76er Swallowtail K-Jet turbo build

[Oneofthegreats]

Over the last few month's I've been increasingly getting bored & needed something to do, other than help my friend's with there project's.

Which has led me to get motivated to continue carry on with phase #2 on the 76er, my daily since building it in May 08.

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I've been gathering part's for the build over the last few month's for the turbo build up.

I thought I'd have a go at doing it "ol skool" style being a K-Jet turbo.

The spec is very basic & very, very mild. (only running 10psi, but maybe more if I can get the fueling right!) Nothing outrageous - Power expectation is unknown at this point. But hopefully it should be fun for awhile once sorted out.

Bone stock low compression "GX" "SLUG"
Autotech 270 Cam & Valve springs
Modified G60 intake
Ol Skool "BIG" Weber/Redline Throttle body I found. (This was a common mod to replace the stock twin throttle body in the 80's & can be a pain in the arse to find one)
Same stock Volvo K-Jet I've already fitted, except deleted Aux. air valve & Cold start valve
Audi 5000T boost referenced Warm up Regulator
Stock modified Distributor
ATP Cast 8V exhaust manifold
Saab T3 oil/watercooled turbo. V-Band 3" wastegate/dump pipe
Mitsubishi Galant VR4 Intercooler
Custom 2.5" exhaust & 2" intercooler piping
Tial 50mm BOV. (I'll be using this for my next project in the future.)

I'll also be fitting a Innovate Motorsport's wideband Air/Fuel meter/data logger to help me with the tuning side of thing's along with a modified Autometer fuel pressure gauge setup & also my favorite part. A genuine Callaway boost gauge, as fitted as part there Mk1 turbo kit's in the 80's!
I'll be tuning this myself, as there isn't a hell of alot of people out there who can successfully tune this sort of injection system, especially turbocharged too!
Once I'm happy with the tune, I'll put it on a dyno to get a idea of the power output.

I'm still waiting on some part's to arrive soon, but I'll post up what I've got & work done so far.

Saab Turbo & boost regulator (Just have to remove a broken bolt from the exhaust housing! DOH!) It's not a big turbo by all mean's (it's tiny to the other one I have here!), but it should be enough for now, until I get really power hungry. Only a matter of time! haha

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New Engine Breather/catch can setup. I know. No more Powerade bottle! haha

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Audi 5000T boost referenced Warm Up Regulator fitted

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Autometer Fuel pressure tester I modified for testing purposes of the K-Jet, as this is how you basically tune a K-Jet system Note: the fuel tap to switch between "System" pressure & "Control" pressure

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Weber "BIG" Throttle body

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Test mounted up the intercooler to work out the bracket's & mounting after it was pressure tested. All good.

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I placed it so it has full frontage coverage of the intercooler core & still has room to have the piping fitted. Once painted black, you won't even know it's there!

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Had to relocate the Radiator back 1" & across to the driver's side 2" & then bend up a cover plate for the radiator core. Note: Underneath is is lined with some stick on foam to protect the rad. fins & keep it from moving.

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[Oneofthegreats]

Intercooler with the mounting bracket's welded on

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It's not a very big intercooler, but it will do the job easy as. A friend fitted one of these to to his TRX CA18T & on 20psi it made 199rwkw's & didn't have any trouble keeping the intake charge cool as!

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Assorted boost piping & oil supply & return braided hoses & fitting's.

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Volvo "Cobra head" K-Jet airflap intake boot

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Innovate Motorsport's wideband A/F meter & data logger equipment

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Callway Boost Gauge. (I've had this for year's waiting for the perfect project!)

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Another Project that has been waiting in the wind's for a few years now. One day!

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Stay tuned for more. Just waiting on part's now!

[Oneofthegreats]

Alittle bit has been happening in the way of Preeny helping me out with a custom adjustable one way valve for the warm up reg boost reference.

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Now still waiting on part's to arrive.

[Oneofthegreats]

Well not much has been happening as of late due to other project's & job's to get done first. (see below),
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Enough of that! Onto the intake.

I did get a chance to remove all the useless mounting boss' off the G60 intake I've got here & went & sandblasted it today at a friend's workshop. I also drilled & tapped one of the manifold fitting's with a plug, as I only need one port for the brake booster. It also came standard with a boost/vacuum fitting on the end, which will come in handy for the other component's


These intakes do look alot bigger, but these intakes aren't really suited to NA purposes. These are mainly for forced induction only, due to slow air speeds through the runner's on NA application's. You'd be better off with a properly match ported & bottom 1/2 half of the runner ported/blended.

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Here you can clearly see how much larger the intake runners are compared to the standard 8V K-Jet intake of a GTI.
I'm also not running any cold start injector or a aux. bypass valve to simplify the setup & also less chances of boost leak's too!

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Rest of the part's arrive next week, but I'll have to get these other job's done first.

[Oneofthegreats]

Another piece of the puzzle "finally" turned up this week too!

Weber Throttle body & Redline adapter!

Needs only alittle clean up. Very happy with it.

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[Oneofthegreats]

Well I thought I'd match port the redline intake to the G60 intake as I've been motivated lately just to do anything around the house & in the shed, so I went shopping for some more porting burrs of different sizes & shape's, as I've already got a bluepoint die grinder & snap-on 8 carbide burr kit here.

But here's the problem. As much as I love going tool shopping, I bloody hate it, as I always come home with stuff I don't really need, or had future plan's on buying when the need arose.

All I wanted was some nut's & bolt's & a couple of porting burrs!

So here's what I ended up with -

8" Abbott Ashby bench grinder with a wire wheel attachment
M16 x 2.00 Tap
Various stainless nuts & bolt's for the project & shed supplies
Carbide burrs with short & long shank's of different shapes & sizes
Porting flapper wheels
WD40 gun & 4 litre container

Pic. time

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Snap-on burr set & Bluepoint Die Grinder

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Mounted up the bench grinder on an old truck drum stand I made ages ago

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To match the other grinder/linisher & drill press on truck drum stand's. These are sturdy as all buggery & I got them for nothing as they were scrap. All it cost me was the metal to make up the rest of the stands

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[Oneofthegreats]

On with the build

I dismantled the Throttle body for a clean up & inspection & removed one of the ugly brass fitting's it came with standard so I could plug it up.

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Where the brass fitting used to be. You can see in a previous pic, a big tube style fitting hanging out of the side of it with a screw head on the end.

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Get the Tap & cutting compound. This stuff is by far the best stuff I have ever used for cutting threads & even drilling!

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Run the Tap down gently

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New thread all cleaned up

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Bung fitted & sealed with pipe sealant

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Then onto match porting the redline adapter with the intake manifold gasket.

I didn't follow the line to the letter, as the material would have become very narrow even for the gasket, especially under boost pressure too, so I left some meat where it open's up the the bigger end!

You can see how much material had to be removed!

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[Oneofthegreats]

Finished product. I finished it off with the flapper wheels. They work awesome at smooth everything out!

Redline adapter

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Intake Manifold

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I blended in the opening into the first port runner as smooth as I could. I'm not a pro at this. Just enjoy doing it! haha

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With the adapter mounted up. I tried to make the transition as smooth as possible without sharp edges or turn's & blended it into the manifold.

Came up ok I reckon

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With the throttle mounted up. I also tapped & inserted a bung into one of the fitting's I didn't need in the intake too. I only need one fitting for the brake booster.

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Open wide!!!!!

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I'm not too worried about port matching to head at the moment. If the engine blows a headgasket & I remove & dismantle the head, I'll do it then. But can't be stuff with the engine still in the car.

I'll also do the exhaust manifold too when it turn's up, but I'll only match it to the exhaust manifold gasket's.

Enjoy

[Oneofthegreats]

Well I've been flatout here lately, with car shows/event's & other general service stuff, but a big shipment has finally come in & everything has been going full steam ahead.

Heres the latest shipment of part's. Mainly the main part's I've been waiting on to get things going

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I decided to get a Tial BOV with V-Band, as it matchs a Tial Wastegate I've got here for another engine build later on

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Internal Wastegate assembly which transfers into a 3" V-Band

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BIG difference to the standard Saab exhaust/wastegate assembly & the "whopping" great big 2" dump pipe! Very restrictive too!

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The all important 8V cast exhaust manifold

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Various gasket's, adapters & oil fittings

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Some new brakes, as the old ones are, well old & warped!

ATE Power disc's front & rear. I got some 280mm for the big wheels & some standard 239mm Ive I ever decide to put smaller wheel's on to drag it

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[Oneofthegreats]

So with nearly all the major parts in hand, it was time to get thing's moving along as fast as possible

Before Engine bay shots

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Didn't take too long to strip it all down & start mocking everything up & then came across some trouble! All this kit is for a LHD car! DOH!

There will be a few mod's here & there to get everything to fit O.K.!

But after scrounging through some various nut's, bolt & studs & even having to make different bolt's with the help of Dom, I finally got there

Fitted up the ATP 3" wastegate V-Band adapter in the process

I painted all the cast exhaust manifold, turbo housing in VHT High temp Matt Black . Awesome stuff & the rest of the dump pipe will get the same treatment

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It's a bloody tight fit! It's less than 5mm off resting on the steering shaft boot! Ah well. The old extractor's rested on it anyway!

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[Oneofthegreats]

Assembly mocked up on the bench with a few more part's fitted

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Mocking up a new Wastegate actuator.

I can see why company's such as Callaway etc all ran external WG. There is bugger all room down there for them. But I've come this far not to turn around, so I'll stick at it & make it work

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Then the die grinder had to be broken out again due to clearance issues with the G60 intake!

This took quiet some time & alot of fitting & refitting to get it right

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[Oneofthegreats]

With some of the stuff off getting finished welded & a few other part's I'm waiting on, I decided to tackle some other part's incl. modifying the dizzy.

Early "twin port" vac canister

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Stock GTI vac advance canister

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To enable more boost retard, I drilled out the vac pot stop

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All mounted up after drilling some new mounting holes

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I also fitted a set of MK4 GTI 20vt spark plugs too. This should finish off the ignition system with only a couple of minor timing adjustments during tuning

I also decided to have another play around with the Audi Warm Up reg after some long thinking sessions.

The more I played around with it, the more I learned about it & decided to apply the boost pressure to the other chamber of the warm up (not the barbed fitting side) & put it to the test. I wound down the compressore to 10psi & put it to the test. It worked spot on & I played around with different pressure setting's & compared them to some old porsche K-Jet turbo spec's & were right on the money.

I no longer need the one-way valve my friend made for me.

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During my thinking stage, I also wanted to try & add more fuel enrichment for higher boost level's, but didn't want to go down the programmable extra injector(s), as this basically defeats the purpose of building a K-Jet turbo. If you've got one or two extra injectors that can be programmed the way you want to supply the fuel, you might as well go to a full standalone ECU like Microtech, Autronic etc.

So I've had a flat plat of alloy welded to the face of the intake plenum & have drilled & tapped holes for an extra 2 cold start valves run off a adjustable hobbs switch.
Because the G60 intake doesn't have a spot for it, I can put them where I want. The stock GTI spot isn't efficient enough to mix up the right mixture anyway, as you've got say 10psi blowing right as the face of the valve, which will just blow the fuel right up against the No1 plenum wall & force it all into cyl. 1.
So I've placed one of them between cyl 1 & 2, & the other between cyl 3 & 4. Hopefully this with mix it up nice & supply an even amount of fuel to all cyl's.

Even if this setup runs rich as buggery on boost. It's better than running lean! Running rich can also drown out the piston melting pinging! We'll see how it goes. If it does run on the rich side under boost, I'll screw some more boost into it & see what happens.
My friend is also good with setting up water/meth injection kits as well, so theres another option too.
I plan on starting off tuning on Wastegate spring pressure which is roughly 7psi & work my way up.

In the event of it melting a piston, I've got some 20vt spare piston's & rods, I'll throw in along with a G60 metal head gasket, which should be more than enough for the little 8v

I'll put up some pic's when I get the intake back.

[Oneofthegreats]

More pics

Various silicone hoses of different sizes & shapes. (What ever doesn't get used will get put away for the next turbo build) I't shard to judge what you might need when building these sort's of things without having most of the stuff already fitted.

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Various mild steel mandrel's & piping.

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A couple of my friend's came down & built the dump pipe while I was at work & also installed the oxy. sensor bung. They done an awesome job too smoothing off the welds & making it flow nice & smooth. They'll also be helping with the intercooler piping.

I'll drive it to my friend's exhaust place like this & he'll rig up the rest of the exhaust. It will just be a 2.5" with a resonator & turbo rear muffler. Don't want it too loud as I travel 200km a day in it. So no drone for me!
In case your all wondering, this is my everyday car & travel 700+km a week in it, not a weekend warrior.

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Hobb's switch & Mk4 GTI 20vt (AGU engine code) spark plugs

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A good friend of mine also gave me this.

A factory 1977 Mk1 GLS Radio.

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[Oneofthegreats]

Well, I finally got my intake manifold & intercooler back!

These were the last piece's in the puzzle from stopping my progress.

Now on with some more work

My friends tackled the dump pipe, so it was my turn to do the rest of the pipe work. Good fun!

Intake with it's modded twin aux. injector (cold start valves) plate

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Hopefully it should work ok. If not, the weber throttle body has another mounting for a 3rd cold start valve.

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Intercooler with all it's mounting brackets on

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Mounted up the intercooler & then installed the radiator to start mocking up all the piping

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There is still alittle bit of room between the intercooler & radiator. They aren't hard up against each other.

I also mounted it using scrivet's (pop rivet nut's) Work awesome!

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[Oneofthegreats]

Various silicone hose joiner slugs

http://www.vwwatercooled.com.au/forums/images/imported/2009/12/IMGP3139-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2009/12/IMGP3140-1.jpg

Had to get the turbo intake pipe stretched to fit snugly in the volvo intake boot.

http://www.vwwatercooled.com.au/forums/images/imported/2009/12/IMGP3142-1.jpg

Turbo intake pipe all done & mocked up. I'll get some more pics of this when it's back out of the car along with all the pipes

http://www.vwwatercooled.com.au/forums/images/imported/2009/12/IMGP3155-1.jpg

Then started mocking up the intercooler to throttle body piping

http://www.vwwatercooled.com.au/forums/images/imported/2009/12/IMGP3157-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2009/12/IMGP31621-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2009/12/IMGP31631-1.jpg

Finished pipe

http://www.vwwatercooled.com.au/forums/images/imported/2009/12/IMGP31611-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2009/12/IMGP3160-1.jpg

Then mocked up the Tial BOV mounting position & then the Hobb's switch as well

http://www.vwwatercooled.com.au/forums/images/imported/2009/12/IMGP31731-1.jpg

[Oneofthegreats]

Then started in the turbo outlet piping. Sorry but I forgot to get a pic of this out of the car

http://www.vwwatercooled.com.au/forums/images/imported/2009/12/IMGP31711-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2009/12/IMGP31681-1.jpg

Working out intercooler piping position

http://www.vwwatercooled.com.au/forums/images/imported/2009/12/IMGP3158-1.jpg

I wanted both pipes to run parallel with each other & make it a clean fitment.

http://www.vwwatercooled.com.au/forums/images/imported/2009/12/IMGP31661-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2009/12/IMGP31671-1.jpg

Everything appears to clear everything, but only a test drive & time will tell. Hopefully I'll be fine with engine movement

Progress will slow down this weekend, as I've got a 2 day training course over the weekend, but I'll try & get in some work during the night's & back on it on Mon.

[Oneofthegreats]

Well this weekend was alittle dissapointing & not really happy with the progress. Crappy weather put a stop to painting & a so called dash -4 fitting decided to strip an oil supply adapter! Mmmmmmm.

But I did get some stuff done.

I finished welding all the pipe work, smooth & blended everything which took quite some time. Especially around the BOV. But the extra effort was worth it

http://www.vwwatercooled.com.au/forums/images/imported/2009/12/IMGP3174-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2009/12/IMGP3175-1.jpg

All the piping ready for paint tomorrow

http://www.vwwatercooled.com.au/forums/images/imported/2009/12/IMGP3178-1.jpg

Dropped the sump & fitting the oil drain fitting

http://www.vwwatercooled.com.au/forums/images/imported/2009/12/IMGP3181-1.jpg


I also decided to fit a VW Motorsport Windage tray I've had here for a long time. What better time to use it than now.

http://www.vwwatercooled.com.au/forums/images/imported/2009/12/IMGP3182-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2009/12/IMGP3183-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2009/12/IMGP3184-1.jpg

[Oneofthegreats]

Made up the oil return line & oil supply line For interest sake the supply is dash -4 & return is dash -10

http://www.vwwatercooled.com.au/forums/images/imported/2009/12/IMGP3188-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2009/12/IMGP3186-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2009/12/IMGP3191-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2009/12/IMGP3189-1.jpg

I also got time to modify the wastegate mounting bracket, due to how the turbo housing's are clocked, the original bracket jammed the wastegate pot against the intake manifold. I also had to mod the swing/push rod end too.

So out came some scrap metal, the hacksaw, linisher & welder.

My welds are slowly getting better.

http://www.vwwatercooled.com.au/forums/images/imported/2009/12/IMGP3196-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2009/12/IMGP3197-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2009/12/IMGP3200-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2009/12/IMGP3202-1.jpg

I'll be ordering some more part's tomorrow which broke, painting the piping & hopefully start reassembly tomorrow night!

[Oneofthegreats]

Got another good day in of work today.

Decided to set up a makeshift booth in the shed as it was crap weather all day again & line it with old massive blanket's & got the patio heater going! Crap I know, but it all didn't turn out half bad.

Managed to etch & spray all component's & then fit everything up.

Just waiting on an oil supply fitting & then onto the wiring which shouldn't take all that long & then brake booster pipe, exhaust & aux. injector fuel line

On with the pics. Very pleased with the final product. Almost look's factory apart from the Tial BOV.

http://www.vwwatercooled.com.au/forums/images/imported/2009/12/IMGP3204-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2009/12/IMGP3206-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2009/12/IMGP3207-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2009/12/IMGP3213-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2009/12/IMGP3210-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2009/12/IMGP3212-1.jpg

[Oneofthegreats]

Before & after shot's.

http://www.vwwatercooled.com.au/forums/images/imported/2009/12/IMGP3065-1.jpg

Engine look's alittle cleaner now with less aux. air valve supply hoses & the Warm up reg hoses tucked away too.

http://www.vwwatercooled.com.au/forums/images/imported/2009/12/IMGP3204-1.jpg

[Oneofthegreats]

Got a chance when I got home to wire up the A/F meter, calibrate it & fit the boost gauge. These will only be fitted temporarily for tuning. Once I'm happy with it all, it will all get removed & back to stock interior.

Anyway I can safely say it runs!

Cranked over on the 2nd revolution & fired into life. Although alittle noisey & once all the gasket goo & exhaust paint had settled, it idled perfectly as before at 1000rpm.

I'll get a chance tomorrow arvo to drive it & see how it all goes.

[Oneofthegreats]

Well with the car still without an exhaust, test driving has been kept to a minimum.

I did get a chance to drive it though & initially boost was kept as 5psi. The turbo isn't even working!

The A/F ratio is spot on at idle & cruise. approx 14.6-14.9:1, but under boost it richen's upto low 10's:1! That's without the Extra injectors even hooked up!

But after a few goes & alittle bit of playing around, I wound it up to 10-12psi & the surge starts to come in. Its still running rich as under boost, so there is sill some playing around to do yet with adjustment's etc.

I'll get more tuning in, once the exhaust is fitted which should be tomorrow.

But it's slowly getting there.

No leak's, no fires & everything is smooth.

[Oneofthegreats]

Well fella's, the full exhaust is now on which is a 2.5" full mandrel system with a resonator & high flow rear muffler.

The car is now nice & quiet to drive, idles nice & after a few runs, I'm seeing better increases.

I've since increased the ignition timing & set boost at approx 10-12psi & now it's taking off!

This would eat my old NA setup for breakfast!

At the moment I'm getting closer & closer to the tune. It's just timing & boost. Fuel is spot on!

[Oneofthegreats]

Some more pics for the sake of it

Innovate Motorsports Air/Fuel meter. Awesome bit of gear & should be on everyone's list for the home tuner!

Happily idling away at 14.5-.14.9:2

http://www.vwwatercooled.com.au/forums/images/imported/2009/11/IMGP3217-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2009/11/IMGP3214-1.jpg

Fitted the LC-1 in the rain tray. The oxy. sensor lead isn't long enough to reach into the car

http://www.vwwatercooled.com.au/forums/images/imported/2009/11/IMGP3215-1.jpg

Callaway boost guage

http://www.vwwatercooled.com.au/forums/images/imported/2009/12/IMGP3216-1.jpg

The matching pair of tuners tool's!

http://www.vwwatercooled.com.au/forums/images/imported/2009/11/IMGP3218-1.jpg

I'm still slowly honing in on the tune, but I'm now running out of fuel up top in the higher gear's/load, so the car is booked in next Fri. to have the aux. injector hosing made.

I took a friend for a spin on the light setting & he reckons it's alittle bit faster than a lightly modded WRX. Not sure on that though. It's scrabbling for traction in the first 2 gears, but it's still slow to me!

[Oneofthegreats]

Got some more work done this arvo & also getting to the end of the part's list.

The faster I get this done, the sooner I can move onto other projects.

Fitted up my new ATE Powerdisc's & Pagid brake pads front & rear

I also decided to give the underneath a pressure wash, due to the weekend away bush bashing a few weeks ago.

http://www.vwwatercooled.com.au/forums/images/imported/2009/11/IMGP3220-1.jpg

Fronts are Corrado 280mm discs & stock Mk1 GTI style pads.

http://www.vwwatercooled.com.au/forums/images/imported/2009/11/IMGP3224-1.jpg

Rears are just standard size Mk2 16V rear disc's & pads
http://www.vwwatercooled.com.au/forums/images/imported/2009/12/IMGP3221-1.jpg

[Oneofthegreats]

Well I finally broke something today.

My old ABD short throw shifter. The top relay lever broke clean off the shaft!

Stopped,opened the bonnet & manually selected 2nd gear on the gearbox & drove back to a mates house for some repairs too.

Other than that, its been smooth sailing. the car is performing without fault. Mixture's are good, fuel economy is the same as before if not better.

I've removed the tuning gear out of it, till I get my next upgrade which will be a MSD 6BTM. Boost retard ignition

The aux. injector fuel hose will be going on the Fri & I'll have some wiring to do as well.

[Oneofthegreats]

Well not much has been going on apart from driving the car everyday & no problem's have arose since getting it going.

I managed to get in some time to get the Aux. injector fuel hose made & then wire it all up today. I also tested the system to see if it would all work

System all up & running

http://www.vwwatercooled.com.au/forums/images/imported/2009/12/IMGP3237-1.jpg


http://www.vwwatercooled.com.au/forums/images/imported/2009/12/IMGP3238-1.jpg

The cold start valve outlet

http://www.vwwatercooled.com.au/forums/images/imported/2009/12/IMGP3239-1.jpg

With the Hobbs switch bridged out

http://www.vwwatercooled.com.au/forums/images/imported/2009/12/IMGP3233-1.jpg

I'm yet to hook up the A/F meter & see what's going on. I'll do that once the MSD 6BTM has been fitted & then see how it all goes.

[Oneofthegreats]

I also received another xmas present today. I ordered it Mon. night AUST time & it arrived THURS. morning form the States! Hell yeah!

All my Ignition component's arrived today incl. MSD 6BTM & RPM limiter pills, Blaster 2 Coil & bracket, Ignition Leads & separator's.

http://www.vwwatercooled.com.au/forums/images/imported/2009/12/IMGP3292-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2009/12/IMGP3294-1.jpg

This weekend should be fun.

Once this is all fitted, I'll refit the boost & A/F meter & hopefully start to turn the wick up on this 300+K old stock GX engine! hahahah

[Oneofthegreats]

well I finally managed to get some more work done, but it was a very very slow process. I started working on installing my new ignition when a friend decided to come down & help me. Well it was only a matter of time before the booze came out. That basically put an end to my progress.

I got the MSD & coil mounted & ran the wiring & started on the ignition lead's

Not much!

MSD box mounted up in the rain tray against the fire wall. I also fitted a 6600rpm limiter pill. I think I will change this back to a 6200 or 6400 pill.

http://www.vwwatercooled.com.au/forums/images/imported/2009/12/IMGP3309-1.jpg

MSD Blaster 2 coil mounted under the Expansion tank.

http://www.vwwatercooled.com.au/forums/images/imported/2009/12/IMGP3310-1.jpg



Onto today. Very slow & one very "very" bad hangover!!!!!

I finished off all the wiring, made the ignition lead's & got everything tidied up.

Bit of a mess under here, but aren't all Mk1's like this?

http://www.vwwatercooled.com.au/forums/images/imported/2009/12/IMGP3307-1.jpg

When I built this Mk1 I mounted alot of stuff out of view to clean up the engine bay. The only place to put it all is in the cabin under the dash!
Here is the TCI switch mounted up

http://www.vwwatercooled.com.au/forums/images/imported/2009/12/IMGP3308-1.jpg

Mounted up the Boost retard controller.

http://www.vwwatercooled.com.au/forums/images/imported/2009/12/IMGP3348-1.jpg

With all the lead's made & fitted

http://www.vwwatercooled.com.au/forums/images/imported/2009/11/IMGP3339-1.jpg

With everything refitted, the MSD is hidden away not too bad.

http://www.vwwatercooled.com.au/forums/images/imported/2009/12/IMGP3346-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2009/12/IMGP3347-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2009/12/IMGP3345-1.jpg

Anyway, I did get to drive it & have a quick play around with it tonight. I've now wound the boost upto 15psi & I can safely say the car is now fun to drive!

There is still some tuning/sorting out to do, as it now is just starting to lean out in the top end. I'll have more of a play around tomorrow. I think I'll start increasing the system pressure, to supply the aux. injectors with some more fuel & also retard the cam timing alittle bit. I can start to feel the engine nose off near the topend. I also had this problem when it was NA with the 270 Autotech fitted. I found 2-4 degrees retarded made a big difference to topend.

But just going off initial setting's, I can roll along at 60kph in 2nd & plant it & it will start to break traction. Whether it is turning the tyres or just trying to yank the steering wheel out of my hands & skipping the tyres, it's now very fun. It also try's & yanks the wheel in 3rd roll on from 80 too.

[Oneofthegreats]

Well I had alittle bit of a sleep in but managed to pry myself outside to have a play around with some System Pressures on the K-Jet.

Here is what the system pressure was before

72psi.

http://www.vwwatercooled.com.au/forums/images/imported/2009/12/IMGP3350-1.jpg

Here is where the system pressure regulator is located on the side of the fuel distributor. Above it are is the warm up regulator supply, then the fuel return & then the cold start valve fuel supply.

http://www.vwwatercooled.com.au/forums/images/imported/2009/12/IMGP3360-1.jpg

This is what I'm going to adjust to increase fuel flow onto all the injectors incl. the aux. injectors too.

Here is what the regulator looks like removed. This one is out of a spare fuel dizzy I've got here & what I raided the o-ring & pressure spring shim's out of

http://www.vwwatercooled.com.au/forums/images/imported/2009/12/IMGP3353-1.jpg

Here is the one out of my car :Note the two shims on the left of the o-ring.

http://www.vwwatercooled.com.au/forums/images/imported/2009/12/IMGP3355-1.jpg

Shims removed

http://www.vwwatercooled.com.au/forums/images/imported/2009/12/IMGP3356-1.jpg

Then measure what size the shims are to increase or decrease if need be the fuel pressure.

My stock shims were a 0.30mm & 0.50mm giving a total of 0.80mm.

The fat shim was 1.3mm, so I installed this along with my other shims giving a total of 2.1mm

http://www.vwwatercooled.com.au/forums/images/imported/2009/12/IMGP3359-1.jpg

Everything refitted & onto testing the fuel pressures.

Now 82psi

http://www.vwwatercooled.com.au/forums/images/imported/2009/12/IMGP3362-1.jpg

As far as how much improvement is made.

It no longer lean's out in the top end & keeps a stable mixture right through the rev range, although on initial boost build up & can shoot as far as 9.5:1 A/F, but quickly lean's back off to normal.

Mind you today was 26+°C & I didn't have any problem's with pinging etc.

Very happy with all this has turned out.

[Oneofthegreats]

Only after 3 full days with the boost turned upto 15psi, the clutch is starting to let go.

Alittle pissed, as it's only a new clutch that I fitted when the engine let go & its only done approx 20K & thats all highway use.. Its also a Heavy Duty job with the 16V pressure plate.

So at the moment, I've had to wind back boost pressure to wastegate spring tension. approx 6psi!

I also haven't been riding the clutch either. All the work its done so far has been roll on full throttle stuff. It must be making some good power! haha

I think I'll have to source a button clutch in the mean time till I get the auto done.

If I can't get the right clutch landed in time for DOVw, I'll just bang in a stocky 210mm clutch.

I'll also refit the diesel 4spd & probably lock the diff too, so I can drag it.

[Oneofthegreats]

Thought I'd do a quick update on whats been happening.

I've been using the car everyday as my daily driver & it has done 5000K with the turbo setup & nothing out of the ordinary has happened (yet!). Getting better fuel economy than the NA setup too!
The engine is still breathing & filling up the catch can approx 3-4 weeks as it was doing when it was NA.
Its also not using any more oil than before either, which is a good sign.

There is some bottom end noise now, when cold though! I think the 15psi beating on the stock bottom end is taking its toll! haha

Other than that it has been fun so far & has already added a few fast cars to its "win" street drag resume.

At the moment I'm happy to leave the car as it is on 15psi & hopefully get it to a street meet after dovw, as calder park is reopening very soon.
Will bang on the semi slick's I've got here. Just hope the clutch holds out till then.

[Oneofthegreats]

Well I finally managed to get the car to the drags.

Fitted up the soft semi track/road tyres. Drove to the track 1.5hr's one way!

Lowered the front tyre pressures to 20psi.

Got in a burnout, staged, took off with about 4000rpm dialled in, boosted up, shook the tyres hard (a few friends in the crowd said it had bad axle tramp!) grabbed 2nd & broke the shift relay linkage only to have to roll down the strip in neutral! Not happy!

Had to trailer it home!

Waist of a night, but ah well. Hopefully next time

[Oneofthegreats]

The car has had a quick make over earlier this week & these pics were taken from the "Day of the VW" i

I basically made the car as visually stock as I could, except for the sunvisor, roof aerial (even though it doesn't have a radio!) lowered, & large exhaust tip!

Very sedate & the best sleeper! haha

http://www.vwwatercooled.com.au/forums/images/imported/2009/11/IMGP35371229x922-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2009/11/IMGP3639_1024x768-1.jpg

Also fitted a bench seat too! Not many people noticed it, but when they did, they loved it!

http://www.vwwatercooled.com.au/forums/images/imported/2009/12/IMGP3540_1024x768-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2009/12/IMGP3538_576x768-1.jpg

http://www.vwwatercooled.com.au/forums/

[16v_kid]

:bowdown:

Well done mate, first time iv seen a vw mk1 turbo in a Australia too, 6/11/09. (Calder Park)

Love this thing!


:banana::banana:

[Oneofthegreats]

:bowdown:

Well done mate, first time iv seen a vw mk1 turbo in a Australia too, 6/11/09. (Calder Park)

Love this thing!


:banana::banana:

Theres a few out there. incl. petrol & diesel.

Trust me.

I know of one in SA, a couple in NSW.

A bloke around the corner from me built a mk1 GLD diesel turbo along time ago. Was a time bomb though & it was still slower than a wet week

[DVR68U]

awesome build up ,
cheers brenton

[Whubbsie]

epic Tim, good to see ya around again.

[funkamedic]

nice work again bro! u talented bastard! i love threads like this where i get to learn stuff. it's amazing how different the car looks on the standard steelies. sleeper indeed. and props for the bench seat :cool:

btw... that's gotta be a record build. 26mins :eek: you ain't got a flux capacitor hidden under your dash too by chance?

[Oneofthegreats]

nice work again bro! u talented bastard! i love threads like this where i get to learn stuff. it's amazing how different the car looks on the standard steelies. sleeper indeed. and props for the bench seat :cool:

btw... that's gotta be a record build. 26mins :eek: you ain't got a flux capacitor hidden under your dash too by chance?

Always nice to help people learn new stuff, especially when they are willing to learn!

haha. I wish I could build this in 26mins! hahaa

Nah. I gathered as much of the main parts as possible to carry out the build & everything else was bits here & there I couldn't plan on what I'd needed. eg. what piping, hoses etc.

But when everything arrived I pulled the car off the road on a Monday arvo & it was running & tuned the Friday week. So less than 2 weeks to do the entire turbo build.

I hate having a project car sitting around & I've still got one sitting here for 7 years!

Best to plan as much as you can& bang it out as soon as possible!

[DUB 12V]

very well done awesome stuff...:eek::eek::eek:

[86gti]

WOAH!!! This excites me!! You have been busy.
Awesome work as always, your attention to deatail is 2nd to none.
Great job!

[Oneofthegreats]

Thanks fella's.

Cars been going really good, even in the boiling hot weather it will still cruise along at 100km/h without any problems. But it will ping when boosted in 3rd & up.


Solution = don't boost it when hot! Just cruise!


I've also covered 10K in it since fitting the turbo kit & its only broken 2 exhaust mounts which isn't too bad I reckon on a stock engine & has also wrecked the diff bearings & an outer C.V. joint too. They are still in the car though & are still going strong! haha I'll replace the gearbox & driveshafts soon enough

Engine still isn't using any water & only alittle bit of oil due to an oil leak ( & it's bloody noisey as when cold too!) & still pulls hard when you feel the need to motivate!

Oh, & the front tyres don't seem to be lasting very long either for some strange reason too!

[Spyda]

Will we be seeing any dyno or 1/4mile figures in the near future? Im realy interested to see what power its making.

[DubSteve]

Do a skid :banana:

[WABIT]

Will we be seeing any dyno or 1/4mile figures in the near future? Im realy interested to see what power its making.


im pretty sure the 1/4 mile time will be happening in the near future
he tried without success about a month ago, broke his shifter linkage trying to change into second

dom

[16v_kid]

im pretty sure the 1/4 mile time will be happening in the near future
he tried without success about a month ago, broke his shifter linkage trying to change into second

dom

Thats right.

But, 1st gear was insane!!

[Oneofthegreats]

Will we be seeing any dyno or 1/4mile figures in the near future? Im realy interested to see what power its making.

Seeing as its coming up crissy, new year & all the festivities that go along with it, there won't be anything going on for a while sorry. Hopefully Feb next year.

This bank balance cop's a hiding this time of year!

I don't plan on dyno'ing it sorry. The 4th gear low rpm ramps ups won't do it any good at all due to the massive stutter & stubble.

On the road cruising in 4th at 60 & plant it it, the engine can't build up revs fast enough to overcome the stumble.

In 2nd as you seen it will power through it & 3rd also. $th is just too tall for it.

If you nail it from 100 in 4th it will be ok, but it depends on the weather too.

It really is one very temperamental system!



Today in the 40 degree heat!!!!!!!

Now that was something!

Cruising home this arvo from work on 95 & the temp guage was nudging red all the way! haha

My response to the guage "like i give a crap! I'll drive you till you stop!" haha


http://i287.photobucket.com/albums/ll148/golfworx/Image0191.jpg

[16v_kid]

DAMN!! that nearly overheated...:eek:

Never seen my dial go the far up to the red.

[Jarred]

DAMN!! that nearly overheated...:eek:

Never seen my dial go the far up to the red.

my old 76er used to run that 'hot' all the time. never hit red, nor did it ever actually overheat.

[16v_kid]

my old 76er used to run that 'hot' all the time. never hit red, nor did it ever actually overheat.

farrrr out!!

maybe i just never got to drive the old girl on hot weather.

[Oneofthegreats]

I wouldn't say it was overheating but to give you an idea where it normally sits....

The thermo fan comes on at 1/4!

The guage did push further up & once it came down a tiny bit I thought I'd grab the camera for a laugh.

[Spyda]

Mine was that hot today and it wouldnt rev over 1100rpm, i got stuck in a major intersection. I stoped at a carwash and sprayed the radiator so i could get home.

[Oneofthegreats]

A quick update on this car.

I've done just over 10K with the turbo setup & all seem's to be going as normal.

The engine is still noisey on cold start up, but still isn't using water or oil. Only the oil it leaks.

The old engines must have been manufactuered with high quality material's I reckon to withstand this sort of abuse for this long. Especially as the engine was never designed to take positive pressure.

Still tuned on 15psi & still lights the tyres up when you feel the need! haha

It's definitely lasting a lot longer than I first expected & still surprises me everytime I stand on it (& the people around me too when the tyres start to turn at 60+km/h!)

Keep on keeping on!

[Golf Loon]

This is a top car, keep the updates coming mate.

Have you managed to break that diff yet??

[euroequip]

Going to need a video of this Tim! :bowdown:

Good stuff mate.

[Oneofthegreats]

This is a top car, keep the updates coming mate.

Have you managed to break that diff yet??

Nah not yet sorry Loon!

I'm surprised how long its lasting. haha

I'm fitting some new wheel bearing hopefully this coming week & getting a wheel alignment.

I'll be looking into fixing the oil leak at the next service too which isn't too far off.







Going to need a video of this Tim! :bowdown:

Good stuff mate.

Sorry matey. No video.

Don't have a video recorder & there wouldn't be anything that's legal to put up either.

[Oneofthegreats]

Well after months of trouble free motoring with the turbo setup, it finally played up & came crushing down. Big not in a big way!

It happened the day Preeny came down.

Must be murphy's law I reckon.

When you actually want to show someone how it goes, it fail's!


It just wouldn't boost & felt like a massive slug. It would spool up, but only felt like wastegate spring pressure, which is approx 6psi!

So after messing around with it & deciding I needed to really fix the oil leak's, I'd investigate the boosting problem too.

So off with the sump, front timing cover & dump pipe.

Replaced the front timing cover seal & gasket. Resealed the sump & windage tray & gave it a service too.



Then onto checking the turbo blades & wastegate. All good.

I checked all the boost control piping & found the boost regulator base had come loose & also pinched the wastegate control hose!



The base had loosened which cause the unit to twist around & drop boost pressure & also causing the following pic's

http://www.vwwatercooled.com.au/forums/images/imported/2010/02/IMGP0274_576x768-2.jpg

Split hose in two places! It actually looks like its been pinched with pliers, which is strange. As I'm the only one who has played around with it!

http://www.vwwatercooled.com.au/forums/images/imported/2010/02/IMGP0277_576x768-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/02/IMGP0280_576x768-2.jpg

The culprits of my car turning back into a slug!

http://www.vwwatercooled.com.au/forums/images/imported/2010/02/IMGP0281_1024x768-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/02/IMGP0284_1024x768-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/02/IMGP0285_576x768-2.jpg

So after everything I'd fixed everything up, it was onto tuning again.

What a pain in the arse!

I re timed the ignition timing to how I'd set it ( which was wound up fairly high!), I had to reset the boost control, but it wouldn't play nice & I couldn't get it to consistently boost to 15psi no matter how I adjusted everything.

I did get it to spike to 20psi & christ did it go (turned the tyres hard in 3rd!), but it was very unsafe on the poor old stock donk.

So I'm still at the point of trying to find the old setup tune, which may take alittle bit longer than expected.



I also have left the shed in an absolute mess trying to get this thing back on the road.

Hopefully I'll have it sorted by the weekend. I also have to replace the gearbox selector shaft seal too & then give it a complete pressure clean to clean off the mess.

[gldgti]

always the way to have something fail right when you want to show it to someone, haha.

You really run that thing on skinny 13's??? Must eat tyres!

Looks like a lot of fun, to be sure.

***edit***

On your hot running issues - and believe me, i know your no amature, but just to be sure - are you positive you have really good earthing to the block? i used to have a bazillion problems with spark, instruments, rough running and stuff on my LS until I finally diagnosed it as bad earth to the engine. I know its not likely, but sometimes unless you actually get the multimeter out and test resistance its hard to be sure.

Just trying to help :-D

[Oneofthegreats]

always the way to have something fail right when you want to show it to someone, haha.

You really run that thing on skinny 13's??? Must eat tyres!

Looks like a lot of fun, to be sure.

***edit***

On your hot running issues - and believe me, i know your no amature, but just to be sure - are you positive you have really good earthing to the block? i used to have a bazillion problems with spark, instruments, rough running and stuff on my LS until I finally diagnosed it as bad earth to the engine. I know its not likely, but sometimes unless you actually get the multimeter out and test resistance its hard to be sure.

Just trying to help :-D

True.

Yeah I run it on 165/75R13's.

The tyres are lasting not too bad, cause its all powerskid stuff which isn't hard on tyres, as appose to actually stopping & doing skids wreck's them heaps faster!

Why stop & do a skid when you can roll along & in 2nd at 60 & do them I say.

Even though I'm running 13's, it doesn't really matter. Even with the 205 sticky semi-track tyres. It still turned them from 60-80km/h!

Still haven't got back to the strip yet, but have had some good runs with it & have upset a couple of low 13 sec cars incl. a cammed up gen3 with 250rwkw! Now he wasn't a happy camper!



The hot running only became an issue on really hot days like 37+.

Plus it also has a blacked out intercooler pumping added hot air across the radiator, so in extreme weather it can run hot on the highway, but I don't get all that worried. When I come back into traffic, the fan bring's the temp down.

On the earth side of things, I can understand where you are coming from. I made new battery cables,along with alot of other little bits & pieces when I built this car to make sure all the electrics were spot on first off.

On normal days it runs on 1/4 on the highway & get's upto 1/2 in traffic which is exactly how all my mk1's have been

Thanks again. After all, its all food for thought.

[Preen59]

Great car. Lots of fun to drive. Soooooo smooth off boost. It's a credit to Tim for being able to do so much with very little. Just goes to show if you use your noggin and you have some skill, you can make something pretty cool without spending a lot of money!

Even on the "Golfworx certified" calibrated arse gauge 10psi, i reckon it goes pretty hard for what it is.


Oh by the way Tim.. You forgot to mention I pulled the Timing belt off for you and passed you some tools.. Where's the recognition, man?! Haha.

[Oneofthegreats]

Great car. Lots of fun to drive. Soooooo smooth off boost. It's a credit to Tim for being able to do so much with very little. Just goes to show if you use your noggin and you have some skill, you can make something pretty cool without spending a lot of money!

Even on the "Golfworx certified" calibrated arse gauge 10psi, i reckon it goes pretty hard for what it is.


Oh by the way Tim.. You forgot to mention I pulled the Timing belt off for you and passed you some tools.. Where's the recognition, man?! Haha.


hahaha

Yeah. Was more like 6psi! hahaha. Was still slow!

After mucking around with it tonight, I've got a funny feeling I've been running it on 20psi the whole time too! haha.

Cause 15psi doesn't stutter & light the tyres up like it used too! I'll get there soon enough.

More timing & more boost is the key!!!!!!!!

Poor old engine!


& yes preeny. Sorry matey. You did help out with dismantling the car & passing some tools!

But you also rethreaded the boost reg too with a file too!

I have got a good memory!

[Preen59]

Now if it blows up you can say "Well.. It's my fault.. But it's kinda your fault too!" haha.

[Geoffrey Hale]

Hi all ...... I hadn't looked at this thread till Preeny put me onto it. Excellent job Golfworx. What a sleeper. I'm sure there must be a few motorists out there wondering why they paid so much for there cars when they cant keep up with an old Mk 1 Golf. ....... cheers ....... Geoff

[16v_kid]

Nice work! :eek::eek:

[gldgti]

True.

Still haven't got back to the strip yet, but have had some good runs with it & have upset a couple of low 13 sec cars incl. a cammed up gen3 with 250rwkw! Now he wasn't a happy camper!



please come up to NSW and beat my workmate in his new VE Maloo. He got it chipped/dyno tuned before it left the dealership (holden eh...) and made nigh on 275rwkw - i would love to see his face when beaten by a mk1 golf, haha.

maybe i'll have to build a turbo golf...




The hot running only became an issue on really hot days like 37+.

Plus it also has a blacked out intercooler pumping added hot air across the radiator, so in extreme weather it can run hot on the highway, but I don't get all that worried. When I come back into traffic, the fan bring's the temp down.

On the earth side of things, I can understand where you are coming from. I made new battery cables,along with alot of other little bits & pieces when I built this car to make sure all the electrics were spot on first off.

On normal days it runs on 1/4 on the highway & get's upto 1/2 in traffic which is exactly how all my mk1's have been

Thanks again. After all, its all food for thought.

Ahh i suspected as much - but never hurts to mention anyway.

Like you said, if you've been running 20psi all along, that could well have something to do with the sputtering, etc.

[Oneofthegreats]

please come up to NSW and beat my workmate in his new VE Maloo. He got it chipped/dyno tuned before it left the dealership (holden eh...) and made nigh on 275rwkw - i would love to see his face when beaten by a mk1 golf, haha.

maybe i'll have to build a turbo golf...



Ahh i suspected as much - but never hurts to mention anyway.

Like you said, if you've been running 20psi all along, that could well have something to do with the sputtering, etc.

As much I'd like to say I could keep up with the ute you speak of, thats a mid to low 12 sec & the poor boosted stock engined mk1 won't get within a wiff of it. Plus its a 6.2L which carry's alot more torque too.

The sputtering is the warm up reg. not being able to cope with how it develop's boost when wound up to what I had it at. As its not nice & smooth, rather 4000rpm & "BANG" & it over fuels & fuel dumps pretty violently with A/F ratio jumping into the low 9's for a split second!

In the lower gears it can power through the sputtering very fast & turn the tyres. In higher gears eg. 5th @ 100km/h, it will just sputter without boosting.


On 15psi with conservative timing, it unbelievably nice & smooth, with the turbo getting a big surge at 4000rpm. But just doesn't give you the kick in the pants. Its funny. Once you've had power, its hard to detune & go back! haha



The joy's of a turbo'd mechanical fuel system.

Can't wait for next turbo'd engine. 20V, EFI & big turbo all the way.

[POLARBEAR666]

If you seal around the intake area that goes to the intercooler / radiator complex you will find you run much much cooler. I know you have sealed the gap at the top but you need to seal the sides and bottom so that air has no place to go except through the whole lot.

Half the air that comes in the front will be pissing out the sides or going underneath the radiator and intercooler.

Get some aluminium sheet from bunnings for about $12 a sheet.

Bend it to make air trays that close the sides/bottom and watch your temps drop! My radiator struggles to get past 86-87' on very hot days even though it used to sit religiously on 88' before my mods and use the fan often to bring temp back to 88.
http://www.vwwatercooled.com.au/forums/images/imported/2009/12/IMGP3151-1.jpg
http://www.vwwatercooled.com.au/forums/images/imported/2010/02/IntercoolerAirDiffusers-1.jpg

[Preen59]

Way to go, Tim! Good to see you've got it sorted.

Polar's post does make sense. I know of quite a few people who have made similar shrouds to get the same effect of a variety of different applications, with positive results. I've experimented with that a few years ago in Karts and trapping the air does make quite a difference. :)

[Oneofthegreats]

Make good sense Polar.



You really have to have a look with everything in there to see how everything is mounted & routed though. Its a bloody tight fit.


Next time the rad. is out I may look into bending something up with some thick foam seal ends

But at the moment on a normal day, its fine. Its only on really stinking hot days eg. 37+.



The opening on the grill being a small open version is right at the edge on the intercooler core.

The rad. is alittle wider than the intercooler & run's all the way to the bottom on the rad. support.

The only place for major bleed off would be the passenger side & there is bugger all room there to fit in a tray/deflector.

http://www.vwwatercooled.com.au/forums/images/imported/2009/12/Image0049-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2009/12/Image0050-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2009/12/IMGP3210-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2009/12/IMGP3212-1.jpg

In a factory Mk1 it has a top & side deflectors. Nothing on the bottom, as the rad. runs all the way to the rad. support.

[Oneofthegreats]

Well after Preeny came down & drove this around alittle bit.

We sat down, had some drinks & threw some ideas around about the tune & how to improve & fine tune it. Cause after the boost regulator unscrewed & boost regulator hose split, it threw the tune way out & I just couldn't find the old tune again.

So I thought I'd give a few of the idea's a try & play around with them.

First off, I cleaned the K&N air filter which hadn't been cleaned since I built the car. So more or less 50+K!!!!! To say it was black & chocka block with dirt is an understatement. I've seen cleaner filters in vacuum cleaners!

Then replaced the fuel filter too.

Then onto refitting both the tuning equipment, being the Boost gauge & Air/Fuel Meter Gauge.

I started off repairing one of the cyl. head plastic fitting's that broke after a backfire yesterday which was basically the start of whole process of playing around with the tune.

I removed the Hobbs adjustable pressure switch for the Aux. injectors (cold start valves) & bench tested & then readjusted it from a 7psi cut in to 13psi cut in.

So when it hits the magical 13psi mark the extra injectors cut in & supply extra fuel on boost. Instead of dumping fuel in earlier at 7psi. Now it has a fair amount of extra air volume before dumping in extra fuel.

Then I readjusted the system pressure of the K-Jet system. I reshimmed up the system pressure regulator from 82psi to 94psi.

Then redjusted the ignition timing to approx 10BTDC.

Reset the Air/Fuel mixute at idle to approx. low 14's/high 13's:1 & seemed very happy.

The onto the R/test to reset the boost regulator. This took several start/stops to get it right. As when bench testing it, you don't get the same volume of air from the turbo as you would from 60 gallon air compressor tank.

After alot of R/testing & playing around, I ended up with it set at 20psi & adjusted the timing retard to approx 1.5 degrees per pound of boost.

With these few changes, the car has now come alive.

It certainly doesn't have the same amount of kick it did, but now it doesn't have any stutter or fuel dump at all. It will pull cleanly in all gears with a nice smooth surge & then when it hits 4K the surge gets greater!

So you can cruise along in 4th@100km/h, plant it & without any stuttering, it can (let your imagination take over).

Now it doesn't wheel spin like it did & makes bugger all boost in 1st due to not building up enough engine load, but in 2nd it will boost & turn the tyres, hook up & away you go, 3rd & 4th come about very fast!

If you in 3rd at 60, it will also squeal the tyres on hot mix & pull nice & smoothly past the legal speed limit.


So overall. Even though the car isn't as fast as it was or turn the tyres as violently as it did , its feels only a fraction slower & it's a much nicer & heaps easier car to drive. Which is also pretty bloody fast.

Big round of applause to Preeny! Without the booze he's useless! haha

P.S. but it wasn't all him!

[GoLfMan]

good to hear you've sorted it mate :)

now I need to have another ride in it! :D

[DubSteve]

After being in the car the other week, anyone can ask Tim the laughs I had with this car with just the sheer awesomeness that comes out of it! A pure sleeper I love it!

[Jarred]

You still owe me a drive! :P

Glad to hear you have refined the tune though.

[Preen59]

Great stuff, Tim! Glad to hear you got it all sorted.


PS.. The invoice is in the mail mate. hahahaha. :P

[velly_16v_cab]

great result guys, i will pop around for a blast some day soon tim ;)

[gldgti]

sounds brilliant. we need a private server for video hosting :evil:

[Oneofthegreats]

Ok. Alittle update.

The car has now done 20K on the turbo setup & all has been going well until last Fri. night when the gearbox decided to start making some unusual noises which were more prominent in 2nd gear. (this is the powerskid gear, so it copes all of the abuse I dish out to it!)

I thought. Bugger it & I'll keep driving it. Whats the worst that can happen? right?

So I've been bumming around in it for the last couple of days & with a last minute decision to head upto the VW Jamboree, I was off with gearbox noise in tow.

By the time I finally got to the park, the car was making a loud enough racket that I could hear it over the engine especially in 2nd gear! Even with light taking off & babying it ,it was noisy as hell. You could even just have it idling away in neutral & it was noisy.

So after the show, we heading back to Waterboys house for a catch up & once again we were off. Well by the time I got into Melb. people were actually taking notice at how loud the noise had become in traffic! haha

But I pushed on (more like babied on!) for the 2 hour drive & finally made it into my driveway where on arrival it went ""BANG""

It locked up in 1st gear & had no drive what so ever. The noise in neutral & idle is unbelievable! Just full of bearing & crunching noises! Lucky it didn't punch any holes in the casing either. But by the sounds of it, I reckon its junk!


So I'll bang in the ever trusty diesel 4spd which I always rely on in need which has never let me down.



that is until I push god knows how much power though it! Only time will tell.

I'd post up a vid of it idling away, but I have no idea how to upload vids off the camera & they are bloody massive files too!


http://www.vwwatercooled.com.au/forums/images/imported/2010/03/IMGP0443_1024x768-1.jpg

[Golf Loon]

Thats Gold that the old girl got you home, then died on the driveway.

I have some great TDI 020 boxes that have awesome ratios for what you are doing with it and are strong enough to hold the power. Hit me up if you feel the need.

[Oneofthegreats]

Thats Gold that the old girl got you home, then died on the driveway.

I have some great TDI 020 boxes that have awesome ratios for what you are doing with it and are strong enough to hold the power. Hit me up if you feel the need.

Thanks Matt!

Your right about getting me home & then dieing!

It broke a clutch cable last Wed. in peak hour Melb Westgate traffic & I had to nurse it over to St Kilda for a important meeting & then had to get over to Essendon through the city to replace it!
I could only manage just a tiny amount of clutch for takeoff only & had to go clutchless the rest of the trips. The pedal sank to the floor as usual!
When I removed & inspected it was fried to the max & only was holding together by 2 strands!

I reckon I've replaced more clutch cables & components in Mk1s than I have replaced brake pads, discs & also any light globe in a mk1! They are bloody terrible! But that's the joys of running a heavy duty clutch!

I'll definitely keep this in mind, but I reckon the TDI boxes may put alittle too much load on very tired old engine under long periods of boost.
I'm not really into crazy long ratios or top speed.


You can only do 100, but its more about how fast you can get there, or turn the tyres trying! haha.




I might just try the stock old 4 spd for the time being, as I'd really like to hopefully get some sort of movement on the custom auto build up

[GRN_VAGN]

Will have to come and have a look when im in Melbs in couple weeks.

Thats pretty awesome about the box lasting the 2 hour trip home haha!! good work VW!

[Jarred]

Funny how your cars always seem to get you home isn't it Tim?

the old 8V and now the gearbox finally!

[Oneofthegreats]

Funny how your cars always seem to get you home isn't it Tim?

the old 8V and now the gearbox finally!

True!!!!


It must just be that the car knows that I'll look after it & if it gets me home it will get good going over.

The 6 hr trip home from wagga with a severely blown head gasket comes to mind!

http://www.vwwatercooled.org.au/newforum/upload/showthread.php?t=38088&page=2

Post #17 onwards

http://www.vwwatercooled.com.au/forums/images/imported/2008/07/Imgp1648-1.jpg



Funny. My old silver banger was a jealous bastard!
When ever I'd get another car, it would chuck a hissy fit & either start playing up or jinx the other car!

Especially when I swapped a spare mk1 for a 350ci Landcruiser "shorty" to be my daily & it blew up the first day I got it!

[Oneofthegreats]

Well I finally got enough motivation to get out into the shed & carry out what I thought would be a straight gearbox swap.

Not too be.

Once I removed the gearbox, I found bits & pieces of metal fragments inside the bellhousing & scratch marks all around the flywheel!

So off with the clutch & with a light I also found not only did I destroy the gearbox, I also destroyed the clutch drive plate!!!!!!

On with the pics

Think of your clutch plate drives your gearbox input shaft & from friction material drive section (outer section) is drives through a set of dampening springs & onto a metal star shaped item which then drives the input shaft.

Well I smashed up the metal star drive plate & nearly stripped out the dampening springs out of the housing too!

http://www.vwwatercooled.com.au/forums/images/imported/2010/03/IMGP0493_1024x768-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/03/IMGP0495_1024x768-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/03/IMGP0499_1024x768-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/03/IMGP0500_1024x768-1.jpg


http://www.vwwatercooled.com.au/forums/images/imported/2010/03/IMGP0501_1024x768-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/03/IMGP0503_1024x768-1.jpg



So after having a bit of a "what the f$#k do I do now?" moment, I moved onto stripping the gearbox to have a "captain cook"

What I found was no great surprise to me by the sounds the old gearbox was making but...

It stripped both 2nd gear driver & driven gear & also mashed up the layshaft out support bearing!



http://www.vwwatercooled.com.au/forums/images/imported/2010/03/IMGP0486_1024x768-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/03/IMGP0487_1024x768-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/03/IMGP0490_1024x768-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/03/IMGP0491_576x768-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/03/IMGP0492_576x768-1.jpg


So all in all, pretty much screwed! No signs of the diff rivets letting go or any other bearing marks from little metal fragments getting through the oil.


So for now, I'll source another HD clutch hopefully this week & refit the trusty old diesel 4spd which I always resort too in times of need!

[Water Boy]

Nice effort on the clutch Timmy...

[Oneofthegreats]

Nice effort on the clutch Timmy...

Cheers dude

Who was to know.

I've never seen a clutch let go like that. Not even reading through all the drag & horror stories on vortex!

This was also a HD Sachs clutch with the 3 drive tabbed pressure plate!

Depends on what I can get, but may just bang another HD one in. Don't have time to get one in from the states, as much as I'd really like to!

I was hoping the clutch would have lasted until I finally had the auto up & running, as there was no point buying a solid centred 4 puck racing clutch & only having it in there for a few month's!

[Peter Jones]

MIG the centre soild :) CIG clutch FTW.

Nice effort, I only managed a pressure plate.

http://www.vwwatercooled.com.au/forums/images/imported/2010/01/P1340043-1.jpg

Pete

[Oneofthegreats]

MIG the centre soild :) CIG clutch FTW.

Nice effort, I only managed a pressure plate.

http://www.vwwatercooled.com.au/forums/images/imported/2010/01/P1340043-1.jpg

Pete

hahahaha

didn't really think of this! Mmmmmm

Nah better not.

Remember the clutch spins at double engine speed (ie double the tacho reading), so if it was to let go, it would let go in a BIG way!

Plus I reckon the balancing will be way out!


I can be dodgey, but not "that" dodgey! I don't mind welding up diff centres though! hahaha

[Peter Jones]

Or to be a little more serious

Call Jim Berry.

PHONE: 07 3847 9999
ADDRESS: 26 GLADYS STREET
STONES CORNER QLD 4120
CONTACT: JIM BERRY HOURS OF OPERATION: Monday-Friday: 8.30 a.m. – 5.00 p.m.

Apparently he can make just about anything and is highly regarded.

http://www.motorsportworld.com.au/outlets/raceclutch/index.htm

Pete

[Oneofthegreats]

Or to be a little more serious

Call Jim Berry.

PHONE: 07 3847 9999
ADDRESS: 26 GLADYS STREET
STONES CORNER QLD 4120
CONTACT: JIM BERRY HOURS OF OPERATION: Monday-Friday: 8.30 a.m. – 5.00 p.m.

Apparently he can make just about anything and is highly regarded.

http://www.motorsportworld.com.au/outlets/raceclutch/index.htm

Pete


Thanks heaps Pete.

Think to save myself some time I may just order a clutch plate from work seeing as VW don't do kits for anything these days incl. headgasket VRS sets, I can just get a replacement disc.

Hopefully be Tuesday!

I would've loved to get a spec stage 4 solid centred setup. But I really need this thing going again ASAP

[Peter Jones]

Remember the clutch spins at double engine speed (ie double the tacho reading), so if it was to let go, it would let go in a BIG way!


I'm having trouble seeing how a friction disc could rotate twice as fast as the crankshaft it's clamped to. Care to explain?

Pete

[Oneofthegreats]

I'm having trouble seeing how a friction disc could rotate twice as fast as the crankshaft it's clamped to. Care to explain?

Pete


I'll try & make it as simple as I can


A Crankshaft rotates at twice the speed of the Camshaft (& intermediate shaft in these engines)

The Crankshaft rotates twice in a full ignition cycle in a 4 stroke engine



May have got our wires crossed.

I meant that the clutch incl. the crankshaft, flywheel, crankshaft pulley, gearbox input shaft etc spins at double "indicated" engine speed off the tacho ie if the engine is indicating revving at 5000rpm on the tacho, the crank & all components attatched directly to it are spinning at 10000rpm.

[Peter Jones]

I'm pretty sure Tachos are measuring crankshaft RPM.

I just built one. For each "revolution" it's expecting 2 Ignition pulses which would equate to 1 Crankshaft revolution and 1/2 a camshaft revolution.

Is engine RPM not equal to Crankshaft RPM?

Pete

[Oneofthegreats]

I'm pretty sure Tachos are measuring crankshaft RPM.

I just built one. For each "revolution" it's expecting 2 Ignition pulses which would equate to 1 Crankshaft revolution and 1/2 a camshaft revolution.

Is engine RPM not equal to Crankshaft RPM?

Pete

Well, for every time the dizzy rotates around one full cycle, the crank turns twice. So when your using a timing light the crank is effectively rotating twice for every time the timing light flashes from the ignition pulse.

[Oneofthegreats]

Now you've got me all confused Pete! hahaha.

[Peter Jones]

Well, for every time the dizzy rotates around one full cycle, the crank turns twice. So when your using a timing light the crank is effectively rotating twice for every time the timing light flashes from the ignition pulse.

Yes, that's right but a timing light is sensing off 1 cylinder which fires only once for every two crankshaft revolutions. A tacho is sensing off the coil which fires twice per crankshaft revolution (4 cyl).

[Peter Jones]

Now you've got me all confused Pete! hahaha.


Me too :)

Nighty Night!

Pete

[Oneofthegreats]

I think somewhere down the line, I've had a momentary lapse in concentration knowing that the crank spins at twice the speed of the camshaft, intermediate shaft & distributor.

Been looking & measuring to many gear sets, gear ratios, diff ratios & tyres sizes! doh!

But forgot the the tacho reads off the ignition coil & recognizes that for every rotation of the crank, the coil fires twice (4 cyl. 4 stroke engine) which is identified as one revolution of the crankshaft by the tacho.

[Preen59]

Nice work there, Timmy boy!

Sorry i didn't reply to the picture message last night. I was at a wedding, phone on silent and was quite drunk. Haha. :)

[Oneofthegreats]

Well I finally drew up enough motivation to fit a new clutch (thanks to Doms dad Nick) & fit another gearbox.

Its just a stock replacement 210mm clutch for now, but refitted my HD clutch pressure plate for alittle more bite.

Hopefully the stock old diesel 4psd box can cope.


Time will tell!

[GoLfMan]

sounds good mate! Good work!

Seems to be the weekend for mk1 work :)

[Pullstarter]

Excellent work Tim, just read the whole thread in one go and am amazed at your ingenuity, very well done indeed.

[Oneofthegreats]

Thanks chief!


I hope you got some info out of it.




Every day is a school day!!!! Never forget.

[Pullstarter]

Thanks chief!


I hope you got some info out of it.




Every day is a school day!!!! Never forget.

Certainly did get a LOT out of it, learnt many, many new things, which is naaaaase :D

[16v_kid]

Seems to be the weekend for mk1 work :)


You can say that again! (:

[straight_fresh]

just went throught the whole thread, awesome work man, you made it look so easy to!

[Oneofthegreats]

Well, I finally got some time to bed in the clutch & take the old banger for a spin.

The old diesel 4spd ratios weren't half bad with the NA's 276TT cammed setup, but with the turbo.....

diesel ratios are 1st & 2nd are close then a long jump to 3rd with a short jump into 4th


So now it will light the tyres up just about where ever & when ever it feels in 2nd, whereas before it would still light them up, but would power on through to nearly 100. It was the power gear!

Now with the shorter ratio, its all over & done with much early & you have to shift into a far away 3rd & bogs down for a split second & then away it goes again.

Coming home it spun up in 3rd through a corner, so its still not tall enough that it can't break traction in 3rd pushing 100!


Will have to deal with it until the next gearbox failure!

[Oneofthegreats]

Bordom has been kicking lately with this car so I thought I'd add something for stupidity & laughs.

Behold.

Garfield!

My nephew & niece love it. Even though they don't actually know who Garfield is!


http://www.vwwatercooled.com.au/forums/images/imported/2010/04/IMGP0513_1024x768-1.jpg

Also removed the stock wheel chrome centre caps for a more conservative base model black cap. I like it, but its a bit more of a pain to clean.

But much better than cleaning the old Ronal R8's & Porsche wheels

http://www.vwwatercooled.com.au/forums/images/imported/2010/04/IMGP0516_1024x768-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/04/IMGP0517_1024x768-1.jpg


Oh nearly 25K on the turbo setup & "still" going strong too! hahaha.

[GOLFBALLS]

Dude i love that thing. Looks sooooo innocent heheee!
You must have an awesome time embarassing 'quick' cars in that...

[Oneofthegreats]

Dude i love that thing. Looks sooooo innocent heheee!
You must have an awesome time embarassing 'quick' cars in that...

Cheers dude.

Yeah, I still get a laugh out of driving it.

Most drivers don't even give it a 2nd glance. But I did take off from some lights to have a P-Plater almost snap his neck when he turned around looking for the car with the BOV! Then he nailed it to prove a point that his car was faster, which I got a laugh out of cause he nearly ran into the car in front of him! hahaha

Although with winter coming up & more & more rain, its becoming more of a hazard than a enjoyment but being my daily, I have to put up with it. Suprised wheel spin at 100 in the wet really wakes you up!

[velly_16v_cab]

love it tim, car is a real sleeper now with those rims and a cuddly friend licking the window lol

[Jace]

Even sleepier! That's a winner.

[Preen59]

Bordom has been kicking lately with this car so I thought I'd add something for stupidity & laughs.

Behold.

Garfield!

My nephew & niece love it. Even though they don't actually know who Garfield is!


http://www.vwwatercooled.com.au/forums/images/imported/2010/04/IMGP0513_1024x768-1.jpg

That is ****ing AWESOME!!

Now all you need is a tissue box on the parcel shelf! hahaha.

[GoLfMan]

thats awesome bro! Looks tops :D

[GOLFBALLS]

Ok, I just spent the last two days reading this WHOLE thread. Talk about givin my ass a schoolin on turbocharging!! Great resource thread.

Now I need to go outside and get some fresh air, and it also won't make such a mess when my brain explodes!

Cheers

[Oneofthegreats]

Well it had to happen again sooner or later.

The brand new, less than a month old 210mm clutch just can't stand up to the abuse anymore & has already started to slip in 3rd under full power.

Less than a month for a new clutch! haha

Plant the foot in 3rd & the revs flare straight upto 5000rpm!

So no racing on the horizon for me or this car for a very long time & was hoping to race it later this week.

Car & myself will also be off the road for a period of a month while I wear out a pair of sneakers & BMX tyres later next month or July.

[DubSteve]

Good to hear tim, do a skid!

[Oneofthegreats]

Well I finally got around to racing the HOS (mk1 golf) this arvo/tonight.

Yes I did trailer it this time too! Call it what you like eg. trailer queen, but with as crap history as I have with racing VW's, they always break on me, so its better to be safe than sorry.


My prediction as many people would know was approx a high 13 @ 100mph.

Tonight didn't disappoint!

Ran the car in full street trim, as I drive it to work everyday. All that was removed was the spare wheel & jack.
Full seat's, trim everything, even down to the crummy 13" Bob Jane Allrounders!

I did cop alittle bit of flack while waiting in line, but after the first run & with that mph & high time, the true drag racers & people that know whats going on took notice, & then alot of people were interested & when I said its my daily driver that does 700+km a week, they were dumb founded & instantly said "that much be one fun street car!"



1st run

14.36 @ 101.8mph 2.6 60ft! Yes very lazy take off, but was also on the bald 165/65R13's!!

2nd

Fitted up the stickier road tyres with 10psi

13.99 @ 101.53mph 2.3 60ft. Still lazy & slow on the take off. Slight wheel spin & mild clutch slip

3rd

13.78 @ 101.6mph 2.2 60 ft. Still very slow take off as I didn't want to just rev it up & dump it & break it "AGAIN!", slight wheel spin & mild clutch slip.


I reckon with a proper race clutch, alittle bit more track time & a few suspension tweaks there is still a few tenth's in it.

Not bad for a a so called "crap" Fuel Injection that people told me it couldn't work & a car that cost less than a just a APR/GIAC remap, Exhaust & CAI on a mk5/6 GTI.

http://www.vwwatercooled.com.au/forums/images/imported/2010/05/Drags15510-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/05/IMGP0548_1024x768-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/05/IMGP0545_1024x768-1.jpg

[Oneofthegreats]

Not bad for a s%$t heap than can stay with if, not beat stock R36's which the tyres alone for an R36 cost more than my car to build!

(not that I'm too concern with R36 drivers! I get more enjoyment out of running with Cammed up Gen3's & XR6T's etc)

It also has alittle bit left in it too!



Forgot to add.

Running on PULP & 1/3rd tank of fuel


13.9 pass


ByhxErXu2RA

13.7 pass


2FgAJiTSm9A

[static1800]

Great stuff Tim!

I was thinking about this sort of thing lastnight on the drive home, I paid $1000 for my car and I will have a ball in it next week at the track i'm sure. How can ou go wrong with that!

Also, how did the guy's ou raced feel after you kept up and beat them :)

[GoLfMan]

NICE!

glad to see you didnt break anything this time!

keep up the good work matey! :D

[Peter Jones]

Great results, good to see old skool power still rules.

[Oneofthegreats]

Great stuff Tim!

I was thinking about this sort of thing lastnight on the drive home, I paid $1000 for my car and I will have a ball in it next week at the track i'm sure. How can ou go wrong with that!

Also, how did the guy's ou raced feel after you kept up and beat them :)

Well your only racing the clock!

Not the person next to you, hence why I sat on the line asleep on every run.


I did get some great comments from the blokes I was sitting alongside in the pits though after a couple of runs. Incl. a high 11sec Torana, low 11 XE Turbo'd 6 on LPG, brand new Maloo ute with 340rwkw's & a bloke in a WRX STI with 240awkws.

At the end of the day, I don't think they would really care anyway, cause they aren't racing me.


The best thing for me is the car is making the power I had a slight prediction it would make & a lot of people OS said it wouldn't make that much power, the setup was all wrong & the tune is s%$t. Even though I told them all the A/F figures were spot on.

They said 200hp wouldn't be acheivable! Go figure!

[Peter Jones]

Don't listen to the opinionated web experts. Do it your way for your own reasons.

There's way too much opinion and very little experience on the web.

You've got to learn this stuff doing the hard yards and figuring it out yourself.

Far too many people talking and not enough doing.

Credit to yourself for getting out there and making a real world result.

Keep it real.

Pete

[Oneofthegreats]

Don't listen to the opinionated web experts. Do it your way for your own reasons.

There's way too much opinion and very little experience on the web.

You've got to learn this stuff doing the hard yards and figuring it out yourself.

Far too many people talking and not enough doing.

Credit to yourself for getting out there and making a real world result.

Keep it real.

Pete

True.

Whats even funnier for me is the people running proper callaway turbo kits for mk1 & mk2 golfs & melting pistons with less than 9psi of boost! Real nice piece of kit even with the fand dangled microfueler!

If you have to run even just one fuel injector which is computer controlled ie. control flow, duty cycle to control A/F ratios etc., it defeats the entire purpose of running mechanical injection..

If you run one computer controlled injector, why not just run 4 & have full EFI & be done with it

[Jarred]

Fantastic Tim!

I'm glad you finally got out there and got some times! Good to see it didn't break, or disappoint you! even better to see that it cracked the ton too!

[Oneofthegreats]

Was just chatting with a friend who reminded me about what a few people were saying last night about the track while we all waiting in pit lane due to an oil down.

Alot of their cars & mates cars were all running slower than usual & a few tenths off there PB's as the conditions were very duey. Or as they were saying.

"The track was slow"

Even the stock & mild Gen3's weren't running as fast as they should have

They were also saying that not only could there be a couple of tenths left in my setup, with suspension tweaks & harder launching etc, but better conditions could also take off a few tenths.

It maybe all hypothetical in theory to everyone, but makes perfect sense to me & the possibility to run a very low 13 is very possible on the current state of tune.

Thats only if I really want to keep racing it. I may race it again if I ever get around to building the auto.

but rather move forward onto bigger & better more powerful projects.

Car has done what I wanted for now though

[Preen59]

There's way too much opinion and very little experience on the web.

Exactly.

Made my night last night when you messaged me and said it went 101MPH! That's awesome dude. I'm glad to see you've achieved what you set out to do. No one can argue with the time slip!

[thestu]

sweeet!!!!! :D love this car soooo much!

i guess you will be peddling like me timmy! but i don't pedal haha

[Water Boy]

Well done Tim.

You have impressed many people and proved many wrong about how good k-jet can really be...

[DubSteve]

Great stuff Tim, too bad you aren't coming to the Nats mate, don't worry I'll be there for DOVW :)

[velly_16v_cab]

great stuff tim, good times too!

[Golf Loon]

Hell Yeah.
I never watch the attached videos, but made sure I watched this one.
Nice work mate, good to see the beast in action.
It does you credit, not many blokes could get kjet to work that well.
What Gearbox and Clutch combo are you running at that point??

[Oneofthegreats]

Hell Yeah.
I never watch the attached videos, but made sure I watched this one.
Nice work mate, good to see the beast in action.
It does you credit, not many blokes could get kjet to work that well.
What Gearbox and Clutch combo are you running at that point??

Cheers Matt.

Its running a stock replacement Luk 210mm clutch disc with a Sachs HD presure plate I was able to salvage from my last clutch disintegration as it has heavier clamping pressure than the stock one. Its still slips though.

Its also running my stock Diesel 4spd.

Still want that race?

[Golf Loon]

Cheers Matt.Still want that race?

Oooh Yeah. JayJay and I drove round till 4am the other night tuning the rocco. Its proper quick now.
Got myself an innovate wideband lambda nad display and its the grouse.
Took heaps of fuel off the pommie tune. UK air must be a different density to Oz.
I`m taking it circuit racing on Sat, but after that, a visit to the quarter will be in order I reckon.
I still wanna see your car go with a TDI gearbox. I`m tempted to send you one for appraisal :)

[Oneofthegreats]

Oooh Yeah. JayJay and I drove round till 4am the other night tuning the rocco. Its proper quick now.
Got myself an innovate wideband lambda nad display and its the grouse.
Took heaps of fuel off the pommie tune. UK air must be a different density to Oz.
I`m taking it circuit racing on Sat, but after that, a visit to the quarter will be in order I reckon.
I still wanna see your car go with a TDI gearbox. I`m tempted to send you one for appraisal :)

Good stuff Matt

I knew it would only be a matter of time before you got yourself a Wideband meter! Well worth the outlay 100% & can be claimed on Tax too!

Good choice going with the Innovate Motorsports one. Love mine. Well only when I was tuning it. Now just sits in its box in the shed till I build a good motor.


I reckon the TDI box may slow it down or either that, I'll break it!

I reckon it would be a good choice though considering the km's I do & highway cruising, but then I'm not really interested in tall as gearing & crazy top speed. For now I'll live with the 3500rpm cruising! haha

What Gearbox code is it again?


Good luck with it at the track & look forward to seeing some 1/4 pass' too!

[Oneofthegreats]

Some pics from the Meeting

http://www.vwwatercooled.com.au/forums/images/imported/2010/05/calder_100515_133b-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/05/calder_100515_143b-1.jpg




One of the most entertaining cars of the day!!!

http://www.vwwatercooled.com.au/forums/images/imported/2010/05/calder_100515_222b-1.jpg

[velly_16v_cab]

i really want to come to the next meeting bro!

[Preen59]

Love the helmet, Dude! haha.

[Water Boy]

So win right there...

[GoLfMan]

So win right there...

x2 great pics :)

[DubSteve]

http://www.vwwatercooled.com.au/forums/images/imported/2010/05/calder_100515_143b-1.jpg

Loving the helmet Tim :)

[velly_16v_cab]

it looks like Chopper is driving lol

[Jace]

Damn I only just saw this!

Great to hear it all worked for you! Solid times too.
I appreciate that you're doing what a lot of people say and think can't be done; but **** those other people because you're proving them wrong!

Good on you for doing it in full street trim! Would've got a good laugh out of a few spectators seeing such a Nanna looking car haul ass down the quarter.

Awesome work man!

[Tim]

it looks like Chopper is driving lol

I was more thinking ZZ top. Needs to let the beard grow for a couple more years though :D

[velly_16v_cab]

I was more thinking ZZ top. Needs to let the beard grow for a couple more years though :D

he need's HATE tattoo across his knuckles lol

[Jarred]

wikid stuff Tim, Vids were great. I'm glad you finally got out and got some times down! (and showed those basterds lol.)

have you cross posted this on vortex?

[drewr]

Bloody great thread mate! Learned some stuff from it! Very inspiring, almost makes me want to get an early year car and give it some power...until i realise i'm in over my head ahha!

[Golf Houso]

I was more thinking ZZ top. Needs to let the beard grow for a couple more years though :D

Haha I was just about to say that he looked like Billy Gibbons! Nice work again mate, I'm happy to say you've proved my expectations wrong about your drag times!!!

[Oneofthegreats]

Cheers peoples for all the comments


Haha I was just about to say that he looked like Billy Gibbons! Nice work again mate, I'm happy to say you've proved my expectations wrong about your drag times!!!

No worries at all!

As I've said before. Its one thing I don't ever like to BS about is, is how much power a car makes & how fast it can/should run.

The equation is simple. It takes so much power to push a car that weigh's so much over that distance to that terminal speed.

With more & more practice & time spent at the drags, you end up with a good general idea of what it takes no matter what the car is


Got to ask! What was your honest prediction?