EXHAUST:

As some of you may know, i was after a performance exhaust and i found that ashley list a system and manifold. I decided (due to the wrong manifold turning up) to use my PSD 4 branch and adapt/modify it to mate up with the ashley system.

First things first, i needed to see if the manifold would fit in the small confines of the mk1 bay without hitting on the rad cowling....

which as you can see.....

It does quite well, anti-roll bar clearance was all good as well

The lamda sensor will come in handy when i fit my air/fuel gauge to set up jet sizes

How it sits in the bay

The only proplem using the PSD manifold is that it ends in a 2 1/2" pipe and the ashley system is 2"

I was lucky enough to find a flexi pipe section from a lancia delta front pipe that would not only be perfect for mating the two exhaust sections but also give a nice bit of flex to the system where it counts.

the PSD end was welded straight to the flexi collar

the other end of the flexi which the original pipe was near on 2" which was handy

The pipes were offered up and cut to suit, tacked up and then fully welded once i was happy

as you can see, it is a really good fit

BRAKES:

I fitted mk3 struts to allow G40 calipers with VW1 carriers (for better wheel clearance) to be fitted with omp pads and brembo discs up front.

SUSPENSION:

Wietec 80/60 kit was fitted along with a G40 rear axle

What do you guys think??

Edited 20 January, 200818 yr by LregG

Sounds pretty good to me! I will be having a chat with you at the RR day about doing bike carbs!

Sounds pretty good to me! I will be having a chat with you at the RR day about doing bike carbs!

Cheers mate, It sounds like a scooby at idle due to the really deep burble with the slight cam induced misfire which will probably get deeper when the system cokes up.

No doubt you will not be the only one asking questions :-)

looking good gregg cant wait to see it

luke

Cheers bud, i can't wait to get my mattigs on it

80/60....will it acctually sit on the rollers?

80/60....will it acctually sit on the rollers?

Not sure to be honest.........There's only one way to find out!!!

I'll take some standard wheels/tyres with me just incase the 195/45/13's don't help with ride height issue lol

Fingers crossed...I am sure Jez got on with his Mk4 once...just needed to remove some body work haha.

Aldon's rollers are quite good for low polos- although gregg's will be -80mm on 13s, I'm sure Jez's old 6n must have been lower to the ground??

Christ knows, I'm not sure it is a 80/60 kit to be pefectly honest, well it certainly isn't 60 at the back now as i've fitted the mattigs and had to put the rear springs on the highest settings to get clearance The front can rub slightly on full lock if you acclerate hard but i'll have to live with that.

My old red mk3 used to get on the rollers fine with the centre plate removed, there was not a lot of gap between the front bumper and floor though

I'll not be coming to the rolling road day now due to personal reasons

Ahh! well at least tell us your expected power?! lol

Was looking forward to seeing this one!!

I was expecting somewhere in the region of 90-110bhp in it's current set up which is as follows>

Rebuilt 3f engine (standard compression at the moment!)

Polo players bike carb spec ported+polished head

PSD 268/268 cam

Custom inlet manifold

CBR 600 bike carbs with 1.5mm main jets

Facet red top fuel pump

Filterking filter/pressure regulator

PSD 4 branch manifold

Custom 2 1/2" to 2" exhaust reducer/ flexijoint

2" ashley twin box system

Lightened Flywheel

I could go larier on the cam but i'd lose lots of low down torque which makes the current set up so easy/flexible to drive

Was just wondering why you've stuck with quite a mild cam, but for a road car, flexibility is pretty important really

What sort of revs does it pick up at? I've got a 2 1/4" stainless system and an Ashley 4 branch ready to go on the Golf, so a cam and something different to the Pierburg will be next.

I'm not sure if I asked this in one of your other threads, but is the flywheel aftermarket or a machined standard item?

Are you going to rejet it on a rolling road at any point or just work with trial and error?

Best of luck with the power output!

Was just wondering why you've stuck with quite a mild cam, but for a road car, flexibility is pretty important really

What sort of revs does it pick up at? I've got a 2 1/4" stainless system and an Ashley 4 branch ready to go on the Golf, so a cam and something different to the Pierburg will be next.

I'm not sure if I asked this in one of your other threads, but is the flywheel aftermarket or a machined standard item?

Are you going to rejet it on a rolling road at any point or just work with trial and error?

Best of luck with the power output!

It's my daily runaround mate so i just wanted something nippy and economical so no lairy cam!!

It literally picks up from bugger all revs and pulls like a train, it's probably due to the head work we carried out and the PSD manifold is worth it's weight in gold, much better than anything else on the market!! The ashley 2" system is spot on as well. I guess i've jsut got lucky and all the mods work well together, only time will tell.........

The Jets have been taken out to 1.5mm so it'll be guess work from then on in. The rolling road i'm going to use measures mixture on the power run so i'll have a better idea after that.

The flywheel was a lightened and balanced standard item

Ace, sounds like a mental daily

As you say, you've got lucky with the way everything has gone together. Wish it was always that simple, especially with carbs!

Yeah I've seen a couple of RRs that do the mixture, I got a printout with the mixture in a graph across the rev range, quite handy for reference.

great car, if only i had the money for a certain left hooker i would of had bike carbs on the day i got it! and such a nice sound and such a sleeper!

Ace, sounds like a mental daily

Cheers, it raises a few eyebrows from other drivers lol

Oh, IMHO toby, 2 1/4" is slightly too big mate, you will lose a little torque with that size system, that is more suited to a golf gti

Edited 26 January, 200818 yr by LregG

That's not a problem. Guess what I've just secured a part-ex on

That's not a problem. Guess what I've just secured a part-ex on

8 or 16v??

Just an 8v. Undecided if I should go for it or not

My 1.3 plus £400 for it, and then its another £300 or so insurance... Although it is tidy. Think I'd be best waiting a bit till insurance goes down.

You had a chance to work out economy on the bike carbs yet?

Edited 26 January, 200818 yr by tobyk

what else you got a deal on toby

Shh, I think I'm gonna shift that on