76er Swallowtail build

[Oneofthegreats]

I haven't been on here very much lately, but if you read on, you'll know why.

Well, I've finally got a little spare time to give some of you an update on some Nat's progress & just progress in general.

This car was for sale last year with no taker's for a virtually rust free 76 swallow tail. Then it was parted out & left as a bare rolling shell.

The build has taken me 6 full weekend's so far & one full week next week.

It's basically everything has been rebuilt, upgraded, customized to make the mk1 a nice everydayer again with some most of the part's from my crashed GTI.

Starting off making new fuel pipes for the K-Jet. These were an absolute pain in the arse to make one & then make a matching one. Also had some "AN" fitting welded onto the end's for some nice Earl's fitting's & braided hoses.

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Had to remove the steering rack to fit them & also rebuilt, regreased & readjusted the rack while it was out.

Then onto the fitting the Mk2 16V booster & master cyl. & making some new brake line's which hug & hide the pipes. This took a fair while too, to match them all up.
I fitted the proportioning valve's under the front carpet & soundproofing to clean up the master cyl.
I also fitted an electric brake light switch on the brake pedal for a more reliable setup.

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Then made up a nice engine wiring harness to hide as much of the wiring as I possibly could.

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Removed the GTI oil cooler assembly & refitted the standard housing with my ever trusty Diesel oil filter. Worked for over 10 year's & never gave me a problem.
also diesel's have a finer filter element & can also hold over 1/2 litre more. With the increased surface area, it's act's like an oil cooler, but not as good.

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[Oneofthegreats]

Refitted the engine & exhaust & made up a bunch of bracket's to fit the K-Jet gear eg. Fitted the accumulator in the correct spot.

Refitted the short shift gear linkage assembly & gear lever & also made a few mod's to make the shifter throw a fair bit shorter. It now take's roughly 4" to go from 1st - 2nd!

Managed to find an old Gates return style radiator cap which turn's your standard non expansion tank radiator into one with an expansion tank!

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Refitted the front wiring harness after making a few improvement's to the headlight/high beam system & cleaning up the wiring that didn't need to be there.
Rerouted the wiper motor wiring inside the plenum chamber out of sight.
Made up new battery lead's too!

Converted the heater box assembly over to 79 spec as well as the steering column & pedal assembly.

Fitted up the a dash wiring harness out of my old beater 79 GLD & the dash, as it is in mint condition, along with some part's from another mk1 brother with another mother.
Swapped over all the door & hatch lock's to match the ignition.
Started on swapping over the interior, which still has to be finished off, along with the front bolt thru style 1/4 glass window's.

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All the wiring is in & everything work's as it should "for a mk1"

Early dash car's take note: No dash sag. Why, It's the early style "clip in" heater box's which cause this to the dashboard. The clip's weaken under the dashboard's weight & sag's as it's the heater box that hold's up the middle section of the dash.
With the later "bolt in" style heater box's, the heater box can take the dashboard's weight & not sag.

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All the brake's have been swapped over to GTI, with rear disc's, braided lines etc.
The KW V3's are also under there with the 28mm rear hollow sway bar. I'm not fitting the front bar, as it's too noisey on the street.
Also fitted up the front upper & lower stress bar's.

The fuel tank has been replaced with a internally rust free Diesel tank which is getting harder & harder to find. I tried repairing one I've got here with some tank sealer & it went pear shaped. I can safely say that I took to it with a 1.6L 8V head I had lying around. It's now flat!!

All the braided fuel hoses were fitted today, filled the tank with some 98 & it finally came back to life after being silent for 6 month! Very good to hear it again.

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[Oneofthegreats]

Also tracked down the original 1976 number plates from new & had a new pair made up by Vic Roads.

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I've got a bigger cam coming along with some new part's, which will be fitted as soon as I get it.

It's not finished yet & still has a bit off work & a few suprises to do before the Nat's.
After the Nat's it's going to friend to have some thing's tidied up. Also converting it to a nicely modded fully manualized auto with a stall to match the cam.
I'm starting on this once I get back.

This Mk1 may look good in the pic's, but it's now show car & it never will be. It has rust bubble's here & there with scratch's all over. It's 32 year's old & the make over is over 10 year's old. This also sat outside for most of it's life.

It's not perfect.

Just a clean everydayer with nice running gear.

[Oneofthegreats]

Well when I got home from work tonight, this was waiting for me in my room.

Ordered it last Thursday & it's here today. Not bad.

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They even threw in a very nice catalogue.

TT = absolute legend's.

Will fit it this weekend & reset the CO% next week.

[Oneofthegreats]

110.7° Lobe centre.

It's not the LC that gives you your rough idle. LC give's you your power band.

A tighter the lobe centre ie. 106° the narrower the power band eg. 4200-7600rpm.
This type of cam will also have a huge amount of duration & will definately require alot of compression due to the increase on valve overlap.

A wider LC ie. 110° has less over lap & normally less duration & is commonly used in a production engine due to it's broad power band. eg. 2200-6000rpm

It's the overlap & duration @ .050" which give's you a cranky idle on a flat tappet cam.
Roller cam's are a little different. You can have a large advertised duration & because the lift acceleration rate is increased 10 fold due to having a roller, the cam can open quickly for much longer & thus the duration @ .050" is low.

There's alot more to it with cam's than just number's. But the number's give you an idea of when the inlet & exhaust are opening & closing in relation to the piston's postion & for how long.

[Oneofthegreats]

Well I fitted a pair of new front wheel bearing today & also had time to fit the cam.

Dialled it in, set the ignition timing & idle at approx. 950rpm. Just need to set the CO% next week.

I can safely say that 95% of you would be more than happy with how it idle's. It is fairly lumpy, which I like.

But I wouldn't mind some more lump for a streeter. I should have gone the 288!

Now the exhaust is holding it back, as the pressure wave at the tail pipe is pretty high!
I think a 2.5 full system is the order of the day, but not a priority.

I don't know about manifold vacuum yet, as I haven't measured it. I will probably do that tomorrow.

The Autotech 270 doesn't compare at all & isn't rough at all, in which they state.

Just to give you an idea, this is the largest hyd. cam you can fit to an unmodified cyl. head with .449" (11.4mm) lift which is exactly the same as the Autotech 270. The lifter bore to cam lobe clearance is less than 6 thou cold!

Once warmed up, the clearance is still fine.
If I had the head off, I would of clearanced this & fitted the largest hyd. TT make which is the 288 Advertised duration, .460"(11.64mm) Lift, 245°/244° @ .050", 110° Lobe Centers.

But Crane do one bigger again at 292° advertised, 12.19mm lift, with over 260° @ .050", which is too way too much for an every dayer.

I'll let you know how it goes once I'm driving it.

[Oneofthegreats]

Fair crack of the whip chief. Christ!!!

Cheer's for coming down too & dropping off the brake part's. I think you just wanted to see it's progress & hear it.

After you left, I turned the work whick up.

Almost there!!!!

Felt real good to sit behind the wheel again. It even felt funny.

RWC, Reg, CO% mixture tune & wheel alignment on Tuesday/Wednesday the latest.

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[Oneofthegreats]

Well it's all RWC, Reg & drivable.

All the nice little surprises are on. You will be surprised.;)

Wheel alignment tomorrow morning, then onto the cleaning side of thing's & tidying up the little thing's.

Also had to drive it Hopper's Crossing today. Felt real good. Very nice power delivery & is way more revvier than the Autotech 270.
This will make power easily all the way from 3800 - 7000rpm.
It's also getting more & more lumpy. Should see the look's you get at traffic light's. It's actually starting to sound like a extend port 13B!

Also spotted a Grey Mk5 R32 on the way home.
Reg. believe it or not was R32R32!!!!!!!

[Oneofthegreats]

Well the car's all done.

Car's pressure cleaned underneath, wheel's are spotless & so is everything else.

All loaded up.

Just made it too!!!

Just finished painting the wiper arm's & refitting them 25 min's ago!!!!

Car look's very good. I actually like it more than the GTI!!! It really is that much better. Also the shell is tighter than the GTI. Must be Ozzie steel.

People were slowing down out the front to have a look at it.

[Oneofthegreats]

I was very pleased with the response the car recieved not only from the watercooled crew, but also from alot of passer's by who wanted a chat about it.

I got home just fine thanks Preen. It did blow a heater tap once I got home & also started to leak oil from the rear main & other places.

Pic's stolen from Dom.

Absolutely awesome pic's & I thank you very much for them.

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[Oneofthegreats]

The wheels were a very last minute decision.

There Porsche 944 16 x 6 ET55 with Hankook 195/45R16 on H&R 25mm adapter's. The combined offset is 30mm. Perfect.
Big shout out has to go to Milan & Michelle from TCCA Motorsport's for getting the adapter's from Germany in such short notice & in 4-5day's!!! Unbelievable effort.

I had a pair of 8's wide but couldn't stuff them under the guard's that low. I also have a 7" wide rim, but haven't tried that one yet. It doe's look good though, as it has some dish to it.

The rear guard's were already rolled from year's ago, but I had to cut the front guard lip's & flares flush.

It was a mad rush at the end. The wiper's were painted at 6.30pm on Thursday night!!!

Cheer's Jame's. The V3's are stuffed under there. The sunvisor. Well that's an untold story, as there very hard to find & can be pricey!

I wanted to do something alitle different in my own style. I know the yank's & other's have used these rim's but none of them had a very clean simple look about them.

[Oneofthegreats]

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And one more with Tims mk5

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[Oneofthegreats]

Just a quick update on the car's progress.

I still haven't washed it since I got back from the Nat's trip & have been using it for daily driving activities since, driving 200km round trip each day for work.

I've reset the coilover compression & rebound setting's from the race setting's used for the Nat's trip & it's now much nicer to drive. It still take's a big bump to upset it & scrub the rear tyres.

I've also refitted the TS Passat steering wheel. I like this much better.

-It's blown a heater tap on the Monday night I arrived home - replaced
-Repaired the fuel supply hose, Earl's fitting & new banjo fitting, refitted the fuel filter & bracket.
-Heater core last week - now replaced along with a pair of new heater hoses
-It's had the throttle jam open (luckily only at cruising speed!) & sticking shut after wide open throttle back off. I removed the throttle body, cleaned up the venturi's with some very fine emery only to find the butterfly's had worked there way loose over a period of 12 year's & the primary return spring had lost it's tension.
Reset the butterfly's, retensioned the return spring's & it's all good now.

So all in all it's been pretty well behaved & not much has gone wrong.

It also look's like a pig sty too! Only on the outside.

Exhaust is been modified next weekend with the longest hotdog resonator I can fit in the tunnel & also a straight through rear muffler to liven up the bottom end, which is how it used to be in the silver beater.

[Oneofthegreats]

A couple of pics 3 week's on from the Nat's & not being washed.

Only thing that's changed is the TS Passat steering wheel & being filthy! It also had a full beer split in it last week, so it smell's alittle boozy now.

It's also living in the same spot it was for over a year. The Garden!

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I"ve re-designed my ratcheting auto shifter & the part's are being made at the moment.
I should have them next week, & once my Falcon ute is sold, I can make some headway on building the transmission.

[Oneofthegreats]

No, bogan hoons do burnouts in their 308 WB ute. Or 5l statesman/commodore. Or ford equivalent etc. :duh:


Careful Preen.

I used to own a HJ bogan burnout ute & I reckon 90%+ of the car's one here wouldn't come anyway near any of it's performance & reliability. Fuel ecomony maybe, but fun factor. No f#%king way! I wish I still had it.

Anyway. I thought I'd post these pic's out of interest to just to prove that the ol 76er is no show car & is used actually as a everyday car.

Just got back from a bit of rally, bush bashing in it. Bloody slippery on the old dirt road's at the moment. Lucky I was leading, otherwise it would be really badly covered in mud & road spray!
Rain has turned all the road's down here into a slush pit.

Sorry for the phone photo's. Don't really do it any justice, or may be they do! Doesn't look half as bad.

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Still haven't washed it, but it's on the card's over the weekend.

[thestu]

:D best!!!

[Oneofthegreats]

Well, the old girl's engine finally gave in to over a decade of pain, abuse & punishment, but I still got one last road trip out of it.

The engine had travelled approx 370-390K of torture.
The engine wasn't even a day old from being rebuilt & I was out drag racing it.

Km travelled - 1300+km
Fuel consumption - don't know
Everage speed - ???? I know I sat on around 4000rpm the whole trip with an average of around 3500rpm.
Trip's cost - don't care
Sight's seen - Plenty

Would I do it again - Hell yeh, if I get another engine!!

I made the trip upto Wagga for my GF's RAAF Graduation & it was a blast! Sorry, but I'm not posting up pics of the grad.

I started the trip off with a bit of hestitation about the engine's health, due to using alot of water & the old Powerade bottle starting to fill up.
I gave the breather bottle a good cleanout, checked & topped up all the level's & I was off.

First fuel stop I took some liquid's & the car took about 2 litres of water. Not looking good, but the breather bottle was empty. Good enough for me.

I decided to go the back way to wagga just out of Holbrook. Big mistake. The road's were rough as gut's. The car took an absolute beating & so did my back. I'm very suprised the KW's didn't give up, as it was that bad. It was also going on dark & the roo's started to come out & I was in full nasty mode.
Then Josh decided he would ring me & wanted to have a chat. I definately had my hand's full.
To give you an idea, I was grasping the wheel with both hand's tight.

Got to wagga, no problem's, took on another 2L of water's, alittle vapour's in the bottle.

Cruised around the sight's having alook around. Never been to wagga so it was pretty nice to see somewhere new.

Stayed in a awesome hotel, massive room's, big bath room, cheap & the owner's were really friendly & welcoming. Will definately stay there again. if I'm back in town.
I had to replace the heater tap again, at the hotel in the morning, due to a leak & bypass the whole heating system. I found it leaking when I started the car up in the morning. The car was also starting to get hard to start???

Decided I'd go the normal way home & go down the Olympic Hwy, but stupid me was to concerned with the phone, I missed the turnoff!!!!

I ended up in Narrandera!!! You idiot. So I thought I'd make the most of it & see some country side. I came down through Jerilderie, onto Conargo, Deniliquin, Echuca, Bendigo, Castlemaine & then I got lost again & ended up on the Calder Hwy. By this point I didn't even care about the right way home & thought of it more as an adventure.

I took on some more fuel in Denni & rechecked the fluid's. It was bad to say the least. It took nearly the whole watering can, 0.5L of oil & the breather bottle was now full! The car was also very hard to start, which I think could be caused by a lack of compression, as I could turn the engine by hand!

I thought, bugger it. Me & this old engine have been to hell, broken the devil's leg's & returned. I had complete condifence that I would make it home - just!

I had to top up the coolant (now pure water!) in Gisbourne, which it took another whole watering can & the breather bottle was now a milkshake.

I had to refill in Melton, as it was also starting to use a bit more fuel, due to extreme blow by. The breather bottle was now over flowing & the milkshake was splattered under the car.

From there on in, it was a straight forward drive home, apart from the sickening smell of the breather bottle!

Funilly enough, the car never over heated once, even when there was nothing in the expansion tank & it could still outrun a Gen3 from a standing start. I think the cold country air & 4k rpm was keeping it alive the whole time & was pumping what ever little amount of coolant around fast enough to heat up & cool down.
It stilled pulled like a train, right up to when I pulled in the drive way.

I'll post up some pic's of the breather bottle content's soon & also a report on the condition of the engine. If I get time tomorrow, I'll do a compression test & when some free time comes up, I'll strip the engine & take some pic's.

Anyway, roadtrip pics. I'm not the best at aking pictures, but I'm sure you'll get the idea.

Also note the car still hasn't been washed.

Hume Hwy

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More Hume Hwy. Amazing how different the scenery can be.

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Whoops!!!

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Cruise control, the easy way.

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Over looking Wagga Wagga.

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Toy car in the scrub!

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[Oneofthegreats]

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If you ever need a cheap place to stay, you can alway's stay in some old horse stable!!!!!

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Not much out here, that's for sure.

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Had to get a picture out the front of Conargo Pub.

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And the same for Denni!

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[Oneofthegreats]

A couple of my favorites.

Note: I had to leave the car running for most of the shot's, just in case I couldn't restart the bastard!!

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[Oneofthegreats]

Well I pulled the motor & done a quick autopsy on it.

Compression Check & leakdown check's were carried out.

Compression Check

Cyl.1 - 185 psi
Cyl.2 - 185 psi
Cyl.3 - 210 psi, filled with coolant though
Cyl.4 - 170 psi

Leakdown check
Cyl.1 - 40%, Inlet valve leaking
Cyl.2 - 30%, ring's leaking
Cyl.3 - 34%, head gasket leaking
Cyl.4 - 70%, exhaust valve leaking

I've been in a pretty laid back & lazy mood, so I was in no great hurry to get the the engine out. I also done some work to the Audi, just in case I have to start driving it again.

Engine was pulled out & as it now stand's everything has been swapped over onto a stock "GX" engine incl the Autotech HD Valve Spring's. I decided to refit the Autotech 270 cam & the MK2 5Spd for everyday use. At least with the 270 I can cruise along smoothly in 5th at 50kph. There's no way in hell you could do that with the TT276! It would buck like a bastard!

It won't be anywhere near as fast as the original old girl's engine, but it shouldl be a nice cruiser & once I re-adjust the CO%, it shouldn't be half bad on fuel either. I reckon it should make around the 105-110hp with the other bolt-on mod's.

Breather bottle content's tell the story, along with the massive buildup of gunk in No.3 inlet port right up the intake manifold.

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Sorry Josh. I had to show the milkshake maker!

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This is one of the reason's I like K-Jet so much. It's such a clean burning engine & also keep's the inlet track very clean, apart from the mishap in No.3

You can also see the burnt coolant crystal's in No.3 exhaust port!

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[Oneofthegreats]

Still pretty clean for a 380+K engine. Also a TT276 in there too!

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It wasn't this clean 10mins before I took this pic, that's for sure.

http://www.vwwatercooled.com.au/forums/images/imported/2008/07/Imgp1663-1.jpg

All ready with the 5spd to go into the car tomorrow morning.

http://www.vwwatercooled.com.au/forums/images/imported/2008/07/Imgp1664-1.jpg

The ol' girl's looking pretty bare now. Also note the oil sweat from the dipstick tube. This was caused by excessive crankcase pressure buildup, even though it has a 1" breather tube. I can't wait to tear it down for further inspection.

http://www.vwwatercooled.com.au/forums/images/imported/2008/07/Imgp1665-1.jpg

Hanging in the breeze. Just airing out the burn't front tyres! Ha haaa

http://www.vwwatercooled.com.au/forums/images/imported/2008/07/IMGP1666-1.jpg

[Oneofthegreats]

Well I fitted the other engine this morning in the rain & is running ok & also done the CO% tune. Was only out by a fraction of f@#k all.

Took 2hr's to refit everything & fire it up.

Car started up straight away after regaining fuel pressure. Oil pressure light went off straight away too!

I decided on fitting the vernier & lightweight pulley's & also took some time to replace the fuel injector braided lines while I was playing around, as I already had them here off the GTI.

Total cost of engine swap. $2! I needed a gasket & didn't have one lying around anywhere.

It doesn't go anywhere near as hard as the original one & in my eye's not very impressive at all, but it will have to do.

Nice to have the Autotech 270 & 5spd again too! Can just cruise along in 5th @ 50kph nice & smooth.

I was right about the valve stem seal's. Only alittle smokey when cold. Not too bad though.

Will go into Vic Road's on Friday to have the engine sighted.

I may also fit the original GTI dizzy with vac advance for an increase in fuel ecomony next weekend & see how it goes. Not interested in performance for this car anymore, as spending any money on this engine is a bloody waist.
I'd like to get around an honest 460+km out of a tank.

You can't even tell the difference. Look's identical, apart from a clean breather bottle!

http://www.vwwatercooled.com.au/forums/images/imported/2008/07/Imgp1668-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2008/07/Imgp1669-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2008/07/Imgp1667-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2008/07/Imgp1670-1.jpg

The aftermath of an engine swap. Took nearly just as long to clean up everything than it did to refit the engine & box!

http://www.vwwatercooled.com.au/forums/images/imported/2008/07/Imgp1671-1.jpg

Also have to thank the two JJ's for their hand removing the engine & box. It's nice to get a hand doing these sort of job's without engine cranes etc.

Alway's good to catch up with you guy's for a chin wag.

[Oneofthegreats]

Haven't been on here much lately, but thought I should give a little update on the 76er.

The instrument cluster finally clicked over half a mill! It only had 10K left to do when I pulled the interior out of my old silver beater.

I've now travelled 10k since building this car too!

I know, I know. I still haven't washed it. 10K of dirt, road grime, brake dust & build up. It's on the "Thing's to do" list, along with a couple of rattle's & squeaks.

http://www.vwwatercooled.com.au/forums/images/imported/2008/07/IMGP1675-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2008/07/Imgp1674-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2008/07/Imgp1673-1.jpg

[Oneofthegreats]

Alittle update on the old girl.

My quest for fuel economy is on pretty good track & recently got 8.9L/100km combined highway/city & about 450km for a tank of juice. The speedo is also spot on 100% with the 5spd & 16" wheels.

I've just fitted the GTI vac. advance dizzy today & hopefully this will come down even further. Will update on progress.

I could also refit the stock K-Jet fuel dizzy & airflap, which will bring it down again, but its not in too good a condition.

I know it's not much to write home about compared to diesel's & new car's but it's pretty good for some very old technology.

Also doesn't come close to the Audi's 6.7L/100km. May have to rob some K-Jet & aux. air part's off it if it doesn't sell soon & wreck it out.

[Oneofthegreats]

I thought I'd give an update to the "what's going on" with this car so far, 6 month's on from being built.

Lately it's been driven, hammered, loaned out as it's turned into a bit of a community car of late. Also known as the "show car/loan car"

But some work has been done on it.

I had both the front seat's repaired by a well known & top notch upholster in Melb.

It wasn't cheap, but the result's were worth it I reckon.

They repaired & double stitched all the pleat's on the base & backrest & also added in a new vinyl section across the top of the seat with piping where they get very bad sun damage, causing the material to shrink, split & tear.

They also gave me some extra vinyl material for the back seat across the top too when it need's it.

http://www.vwwatercooled.com.au/forums/images/imported/2008/11/Imgp1926-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2008/11/Imgp1923-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2008/11/Imgp1924-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2008/11/Imgp1925-1.jpg

[Oneofthegreats]

Since all this was built, its been used as a everydayer & has so far clocked 533+K

I've also since added a slight power upgrade to it, but I'll do another build thread on that.