking about bending it but i am not too sure it is big enough anyways. I have some 3mm alu which i could try and fashion something out of. Shouldn't be too hard, seems this whole conversion is mainly just trial and error. I am aware the idle may need adjusting but its all explained on the paper i got so i should be fine with that just general tweaking and trying.

I noticed that you bent the return spring bracket when you changed to using the pierburg arm i will also have to do this as the spring makes contact with the throttle arm at the moment.

All looks fairly tidy as well. Was a good experience so far. Lots of dremel work and way less daunting once you start assembling it all. Sam was a real help and having a nice big garage with a heater made it so much more fun. Also the the wife making tea and food at intervals was a thing of beauty :-)

Cheers for all the help. I will wirte all this up when i get the chance.

We did mount the carb on backwards when we were about to put the manifold back on dumb ass!!

Barney puts himself down - his dremel skills are nothing short of awesome. Those adaptors fit brilliantly! YOu need to put the pics up to show them what you mean re the throttle cable. I made a series of loops of cable ties (pikeytech i know!) which held the throttle dable in the best position, it was about 20mm up and 20mm to the left of where the current bracket sits. It would be easier to highight if he got photos up here tho lol. Shame i can't just use the gripties instead!!!

Was ace tho, warm dry garage, no wind, his lady just appearing at random moments with drinks, and god she makes good tea!

ha ha ha dremel is good fun but grindling things flat gets tedious fairly quickly!!

I will get some pics uploaded as soon as i can. I think that making our own from something or other will be the way we do it. Just attach it in the same place it will be the same just a bigger version of the bracket thats on there now.

Good fun in the garage though and lots more time in it soon to come :-)

ha ha ha dremel is good fun but grindling things flat gets tedious fairly quickly!!

I will get some pics uploaded as soon as i can. I think that making our own from something or other will be the way we do it. Just attach it in the same place it will be the same just a bigger version of the bracket thats on there now.

Good fun in the garage though and lots more time in it soon to come :-)

You make it sounds ike a dirty weekend away

Aye get some suspension kittage bought mate!

You make it sounds ike a dirty weekend away

Aye get some suspension kittage bought mate!

What happens in the garage stays in the garage......

Was ace tho, warm dry garage, no wind, his lady just appearing at random moments with drinks, and god she makes good tea!

glad you enjoyed the tea sam! Barney has trained me well...

thanks for helping him, you saved me from having to get my fingers dirty !!

Yeah you make great tea... I won;t comment on the other bit... This is so wrong - me and barney talking about dirty times in the garage, and then you with your dirty fingers

Need a new avatar with the lupo nearer the ground tho!!!

So some pictures as these threads get utterly boring when there is nothing to look at!! :-)

This is not a build thread yet as i am not done but i will give a write up when i am done for those who need it:

First of all, picture of the original carb setup, auto choke etc. basically everything under the air filter.

Whipped the carb off plugging the fuel pipes and connecting the autochoke water pipes together, got the manfiold out and the port size difference is comical, cant see very well in the pic to be honest but they are so much better on the GK :-) Sam also wore a hoody with his name on in case i forgot who he was and pimp slapped him for touching my car. Looks like we wore name badges or something

A picture of the inlet manifold ready to go into the car, very pretty as been powdercoated :-) You can see the top right and left pipes are blocked using large bolts, jubilee clips and lengths of hosing, also that small sensor thing is just in place to block hole. Anything will do to block that hole just fine a bolt with the correct thread. Also you can see the de hedgehog manifold heater inside courtesy of dannylee.

Me looking rough as a badgers muff, Dremel in action. Taking out fine bits of the adaptor plates to get them to match,

A few pics of how the carb looks setup on the manifold with both adaptor plates used and layered up with paper gaskets and instant gasket to ensure a good seal.

You can also see the pierburg arm used in conjunction with the weber carb, fits well with some trial and error.

When fitted into the car i had some porblems getting the throttle cable to sit properly as the bracket does not reach the correct place so i am going to make something that will hold it in place. Unless someone has a better solution?? For now Sam has used his legendary cable tie skills to hold my thottle cable in the position it should be in to get the correct pedal travel and full throttle. Also the return spring bracket needs to be bent out for the spring to clear the throttle arm. Should be finished by the end of this week when i can get to it to complete the work then i will get some pics up. Sam also cleaned my bay whilst i did the dremel work. Looks 100 million times better now :-)

Any questions or suggestions and am i missing anything?? I still have all the adaptor bits for the air filter to go on but thats easy as pie.

Barney

Edited 11 December, 200718 yr by demolover

First suggestion is get rid of that beard!

God i didnt realise how grimy that hoody was hahaha. I'm sure pikeytech can provide you with a throttle cable support bracket, we will be flying in thursday evening all being well, to help resolve all your carb related troubles. I think rich is free from 4pm so we will head over as soon as we can after that dude. Can't wait to see how it performs with this on!

The beard is only a temporary measure for the winter just lazy Sam next time i will get a shave, a wash, pretty myself up, and get a suit on just to get covered in oil and crud mucking around with my car. Sorry for my appearance, at least i wasn't looking like a chav with a name badge!!

I want to drive the damn car!! This is just gayness now!

What is the best metal that can be bent with no heat and that will retain enough strength to do the job of the throttle bracket?? I am thinking aloud here as i know nothing about metal. Wish i could weld

Anyone wanna weld something for me??

The beard is only a temporary measure for the winter just lazy Sam next time i will get a shave, a wash, pretty myself up, and get a suit on just to get covered in oil and crud mucking around with my car. Sorry for my appearance, at least i wasn't looking like a chav with a name badge!!

I want to drive the damn car!! This is just gayness now!

I need that badge in case i forget who i am. I shaved this morning, felt right proud haha. I really cbas either but the misses doesnt liek it when i get too hairy. And i get grief off the mother for the semi-beard too! Meh.

When I'm old I'm gona grow a huge one, so i can stroke it and feel educated mwahahaha.

winter mode for the win barney

good work lads

Not good work until it runs in my book. Want to drive the damn thing and instead its just sat in the garage looking all pathetic.

Winter mode is a must. Huge hair, large hat, monster beard. May mean i look like a homeless idiot, who cares.

Sounds like you having trouble with the golf old boy. Not good at all. When you back in the Leeds area?? I will let you have a thrash of the GK, weber coupe and see if you can see a difference. Few more things to be done in the new year should draw a few more horses from the stable!! :-)

Dont expect to much performance increase from it

It will pull with the same force but instead of fading off at 4500rpm it should continue up to 5500-6000, which half the time when driving, those kinda revs aren't being used

Seems like you've put alot of money into this, but don't get too excited, because when you come to drive the car you might be faced with a flood of disappointment.

Don't worry i am aware of this. I am not expecting miraculous power etc etc. Just a better all round drive and as you say top end will be better which will be enough from me. Max has a mk2 1.3 and i am going to see if he can tell a difference. If i was bothered about major power increase i would have gone straight for the Gt convo but i am going to wait until i can build up something fun to put in rather than just a high miler GT. Haven't spent the money for gains in power just to make a nice all round tidy car. The parts will always be worth some of the money back. I will use the weber, GK setup until mid next year when i will think of something to build up over the winter months. I also will gain some valuable basic mechanical knowledge from doing all this and a bit of a build next year so i see it as experience as much as anything.

Thanks for the heads up but i am not a dreamer either!! :-)

Edited 11 December, 200718 yr by demolover