Club G40 Forum

Club G40 => Photos and videos => Topic started by: grungeisdead on January 16, 2012, 12:20:16 am

Title: 1980 Golf LS Turbo
Post by: grungeisdead on January 16, 2012, 12:20:16 am
Model:

1980 VW Golf LS
Yellow (if you know the proper colour please let me know, no sticker in boot and I want to order some paint)
First Registered 17/06/1980

Engine: - Soon to be transplanted

Rebuilt 1272cc 'PY' G40
Garret T25 Turbocharger
6PSI Boost Switch
Custom Turbo Manifold
Forge Dump-valve
540mm x 140mm x 65mm FMIC
Blue Rocker Cover
Full 3" Stainless Exhaust (Downpipe Back)
Alloy RPM Tuning Sump
Aeroquip Braided Drain Line
Mocal Oil Cooler & Thermostatic Oil Cooler


Suspension:

JOM Coilovers

Brakes: To be fitted

Lucas 54 Calipers
Audi 90 Carriers
EBC 256mm X-Drilled/Grooved Discs
Ferodo DS3500 Pads
Goodridge Braided Hoses

Wheels and Tyres: To be fitted

Borbet BS 15x7 and 15x8
195/45/15 Tyres (Need purchasing)

Interior Styling:

Cobra Bucket Seats - To be replaced with Koenig Fixed Back Reclining Bucket Seats
Schroth Blue Harnesses with Pre-Tensioners
Roll Cage extending to A pillers and across windscreen
Twin-Pod Clocks with Rev-counter
300mm Momo Team with Snap-off Boss

Couple of pics:-

Outside the pub in Durham (its previous home)

(http://a6.sphotos.ak.fbcdn.net/hphotos-ak-snc7/394001_10150568303856343_511441342_11035815_555864561_n.jpg)

Back on the drive this morning, meeting its yellow younger sister

(http://a1.sphotos.ak.fbcdn.net/hphotos-ak-ash4/403241_10150569050866343_511441342_11038370_197370399_n.jpg)

Comments:-

After having two series 1 mk1 golfs and 6 others, i took a sabbatical to make polos go faster than they should. After building a 170bhp Mk2 Rallye Yellow Polo and a 170bhp+ Comet Blue Mk2 Polo Turbo, I noticed this beauty which would make a suitable home for the turbo lump.

The drive home was interesting, no stereo and a rather loud cherry bomb exhaust made some for deaf ears! Fuel stop at Scotch corner was met with an old dear taking picture of the car when I got out the petrol station. Top couple, taking pictures of it for thier dub mad son!

Lots of random switches and some choice electrics! - Big red button for a horn by an air vent, hard wired rad fan, with a switch in the glovebox!

Wipers didnt work, which was fine until I got to the M62 where naturally seeing signs for Manchester, she decided to greet me in true fashion by raining! So whilst having a fag and attempting to see out of a very wet window, I noticed a random toggle switch in the ashtray. A flick of the switch saw the wipers come on! RESULT!

Interior heaters don't work so probably either a few fuses out, or going by the state of electrics, so dodgy wiring, so a play with the multi-meter over the next week when the cars in the unit should see all the minor niggles rectified.

Clutch is slipping due to all the 55 raging ponies, but thats no concern of mine really as the car wasnt bought for the engine

Planning on painting the bonnet (had a large black square?!) and engine bay, and completing the turbo transplant before the 28th (our clubs Rolling Road day, which the comet blue polo was due to make its appearance!) Wish me luck =D

My two previous series 1's - Warning upsetting content.

The Muppet

(http://i16.photobucket.com/albums/b12/yousafn/more%20pics/DSC02780.jpg)

The Muppets demise =[

(http://i16.photobucket.com/albums/b12/yousafn/more%20pics/DSC02790.jpg)

Charlie Murphy

(http://i134.photobucket.com/albums/q104/winter_snowball/DSC01602.jpg)

Well sorting out our new unit was a priority before anything could happen with the Mk1. It came in a bit of a sorry state!

(http://a6.sphotos.ak.fbcdn.net/hphotos-ak-ash4/395860_10150578451831343_511441342_11074286_831526261_n.jpg)

which after a weekends effort looked like this

(http://a4.sphotos.ak.fbcdn.net/hphotos-ak-ash4/407672_10150578456301343_511441342_11074316_1708778543_n.jpg)

The blue mk2 coupe is also mine and will be providing its heart for the Mk1. The engines in question

Mk1

(http://a1.sphotos.ak.fbcdn.net/hphotos-ak-snc7/406705_10150578455441343_511441342_11074311_1624742144_n.jpg)

Turbo

(http://i16.photobucket.com/albums/b12/yousafn/DSC_0991.jpg)

If anyones interested in seeing the build of the engine - see this thread

http://www.clubpolo.co.uk/forum/index.php?showtopic=244980&hl=
Title: Re: 1980 Golf LS Turbo
Post by: grungeisdead on January 16, 2012, 11:26:49 pm

So long suckaaaaaaaaaaa!
(http://a3.sphotos.ak.fbcdn.net/hphotos-ak-ash4/381745_10150581102736343_511441342_11085281_305921692_n.jpg)

Holy Moly!
(http://a2.sphotos.ak.fbcdn.net/hphotos-ak-ash4/397845_10150581103276343_511441342_11085286_1186581521_n.jpg)

Just got water lines, gear linkage and driveshafts to come off and engines coming oot!
(http://a1.sphotos.ak.fbcdn.net/hphotos-ak-snc7
/376076_10150581103801343_511441342_11085289_1633380090_n.jpg)

One big jigsaw puzzle :)
(http://a1.sphotos.ak.fbcdn.net/hphotos-ak-ash4/395574_10150581102466343_511441342_11085277_1031233764_n.jpg)

Tomorrow shall see the engine out of the G40, the blue mk2s suspension and subframe replaced with standard items and some rust in the mk1s engine bay cleaned up with a wire brush and sprayed.

Wednesday is a day off and Thursday see's three new arrivals to the unit!

If anyone has a new clutch (or good 2nd hand one) for a 4 speed polo/golf engine, please let me know!

Also after some 195/45/15 tyres for my Borbets
Title: Re: 1980 Golf LS Turbo
Post by: grungeisdead on January 17, 2012, 10:43:53 pm
Got the engine out of the Mk2 this eve

(http://a3.sphotos.ak.fbcdn.net/hphotos-ak-ash4/s720x720/402160_10150582992436343_511441342_11090240_790636748_n.jpg)
Title: Re: 1980 Golf LS Turbo
Post by: grungeisdead on January 21, 2012, 12:49:14 am
See ya!

(http://a2.sphotos.ak.fbcdn.net/hphotos-ak-snc7/s720x720/396897_10150590160551343_511441342_11111856_562501839_n.jpg)

Oh Hai!

(http://a6.sphotos.ak.fbcdn.net/hphotos-ak-ash4/s720x720/397507_10150590160231343_511441342_11111854_1818771249_n.jpg)

Thursday saw the new arrival of Adams 2 of 4 cars and another 2 of my 6 cars =/

(http://a7.sphotos.ak.fbcdn.net/hphotos-ak-ash4/s720x720/408321_10150590161756343_511441342_11111858_454073428_n.jpg)

It was like an episode of chuckle brothers, to me to you affair, especially with the peril, as half the front suspension was still disconnected! (all back together now that I could work in the dry!). The Lupolo is tucked away neatly behind the yellow golf and blue polo, its first indoor home in 2 years after I had to move out of my old unit near Jodrell Bank. Eddie Stobarts son bought the land to turn into a helipad and stables, the motherhubbard!

My head is still caning from walking into the shutter doors, nearly fell thru the beemers roof taking the above pic, and generally me and pidge were walking accidents!

Anyway the day saw more than enough progress and I managed to get some rusty bits cleaned up in the golfs engine bay and gave them a lick of POR-15, ready for Fridays endeavours!

So today I stripped off the polo engine mount and fitted the Golfie one, got the engine in the bay and front engine, side engine and rear gearbox mount fitted (note - you need to notch the rear engine mount to fit a polo box) and refitted the driveshafts.

(http://a6.sphotos.ak.fbcdn.net/hphotos-ak-snc7/s720x720/406530_10150590163261343_511441342_11111863_647139747_n.jpg)

Also offered up one of the borbs - 195/45/15 Goodyear Eagle F1s arrive next week, woohoo!

(http://a8.sphotos.ak.fbcdn.net/hphotos-ak-ash4/s720x720/409361_10150590162671343_511441342_11111860_1486472315_n.jpg)

Hopefully Sunday should see the car back on the road, and thrust into daily action!

Jobs include

Tighten driveshafts
Cut and shut polo & golf front gearbox mount (for zee 5 speeder)
Fit turbo downpipe
Fit Intercooler
Fit oil cooler
Route Boost Hoses
Fit new top fill Rad & Slimline fan
Fit high pressure fuel pump, accumulator, in-tank lift pump and change fuel lines for 8mm ID items
wire up fuel pumps
fit ecu and wiring loom along with relayed power from ign switch
fit oz ruotes from the peril

test drive!
Title: Re: 1980 Golf LS Turbo
Post by: grungeisdead on January 22, 2012, 02:15:25 am
Decided to try my hand at some welding today as I got a decent welder off my big boss at work for 50 dukes.

Et Voila - One polo/golf hybrid mount!
(http://a6.sphotos.ak.fbcdn.net/hphotos-ak-ash4/401148_10150592657981343_511441342_11119963_1750254772_n.jpg)
Welds all look good and penetrated well. Ground them back and started to box off some of the open sections from the joins, and triangluate it at the front, but I ran out of wire! Gutted! So thats on the shopping list for tomorrow.

So onto the Intercooler and Boost Hosing.

Intercooler roughly hung in place (Good old electrical wire)
(http://a1.sphotos.ak.fbcdn.net/hphotos-ak-ash4/403088_10150592658666343_511441342_11119971_1782108658_n.jpg)

Working out the routing from the turbo to the intercooler was a right headscratcher. After pillaging all the boost hoses from the few FI engines I have, I finally settled on this.

(http://a4.sphotos.ak.fbcdn.net/hphotos-ak-snc7/398430_10150592659151343_511441342_11119976_691121_n.jpg)
(http://a5.sphotos.ak.fbcdn.net/hphotos-ak-ash4/402377_10150592659511343_511441342_11119978_183734490_n.jpg)
(http://a6.sphotos.ak.fbcdn.net/hphotos-ak-ash4/404970_10150592658446343_511441342_11119968_1499090413_n.jpg)

So will weld in some brackets to hang the intercooler and radiator from tomorrow.

Need a 90 degree boost hose (top left of the turbo -> intercooler picture) as I'm one short. Anyone around manc way got one? If so PM me asap please if I can collect it tomorrow! otherwise I'll get it ordered off ebay tomo evening.

Lots of jobs for tomorrow, looking forward to cracking on!
Title: Re: 1980 Golf LS Turbo
Post by: randombadger69 on January 22, 2012, 12:00:18 pm
Nice work dude, she looks in wonderful shape for an oldie! This and the engine looks a perfect match.

Have you puddle welded the mk1 golf gearbox mount to a mk2 polo one?
Title: Re: 1980 Golf LS Turbo
Post by: jez1272gt on January 22, 2012, 06:46:27 pm
Good work, loving the unit too. Looks like a proper VW old school hide out. Bet there will be some late evenings down there on the motors!
Title: Re: 1980 Golf LS Turbo
Post by: grungeisdead on January 23, 2012, 02:42:57 am
Well today saw a very productive day

- Got the driveshafts tightened
- Fitted downpipe
- Painted and fitted custom gearbox mount (my first attempt at welding, see pic below!)
- Intercooler, Oil Cooler, Radiator all fitted and plumbed in. Everythings held in place with cable ties at the minute so I know where to fit brackets to.
- In-tank lift pump and new 8mm ID fuel lines fitted
- Clutch, Speedo & Throttle cables fitted
- Servo vac feed fitted

Tomorrow shall see the
- Injection fuel assembly mounted underneath the rear of the car and plumbed in
- Fuel pumps wired up
- ECU Mounting
- Engine bay wiring
- Dump valve vac feed fitting


Also need to do

Relocate the battery to inside the cabin, as the space is taken up by boost hoses now!

Boost/AFM/Oil Pressure Guages fitting (roughly as I dont want to cut into the dash, dont fancy garish on dash pods, so I think a 3 guage centre console is required!)

anyway some pics

(http://a3.sphotos.ak.fbcdn.net/hphotos-ak-ash4/s720x720/397787_10150595149331343_511441342_11129107_288039697_n.jpg)
(http://a1.sphotos.ak.fbcdn.net/hphotos-ak-ash4/s720x720/399946_10150595138491343_511441342_11129029_743687559_n.jpg)
(http://a6.sphotos.ak.fbcdn.net/hphotos-ak-ash4/s720x720/408001_10150595138831343_511441342_11129030_1250995750_n.jpg)
(http://a4.sphotos.ak.fbcdn.net/hphotos-ak-ash4/s720x720/402312_10150595139211343_511441342_11129031_1705065412_n.jpg)
(http://a1.sphotos.ak.fbcdn.net/hphotos-ak-ash4/s720x720/393906_10150595141336343_511441342_11129043_424025038_n.jpg)
Title: Re: 1980 Golf LS Turbo
Post by: grungeisdead on January 23, 2012, 02:47:51 am
Nice work dude, she looks in wonderful shape for an oldie! This and the engine looks a perfect match.

Have you puddle welded the mk1 golf gearbox mount to a mk2 polo one?

cut the rubber mount section of the polo mount off where its spot welded to the gearbox bracket. cut the lower section of the golf mount so the polo mount sat snugly in the middle, held it all in place on the car, with the use of a half a brick and a brake line, tacked a few welds on, took it off and welded it, ground them back, cut down the offcuts of metal to bridge the gaps between the two mounts and welded them in, and once all the initial welds were ground back i laid a track of welds along the entire thing, getting it nice and toasty so it penetrated well. I've stomped on the mount and it doesnt seem to be going anywhere in a hurry, so fingers crossed all is well :)
Title: Re: 1980 Golf LS Turbo
Post by: grungeisdead on January 23, 2012, 02:49:15 am
Good work, loving the unit too. Looks like a proper VW old school hide out. Bet there will be some late evenings down there on the motors!

haha standard behaviour mate! me and adam have had a few 5am finishes when we used to work up at the pit on his farm, i remember falling asleep half over the pit when i was tightening up his arb
Title: Re: 1980 Golf LS Turbo
Post by: randombadger69 on January 23, 2012, 10:16:12 am
I've stomped on the mount and it doesnt seem to be going anywhere in a hurry, so fingers crossed all is well :)

 ;D It passed the initial fatigue test then!

Time will tell..

How are you going about the wiring? Are you changing the golf interior loom?
Title: Re: 1980 Golf LS Turbo
Post by: grungeisdead on January 23, 2012, 10:54:31 am
no modifications required to the interior loom, bar splicing into the black wire from the ignition column.

rest of the engine and fuel pump wiring is pretty standalone
Title: Re: 1980 Golf LS Turbo
Post by: grungeisdead on January 25, 2012, 01:40:19 am
Injection fuel assembly mounted underneath the rear of the car and plumbed in
- Fuel pumps wired up
- ECU Mounting
- Engine bay wiring
- Dump valve vac feed fitting


Wiring all takes longer than expected, but I'd rather do it (semi) right the first time round!

ECU mounted in the scuttle tray
Trusty holesaw saw a hole made in the raintray-> engine compartment for the G40 loom to pass through
Wired up all the G40 sensors
Welded studs to the turrets to mount the coil
Coil mounted, wires extended as passed into the inside of the car
Fuel pump wiring routed and soldered
Fuel pump and coil relays fitted and soldered
Battery earth terminal removed, and earths moved


Tomorrow I'm off to pick up the earth and power lead from a e46 330i and a momo team off a friend (already got one for this, buts its to replace the one I robbed out of the peril!)

Few jobs remaining that I can think of before it can fire up

Vac pipe for dump valve
Weld studs to underside of car to mount fuel pump cradle
Mount fuel pump assembly and route fuel lines up to in-tank pump
Trusty holesaw again to make hole in boot-floor for rear fuel pump loom
Mount battery in boot
Route battery power cable to starter
Move all positive battery connections currently fitted to starter motor
Wire up alternator
weld bracket for header tank and fit
route turbo water lines
fit midbox
rejoice, fire up and drive =D
get tyres fitted on borbets and get the tracking done

Jobs for next week will be getting the comet blue coupe back up on the road, mot'ing the Grey Mk3 G40 and removing the golfs dash to sort out the abomination that is the dash loom, check out the shocking state of affairs in the fusebox!

(http://a2.sphotos.ak.fbcdn.net/hphotos-ak-snc7/397342_10150597640876343_511441342_11136884_1461155921_n.jpg)

I'm finding conflicting threads for the fuses for series 1 fuseboxes, and no idea on the relays, can anyone help?!

(source owners manual 8/79):

1. Dipped beam left (8 amp)
2 Dipped beam right (8 amp)
3. High beam left, high beam warning lamp (8 amp)
4. High beam right (8 amp)
5. Heated rear window (16 amp)
6. Emergency lights, brake lights (8 amp)
7. Interior light, cigarette lighter, radio, clock (8 amp)
8. Turn signals (8 amp)
9. Reversing lights, horn, selector level console (automatic gearbox) automatic choke and pilot cut-off valve (carburetor engines) (8 amp)
10 Fresh air blower (16 amp)
11. Windscreen wipers and washer pump, rear window washer pump intermittent relay (8 amp)
12. Number plate lights (8 amp)
13. Side light right, tail light right (8 amp)

from this thread

http://www.vwgolfmk1.org.uk/modules.php?name=Forums&file=viewtopic&t=35549

1 left headlamp Low beam
2 Right headlamp Low beam
3 Left headlamp High beam
4 Right headlamp High beam
5 Heated rear window
6 Interior light
7 Brake lights Ciggy lighter
8 Indicators
9 Horn
10 Headlamp washers Rear window warning lamp
11 heater Fan
12 Number plate lamps
13 Tail light right front side light right
14 tail light left front side light left
15 Foglamp
14. Side light left, tail light left (8 amp)
15. Radiator fan (25 amp)

One of the unit lads is going to get me a load of wire from his work and I'm probably going to redo the entire dash loom by hand, that way I know it'll be right, as currently its slightly unnerving, but to all who know my previous endeavours, I now keep a fire extinguisher in all cars
Title: Re: 1980 Golf LS Turbo
Post by: G40 AD on January 25, 2012, 10:37:13 pm
Good work, loving the unit too. Looks like a proper VW old school hide out. Bet there will be some late evenings down there on the motors!

haha standard behaviour mate! me and adam have had a few 5am finishes when we used to work up at the pit on his farm, i remember falling asleep half over the pit when i was tightening up his arb

from Sat through to Tuesday we worked till at least 1-2am... needless to say me and saf have been more productive on the cars than at work this week!!!

Hope you get it finished tonight Safwa ready for tomo!
Title: Re: 1980 Golf LS Turbo
Post by: grungeisdead on January 30, 2012, 02:19:08 pm
(http://i134.photobucket.com/albums/q104/winter_snowball/DSC_0014.jpg)
Title: Re: 1980 Golf LS Turbo
Post by: grungeisdead on February 06, 2012, 11:35:09 am

Woke up incredibly late today ( mid afternoon ) to be greeted with snow in Manchester! So with the terrible weather in mind and the fact I'm still rolling around on postage stamps, I thought it would wise to change the braking setup for something a bit more sensible.

It was nice to have a dry workshop but that was very quickly ruined by the fact that the car had collected half of Iceland on the trip there and I was soon rolling around in puddles! But the car is now fitted with 256mm ebc cross drilled and grooved discs, ferodo pads, Lucas 54 callipers. Noticed one of the rear cylinders was leaking so I robbed the 200mm passat drum setup off the mk1 polo, brand new drums, VW shoes, cylinders and bearings. It was all a bit of a mare to be honest had to file out part of the caliper to accept the vented discs which meant the pads had too much meat on them, which wasn't too much of a concern as the extra would get burnt off with a drive home! Some fresh 5.1 fluid replaced the jank old stuff and the car stops on a half penny. Very happy! Left the handbrake cables disconnected as I couldnt fit them ( the Bain of my existence ) and it was getting late (half 1)

Drove out the unit and bam stuck in the snow! After digging for an eternity putting car mats down, launching a load of hot water down and scraping excess snow from around the tyres with a crowbar I finally managed to emerge free! Fully west as its now half 3! Think I'll be spending tomorrow indoors in the warmth playing computer games! Yuck fou snow!

forgot to add I also welded up the exhaust on friday after work, so the bend now clears the rear of the floor pan, still gotta do the over the axle bend, but its knock free now so im happy
Title: Re: 1980 Golf LS Turbo
Post by: grungeisdead on February 08, 2012, 01:38:04 pm
(http://a2.sphotos.ak.fbcdn.net/hphotos-ak-ash4/s720x720/398484_10150635381731343_511441342_11247869_1253507172_n.jpg)
Title: Re: 1980 Golf LS Turbo
Post by: grungeisdead on February 15, 2012, 12:13:40 am
Took delivery of my polythene sheeting and 3m refix tape so made up new door membranes and fitted some black GTI doorcards all round. Getting the rears in was a bit of a pain due to the cage being in the way but managed it in the end.

I do need the following bits if anyone can help
Passenger window mech
Passenger door pull surround and screw cover
Single plastic threaded plug in the door that the door pull handle screws into

Got rid of the chrome golfball gearknob and fitted a new empi leather one I had kicking around. Feels loads comfier. The chromey one is up for grabs if anyone's keen.

Got a new multimeter the other day as my old one had bit the dust, so whipped the throttle body off and rigged up a test system with a foot pump and a boost gauge so I could tweak the pressure switch (which replaces the digifants full throttle switch) to activate at 6 psi.

Also been looking at gauge mounts as I don't want to drill any holes in the dash and don't want a din plate as I will be fitting a stereo soon. Spotted stack rollcage mounts but they were pricey at 25 pound a piece! Far more than I want to spend and I hate the look of the pillar mounts as they look cheap and tacky! Had a brainwave last night for a quick solution involving a jubilee clamp around the cage and some cable ties to hold the gauge in place! Works a treat :)

With the ability to actually see what boost I'm putting out, I've noticed that I'm only getting 0.5 bar max so I'm guessing I either need to tweak the actuator rod length.

Got a few lengths of stainless piping and an over the axle mandrel bend and a flexi pipe so next weeks job will be finishing off the exhaust system, fitting the harnesses and new seats and adjusting the gear linkage slightly. Once that's all out the way I'll be able to concentrate on finishing 2 of the olops at the unit woop woop
Title: Re: 1980 Golf LS Turbo
Post by: randombadger69 on February 19, 2012, 11:14:30 am
Nice one dude, you do crack on! The MK1 must be a beaut with a G turbo?! This is what i want to do with my mk1.

I'll have a butchers for one of them plastic inserts for the door handle screws, iv prob got one somewhere!
Title: Re: 1980 Golf LS Turbo
Post by: grungeisdead on February 19, 2012, 07:52:01 pm
Cheers mate would be much appreciated. Gave the car it's longest drive this week 260 mile round trip, didn't miss a beat and scared a few including me on our country roads. Looking forward to winding the boost up and seeing what it's like when it's pushing out a bar.

Hopefully grabbing an intercooler off pete soon and can start tigging up some 1 piece boost piping to clean up the bay a bit.

I do miss the g lader feel tho so I'm gonna have to get the grey g out the unit and fix the peril so I can have some supercharged fun again!
Title: Re: 1980 Golf LS Turbo
Post by: grungeisdead on February 29, 2012, 12:49:17 pm
Couple of pictures from the Manc:Union meet on Sunday

(http://photos-a.ak.fbcdn.net/hphotos-ak-snc7/s720x720/430990_10150590703252852_645862851_9266819_265858841_n.jpg)

(http://photos-f.ak.fbcdn.net/hphotos-ak-ash4/s720x720/420890_10150590696442852_645862851_9266786_1076751107_n.jpg)


Got a few odd jobs done

Fitted Harnesses
Fitted Mk3 G40 Rocker Cover
Fitted a new t-piece for an oil pressure and oil temp sender
Fitted a new grill with non-broken tabs

Got a few jobs to do tonight

Fit Oil Pressure & Temp Guage and wire up.
Troubleshoot brake lights as they decided to no longer work =/
Complete the rear section of the exhaust system
weld subframes for new seats

Also got some banded steels on the way, 14x8 :)
Title: Re: 1980 Golf LS Turbo
Post by: dubstar on February 29, 2012, 06:59:15 pm
Ahhh dang - didn't know about this meet! When's the next one?

Car's looking schweet. Nice work soldier.
Title: Re: 1980 Golf LS Turbo
Post by: grungeisdead on March 01, 2012, 01:10:28 pm
needs a wash hahah! and yeah forgot to say.

last sunday of every month d00d
Title: Re: 1980 Golf LS Turbo
Post by: grungeisdead on March 05, 2012, 11:50:30 pm
Well I\'ve not driven the golf Last week since the meet due to having other commitments but jumped back on it on Saturday.

Picked up some banded steelies (14x8 driver steels) all with 195 45 14s on, although one had suffered a blow out so has been refitted with a new 195 45 14 yoko I had lying spare.

(http://a7.sphotos.ak.fbcdn.net/hphotos-ak-ash4/s720x720/425267_10150693442861343_511441342_11425087_844769692_n.jpg)

Tooke the fuse box apart and it was a grot fest inside. Cleaned up all the contacts as best as I could and managed to get the headlights working again via the fusebox, omitting another section of sketchy wiring added by the previous owner.

However the brakes still didn\'t work boo! I\'d already tested the switch which was working fine, and if I fed power to the black/red wire of the rear loom the brakes light came on, so it must be a dodgy internal connection of the fuse box. Just rigged up a circuit from terminal 30 on the fusebox to a fuse to the pressure switch, which then feeds into the rear loom for the brake lights.

Rich kindly donated me a later blade type fusebox and hopefully a loom and I can replace the woeful s1 boxs at the fraction of price of replacing the early fusebox.


Made up an over axle bend for the exhaust as its been half finished since I put engine in and welded a flexi into the system where then downpipe meets the centre box.

The rear system is just a straight through pipe with a bastuck style upswept tip.

Wanted to weld on hangers but ran out of gas :( however the mid box is still sitting to low despite moving it further towards the front of the car to clear the handbrake cables, so think I\'m just got to fit a straight through pipe in place of the midbox and use the midbox as the rear silencer.

Finished up this evening by sticking the wheels on, will get some more gas tomorrow and crack on with the rest of the exhaust , hangers and if I get some time, some seat frame adjustments to the new seats.

I\'ll grab some pics tomo of the new wheels in the day

But for now

(http://a8.sphotos.ak.fbcdn.net/hphotos-ak-ash4/s720x720/420303_10150697775436343_511441342_11445178_2020124198_n.jpg)
Title: Re: 1980 Golf LS Turbo
Post by: grungeisdead on March 06, 2012, 01:28:19 pm
Some pics :)

Ignore the wetness, thats from my Mk3 G40, the thermostat housing is leaking so is being replaced this week.

(http://i134.photobucket.com/albums/q104/winter_snowball/DSC_0052.jpg)
(http://i134.photobucket.com/albums/q104/winter_snowball/DSC_0054.jpg)
(http://i134.photobucket.com/albums/q104/winter_snowball/DSC_0056.jpg)
Title: Re: 1980 Golf LS Turbo
Post by: grungeisdead on March 07, 2012, 12:17:05 am
Got some more gas, replaced the centre box with straight through pipe for and used the centre box as the backbox.

(http://i16.photobucket.com/albums/b12/yousafn/c34ff1bf.jpg)

Loads more ground clearance :)

(http://i16.photobucket.com/albums/b12/yousafn/ec66214d.jpg)

Need to buy some 8mm rod to weld some hangers to the exhaust but its not going anywhere in a hurry :)

So just driving and enjoying while I give the grey g a service this week and crack on with the comet blue next week
Title: Re: 1980 Golf LS Turbo
Post by: vwmk3jon on March 10, 2012, 08:58:48 pm
Friendly wheel couriers ftw ;)

Wheels look mad mate. shame the dodgy back street guy put the weights on the wrong side! Scuffed my wheel too :(

was fookin funny watching him try to remove the blown out tyre!
Title: Re: 1980 Golf LS Turbo
Post by: grungeisdead on March 25, 2012, 11:25:46 pm
I was in tears haha. Legend mate ta :)

Well been an interesting couple of weeks! Bumped into the back of some bird at about 5mph, cold tyres cold brakes wet tarmac and people stopping in stupid locations led to...

(http://i16.photobucket.com/albums/b12/yousafn/IMG-20120307-WA0001.jpg)
(http://i16.photobucket.com/albums/b12/yousafn/IMG-20120307-WA0000.jpg)

So parked it up for a few days while I modified and welded up the existing subframes to mount my Koenig seats.

Took the wing out and bashed out the dent out as well as semi straightening the headlight surround, but noticed a few rusty patches at the bottom of the outer sill and some on the floor panel. Welded in some new panels in place which don't look differerent from factory despite bending thick metal ( all I had at the time ) in a vice with a hammer! Now that I'm a bit more confident with welding, I got hold a front floor panel and outer sill and will fabricate my own inner sill. Also going to remove the cage and mount it a bit more sensibly than the previous owners.

So anyway got the car back on the road, running well until my biting point of the clutch was on the floor and eventually non existent! After messing about with the cable I manned up on Saturday and whipped the clutch out, pleasantly surprised to find out there was a helix organically lined clutch on there! However that made way for a helix 4 paddle clutch and new pressure plate. Stupidly I forgot to fit my new vag clutch release bearing but its cool it. Can stay on the shelf for now!

Clutch biting point restored, which means I don't have to weld a proper repair plate in the bulkhead just yet ( bolted a repair in place for the time being )

Woke up this morning to see Yousaf wash me written in the dirt in the side of the car as I haven't washed it since I first got it, so here are the pics.

(http://i16.photobucket.com/albums/b12/yousafn/2012-03-25162212.jpg)
(http://i16.photobucket.com/albums/b12/yousafn/2012-03-25162241.jpg)
(http://i16.photobucket.com/albums/b12/yousafn/2012-03-25162335.jpg)
(http://i16.photobucket.com/albums/b12/yousafn/2012-03-25162318.jpg)

If anyone has a spare passenger headlight and a front panel the hit me up :)
Title: Re: 1980 Golf LS Turbo
Post by: randombadger69 on March 25, 2012, 11:43:33 pm
Wounder on the bumpage! Looking very well otherwise dude!

Wish i could help on the light, but mine are "borrowed" off a mate, haha!

I'm sure they're still available from hella (at a cost).
Title: Re: 1980 Golf LS Turbo
Post by: grungeisdead on March 25, 2012, 11:48:22 pm
Yeah man not bothered about originals will probably get some smoked cross hairs!

I've still gotta get round to finding time to doing a full rewire, going to upgrade to the later series 2 fusebox

George keeps borrowing g40 bits off me and I keep borrowing mk1 bits off my mate Rich!

Way of the world brother way of the world
Title: Re: 1980 Golf LS Turbo
Post by: randombadger69 on March 26, 2012, 12:01:26 pm
I know how it is, cars in pieces all over the place in a unit, shit gets begged stolen and borrowed!

Im thinking of replacing my golf internal wiring loom with a mk2 polo loom. Do you know if the mk2 polo interior loom will run off a mk3 polo engine loom. I.e. GT or G40 loom?
Title: Re: 1980 Golf LS Turbo
Post by: grungeisdead on March 26, 2012, 12:08:22 pm
the GT/G40 engine loom is standalone, you have other engine bay wiring for headlights, alternator, brake pressure switch, reverse switch, coil power but thats about it!
Title: Re: 1980 Golf LS Turbo
Post by: grungeisdead on March 28, 2012, 01:45:59 am
(http://a1.sphotos.ak.fbcdn.net/hphotos-ak-ash3/s720x720/533835_3641481394403_1195353657_3628822_678014292_n.jpg)
Title: Re: 1980 Golf LS Turbo
Post by: randombadger69 on April 03, 2012, 03:07:05 pm
Looking sweet dude!

Love the white wheels, sits really well.
Title: Re: 1980 Golf LS Turbo
Post by: vwmk3jon on April 04, 2012, 12:37:15 pm
You copying my tyre smokings? Didnt flat patch it but did notice a nicely melted patch on closer inspection.

failings on the bump but shit unfortunately happens :(
Title: Re: 1980 Golf LS Turbo
Post by: grungeisdead on May 23, 2012, 01:02:39 am
Wicked weekend at all types, what a night!

On the autojumble (I actually washed it! Albeit quickly and thanks to Matt and Kim for cleaning the wheels!)

(http://i947.photobucket.com/albums/ad316/mattpolo5491/DSCN0613.jpg)

On the return trip from Wales

(http://a7.sphotos.ak.fbcdn.net/hphotos-ak-snc7/s720x720/292644_430301440322804_100000288565361_1559240_1644912522_n.jpg)

Had to finish off with a pub meal

(http://a7.sphotos.ak.fbcdn.net/hphotos-ak-snc7/s720x720/398331_10150970417687152_505377151_11963033_1552732863_n.jpg)

Bai bai gearbox

(http://a5.sphotos.ak.fbcdn.net/hphotos-ak-ash3/s720x720/540260_10150958911416343_511441342_12066437_1763635399_n.jpg)
Title: Re: 1980 Golf LS Turbo
Post by: randombadger69 on May 23, 2012, 01:37:12 am
Oh shit!

You got a spare ATV amongst your "stock"?!

I picked up the bolts for the wishbone brace the other day, i'll get it sent out asap.

Looks like now may be a good time to fit it?

Andy
Title: Re: 1980 Golf LS Turbo
Post by: grungeisdead on May 23, 2012, 01:40:05 am
Still waiting on my seam welded wishbones to come before I can fit my polys anyway so no rush

I've got the perils and an 8p's comin from a mate. Will get the old box inspected and refurbed if ok
Title: Re: 1980 Golf LS Turbo
Post by: randombadger69 on May 23, 2012, 11:27:10 am
Ooh interesting. I'd like to see these when you get them. Presumably could increase the chance of knocking the chassis out though? As the wishbone will be less likely to move. Are you reinforcing around the balljoint mounting as well, to prevent "goosenecking".

8p should be reet for now.
Title: Re: 1980 Golf LS Turbo
Post by: grungeisdead on May 24, 2012, 01:40:44 am
I dunno mate they are coming off a guy called marts gulf blue n orange full on track monster mk1.

I'll take some pics for you as soon as I get them, fit them with some new polys and let you know how I get on

Dunno how you can drive on 13s daily my gearbox mount and the wishbone mounts are taking a beating! Especially into all types! Touching cloth wasn't the word!

Spare atv being whipped out

(http://a1.sphotos.ak.fbcdn.net/hphotos-ak-prn1/s720x720/546423_10150961550471343_511441342_12074594_1179384426_n.jpg)

Atv tAken out of the golf

(http://a4.sphotos.ak.fbcdn.net/hphotos-ak-ash4/s720x720/398902_10150961552231343_511441342_12074603_135030121_n.jpg)

Looks like the splines on the paddle clutch are fubarred!

(http://a3.sphotos.ak.fbcdn.net/hphotos-ak-prn1/s720x720/546226_10150961617696343_511441342_12074735_1244254080_n.jpg)

 I only put this on 3 thou ago, replacing the helix organic clutch and uprated pressure plate that was on because the biting point was on the floor and it wouldn't engage the clutch. Didn't check in retrospect the clutch fitted the gearbox when I fitted it. I've got another paddle and a std clutch in the unit, checked them and they are nice and snug on the spline of the box this one is not surprisingly loose as fook!

During the 3k it's always been notchy in 2nd and 4th unless a blip of the throttle on gear change. And was sounding rattly with the clutch peddle out. When I was on the clutch (foot down) it would go. I meant to change the crb when I last did it but forgot and saw the brand new VW one staring at me as I was driving out of the unit!

Going to fit the new clutch release bearing and clutch, but would you change the box too? I could always have the current box inspected now which would mean it can get a clean bill of health!
Title: Re: 1980 Golf LS Turbo
Post by: Yoof on May 24, 2012, 07:01:13 am
Not sure if it's the angle of the picture but the splined hole doesn't look like its in the centre of the clutch plate... Time to have a measure!
Title: Re: 1980 Golf LS Turbo
Post by: grungeisdead on May 25, 2012, 01:46:24 am
Did some investigation this evening, Both paddle clutches have 24 teeth or did in the case of the deceased above, and both input shafts on the actual and spare known good gearbox had all splines intact.

Span the cvs and the guide for the input shaft was wiggling about, after removing the bearing you can just make out the snapped lug on the guide.

(http://a1.sphotos.ak.fbcdn.net/hphotos-ak-snc7/s720x720/428437_10150964110481343_511441342_12081662_460335048_n.jpg)

Stuck a new paddle clutch on, reused the pressure plate, and popped on the perils atv, gearchanges and selection feel really good now. I do want a new 4 speed shift finger  tho as there is play in the current one, so back in daily action woop

I'll probably get the other box checked out by Tameside or geartorque to know its sweet
Title: Re: 1980 Golf LS Turbo
Post by: grungeisdead on June 06, 2012, 02:58:46 pm

MOT's coming up for the golfie, so its that time to rectify all the lil faults that I've never got round to doing.


Yesterday was spent making up stainless steel brackets for the radiator, realinging the bonnet catch, tucking the exhaust up some more, and welding a rear hanger on the backbox.

Also spent some time investigating the front suspension to assess what needed to be replaced.

Waiting for the following bits before I can rebuild the front of the car :-

Seam Welded Wishbones
New Steering Rack
New Steering Arms
New Track Rod Ends
New Balljoints
New Wishbone Polybushes
New Steering Rack Polybushes

(Big props to EuroCarParts for the 25 percent discount on all the service items)

I would really like to replace the universal joint but at £250+ from VW Heritage, I think i'll pass!

Also got a front lower wishbone brace thats been made up by RandomBadger69, so will be putting the 15's back on when the front is all rebuilt, which should give me the ground clearance I need to be able to not smash the brace off the world!

Further jobs for the MOT include

Welding to passenger floor and inner
Exhaust hanger for both shell and exhaust, for the midbox.
Fit new rear handbrake cable (as the old one is impossible to get fitted, as its too rusty for the springs to move freely enough to connect the cable to the shoes)
Need a new passenger door handle with key
Title: Re: 1980 Golf LS Turbo
Post by: grungeisdead on July 04, 2012, 01:03:12 am

well despite the work rebuilding the steering rack, there was still alot of movement and steering feel through the clutch pedal when i was steering with the clutch in (parking) turns out two welds had cracked on the steering column, and when i took it out, a third was on its way!

so welded them all up, using a g clamp to hold it snugly into where the welds once sat.

(http://i16.photobucket.com/albums/b12/yousafn/2012-07-03214911.jpg)
(http://i16.photobucket.com/albums/b12/yousafn/2012-07-03214924.jpg)

took this opportunity to clean up all the seam sealer and repaint properly in epoxy mastic as i was in no rush to get it all back together as the weekend had just started.

(http://i16.photobucket.com/albums/b12/yousafn/2012-07-03214906.jpg)
(http://i16.photobucket.com/albums/b12/yousafn/2012-07-03214950.jpg)
(http://i16.photobucket.com/albums/b12/yousafn/2012-07-03214959.jpg)

ended up without realising finishing up at half 8 in the morning when me and ads went to mcdonalds. i went home and got some much needed shut eye. my housemate adam who did an all nighter with me was still working on his car when i arrived back at the unit at half 3! see a shattered pidgeon below and his triumph after his epic missions!

(http://i16.photobucket.com/albums/b12/yousafn/2012-06-30172336.jpg)

been a long time since me n the boy done some proper all nighter steez on the cars, so comical. you know its late/early when theyve stopped playing the dance music and started on shitty chart music. and why do we always run out of phone b82rez! i need a digi camera!
Title: Re: 1980 Golf LS Turbo
Post by: randombadger69 on July 04, 2012, 01:34:18 am
Good stuff dude!

As you say.. the realisation of what hour it is occurs when the shitty chart music rears its ugly head again!

Got myself a job on the books recently and been seriously lacking the time for the car. Seem to end up getting on the beeers at the weekend, which results in no progression!

Keep telling myself.. next weekend i'll get on it! ::)
Title: Re: 1980 Golf LS Turbo
Post by: grungeisdead on July 13, 2012, 02:05:13 am
Got the brace painted now lad should be able to fit it now it's on the 15s

Well last weekend was eventful, on Friday night in the work car park the car decided to have a hissy fit and misfiring. Cleaned out the dizzy cap n rotor arm and after a minute it cleared up and it was sweet again all way on the journey home, so I could have some scran and put my feet up!

Come the next morning and it's missing straight away, 2 minutes down the road and I've broken down, out of fuel. Doh! Was on the way to fill up! Tommy to the rescue in the mk1 cabby!

With the help of a few friends at polo show we stuck on diff coil, leads, cleaned up the plugs. Starts up sweet now as was good on the way back from Northampton bar sometimes just refusing to move under anything more than partial throttle, different gear. Changed the fuel pump for a new non vag one ( cheapo bm equivalent ) and it's still the same!

Ahhh well, Mot ran out today and I still hadn't managed to find time to do the welding so as it is my daily it's time to crack on!

(http://i16.photobucket.com/albums/b12/yousafn/2012-07-11231620.jpg)
(http://i16.photobucket.com/albums/b12/yousafn/2012-07-11231548.jpg)

Right I'm going to add these welding pictures with a disclaimer my welding isnt great but it's as good as I can manage at the minute and it's all experience. I'll eventually give this golfie a full resto at some point but I just want it to be mot friendly and it's got to be better than the rusty mess holding it together!

Here's the result of a couple of evenings work.

(http://i16.photobucket.com/albums/b12/yousafn/2012-07-12230145.jpg)
(http://i16.photobucket.com/albums/b12/yousafn/2012-07-12230247.jpg)

Bit annoyed at the pattern sill as the seller didn't package it appropriately so the bit I really wanted was damaged. But I can either repair it or use it as a template to make a new one

If anyone has a mk1 golf thatchams or bentley manual gimme a shout or pictures of how the inner sill should look!

The playground - unfortunately all the cars I own aare in that picture. Waaaaah!

(http://i16.photobucket.com/albums/b12/yousafn/2012-07-12230947.jpg)
Title: Re: 1980 Golf LS Turbo
Post by: quiksilver_jake on July 13, 2012, 01:16:36 pm
You got your rap trap/ poison yet ? ???
Title: Re: 1980 Golf LS Turbo
Post by: grungeisdead on September 26, 2012, 01:03:51 pm

[quote name='grungeisdead' date='Monday 16th July 2012 - 11:22pm' post='2374474']
It'll all be Done with epoxy mastic! Fook seam sealer! Pidge was more delirious after a full on weekender with no sleep on it!

Last repair panel tacked in all other welds ground down, then flap wheeled 40 grit
(http://i16.photobucket.com/albums/b12/yousafn/2012-07-16215245.jpg)

So tomorrow sees the repair panel being welded up, bits being painted and Fudging the pattern sill to fit
[/quote]


[quote name='grungeisdead' date='Thursday 19th July 2012 - 12:00pm' post='2375801']
woop - outer sill tonight

(http://i16.photobucket.com/albums/b12/yousafn/2012-07-18213426.jpg)
(http://i16.photobucket.com/albums/b12/yousafn/2012-07-18213548.jpg)
[/quote]


[quote name='grungeisdead' date='Sunday 22nd July 2012 - 7:42pm' post='2377659']
(http://i16.photobucket.com/albums/b12/yousafn/2012-07-22170839.jpg)
(http://i16.photobucket.com/albums/b12/yousafn/2012-07-22170948.jpg)
[/quote]

Well it’s been a while since I updated this thread, so now is a good a time as ever.
Finished the welding on the sill and got the car back on the road a few months ago.
So now that she back on the road, I could concentrate on trying to sort out some niggly running issues, first was a dodgy internal connection on my new bosch fuel pump, which made me want to cry and meant that I had to refit the new pattern pump I had sitting on the shelf, which buzzes like an orchestra of rampant rabbits at a lesbian convention.
Changed all the vacuum lines, finally fitted an oil catch tank, and eventually got round to fitting a manual bleed valve to the actuator vac line and it still wouldn’t go over 0.5 bar, so fitted an actuator off a friends turbo and on the first drive hit 2 bar! So tweaked it down to 1 bar. Rapid in comparison is not the word and I can finally break past my previous speed-based brick wall.
Also bought a VEMS wideband with datalogging, so welded on a lambda boss into my downpipe and have now realised that I now have an inability to drive as I’m forever watching the guage!
Found the source of the fuel vapours in the car the other day, and replaced the fuel hose, on the same day I noticed that you sort one leak and sprout another two! The two in question being a water leak in the rad end cap from where the brackets had come off the rad and it was sitting on the turbo – bit of plastic leak fix stuff and jobs a good un. Changed the copper washers on the leaky oil line to no avail, the hydraulic hose had actually failed, so a new one is on order with thanks to HEL performance at a bargain price of 25 quid including all fittings, banjo bolts and washers.
Also finally procured a 2.5” stainless system, for the bargain price of 77 quid so a very happy chappy that I will actually be able to have an exhaust system complete with hangers haha – so next jobs are refit the oil feed line when it arrives and make up a new downpipe complete with flexi and fit the new exhaust.
Title: Re: 1980 Golf LS Turbo
Post by: grungeisdead on February 28, 2013, 02:07:16 am


[quote name='grungeisdead' date='Thursday 3rd January 2013 - 1:51am' post='2463667']
Some pictures from last year

(https://fbcdn-sphotos-g-a.akamaihd.net/hphotos-ak-snc7/292644_430301440322804_1644912522_n.jpg)
(https://fbcdn-sphotos-b-a.akamaihd.net/hphotos-ak-ash4/486146_10151881572895538_1672651577_n.jpg)
(https://fbcdn-sphotos-b-a.akamaihd.net/hphotos-ak-ash4/428953_10152015415155384_1064679905_n.jpg)

Latest happenings in the Golfies world :-

Got a K03 turbo and mani to try out to see how it stacks up against the T25
Full stainless exhaust to fit
Track day in February
Blat about until next winter where it gets some much needed restoration in some key areas to preserve it for a bit longer.

Looking at the pictures, I miss it fooking loads, but that being said, if anyone wants to try me with swaps, I'm always open to a bit of bartering!
[/quote]


[quote name='grungeisdead' date='Tuesday 26th February 2013 - 10:34pm' post='2494281']
Decided I've spent far too long having not driven a VW so I needed to rectify the situation and with the start of a month looming its the perfect time to tax and insure it.

Got a small list of stuff to do before Friday,

Replace a fuel line
Replace passenger pre tensioner for harnesses
Fit the stainless exhaust - which involves rewelding the factory hanger back on as I cut it out previously as it was intruding on my pikey'd centre box.
Refit the cages door bars and windscreen bar - bought a step drill bit to make neat holes for the cage leg on the passenger side floor pan, which was replaced when I welded it up earlier last year
Go drive

Today I cleaned up swapped out the ecu and cleaned up the loom contacts, they got grotty from when the scuttle cover was cracked and letting water into the loom :(

Interim plans for this which will proceed when I've finished the comet blue

been measuring up a stainless rad I picked up a while back ( need to get azbar to flip round the water outlets as it was designed for a big block golf engine ) and measuring up the intercoolers I have with metal end pieces so I can decide what needs welding for the tidiest routing of boost pipes, and then I will set out making brackets to neatly hold the rad, intercooler and oil cooler in place.

(http://i134.photobucket.com/albums/q104/winter_snowball/temporary_zps838bb6f3.jpg)

ko3 conversion is just awaiting getting the manifold flange machined flat and sorting out a chip, either the origins of mine, or getting one from PPP, picked up a stainless downpipe from Jose and a gasket and stud set

(http://i134.photobucket.com/albums/q104/winter_snowball/WP_000324_zpsa530944f.jpg)

The rocker cover is being sent away to be powder coated along with a load of engine parts for the comet blues engine, there's also a single wiper there too =D

Wooooop woop golfie times
[/quote]


[quote name='grungeisdead' date='Thursday 28th February 2013 - 12:07am' post='2494801']
Cheers d00d. It's aiight =]

I love the ruotays on anything to be fair haha.

Set about fitting the stainless exhaust this eve,

Welded in a flexi and a sleeve for a reducer

(http://i134.photobucket.com/albums/q104/winter_snowball/6af6770f9df04c460d413cdfc52101aa_zps267846f9.jpg)
(http://i134.photobucket.com/albums/q104/winter_snowball/4c4abb0ed1ce02474d4c744bc1eaf6bb_zps75fdb38f.jpg)

Back box on,  tailpipe will get changed at some point but in no rush

(http://i134.photobucket.com/albums/q104/winter_snowball/95dc45488cf2cd5a47c14b3cf887cdc6_zps7a43e9e7.jpg)

Gotta get 3 new rubbers for the backbox and whip the flexi centre section off, reduce the size of the slits in the flexi with a copper backed weld, and make a new centre hanger, I've got some 8mm rod and a 6n exhaust rubber so should be able to make something up that will take the impact when the centre box invariably catches.
[/quote]
Title: Re: 1980 Golf LS Turbo
Post by: grungeisdead on April 02, 2013, 01:00:03 am
Got bored today

(http://i134.photobucket.com/albums/q104/winter_snowball/temporary_zps836d1172.jpg)

Needed toothies again in my life

(http://i134.photobucket.com/albums/q104/winter_snowball/temporary_zps4f42701e.jpg)

Azbar finished the mod to the ally rad

(http://i134.photobucket.com/albums/q104/winter_snowball/temporary_zpsdb6ed8fa.jpg)

And started chopping up the two engine mounts to make a new one

(http://i134.photobucket.com/albums/q104/winter_snowball/temporary_zps54b810ab.jpg)
Title: Re: 1980 Golf LS Turbo
Post by: randombadger69 on April 02, 2013, 01:12:43 am
Nice work as always Saf! Body-fab skills are looking good mate!

Why are you chopping the engine/charger mounting?

p.s. Are you likely to have a G40 cam-cover for grabs soon? ;)

Regards

Andy
Title: Re: 1980 Golf LS Turbo
Post by: grungeisdead on April 02, 2013, 06:21:13 pm
cheers dude, the welding i did on this is quite old now, middle of last year i think. been doing loads on teh comet blue mk2 but havent been updating the thread on here, check it out on clubpolo members gallery mk2 section if you fancy a read.

as im now fitting a supercharger to the golf, i need to make a hybrid of the supercharged engine mount and the mk1 golf engine mount.

I could have modified the shell to take the standard polo mount, but it's more work and pretty destructive. i got hold of a spare mk1 golf engine mount so i thought id have a play down this route first :)

cam cover is available off the engine that got taken out, ive got the mk2 ally rocker cover painted up for it now
Title: Re: 1980 Golf LS Turbo
Post by: grungeisdead on April 03, 2013, 01:09:02 am
Got a few hours on this tonight.

Did some research into swapping over the driveshaft flanges over from a mk3 box, to fit the 6n box but turned the mk4 flanges and the box wouldnt move, neither would the output shaft! span them on my 2 ATV's and they were fine, albeit a bit noisy. so whipped the 6n box off and stuck another ATV on there. Had to change the guide sleeve on the box, as it had previously broken and ruined the splines on a clutch in the process

so if anyone has number 7 - part #     085141181 from the below diagram off a broken 5 speed gearbox, i would be much obliged it you would part with it for pennies :)

(http://www.vagcat.com/p/B009/019050.png)

Gave a box a quick clean up, and dropped the engine in the bay and fitted all the mounts - some of which are now polybushed, tightened up and off the crane

(http://i16.photobucket.com/albums/b12/yousafn/saf/WP_000693_zpsfc15b216.jpg)

Finished chopping the mounts up, now I can get a jack supporting the engine in the correct place, and mock up the and get the final cuttygrindymcweldy on its ass. bearing in mind that I need to keep enough room for the charger belts in between the mounts otherwise it'll be slappy slappy

(http://i16.photobucket.com/albums/b12/yousafn/saf/WP_000692_zpsadb6af17.jpg)

That'll be tomorrows mission, anything else done will be a bonus :)
Title: Re: 1980 Golf LS Turbo
Post by: Etches on April 03, 2013, 08:38:52 am
Saf I got the sleeve from GSF a couple of months ago for 3 quid. Looks good mate!
Title: Re: 1980 Golf LS Turbo
Post by: randombadger69 on April 03, 2013, 10:43:50 am
Of course, forgot it was a mk1 golf  ;D  I think I'd modify the bracket rather than the chassis!
Title: Re: 1980 Golf LS Turbo
Post by: grungeisdead on April 04, 2013, 03:18:18 am
cheers Tom mate :) good to know, Arun has sorted me out anyhow.

Bit more chopping and grinding saw something close

(http://i16.photobucket.com/albums/b12/yousafn/saf/WP_000705_zpsbfc6d7cb.jpg)

Bit of weldy weldy

(http://i16.photobucket.com/albums/b12/yousafn/saf/WP_000706_zpsb6f86701.jpg)

Bolted up the charger and alternator so i could put a belt on, tension up the charger and check for belt clearance

(http://i16.photobucket.com/albums/b12/yousafn/saf/WP_000718_zpsdecb37fc.jpg)

that's a no then haha

(http://i16.photobucket.com/albums/b12/yousafn/saf/WP_000721_zps720583b5.jpg)

so with that all mocked up nicely, i set the job of addressing that to another day this week.

next job was boost piping - nothing to change on the outlet side of the intercooler so that was all sweet, so just the charger->intercooler jobbie.

armed with a box full of assorted boost pipes from my cupboard of joy, a handful of head scratching and a hacksaw, twas sorted.

(http://i16.photobucket.com/albums/b12/yousafn/saf/WP_000725_zpsdb237727.jpg)

tomorrow I wanna

Make a bracket for the bottom of the intercooler
mount the oil cooler off the lower bracket
mount the rad and make brackets


Job's I still have to do

Finish engine mount and paint
Cambelt - Get
Remove std G40 cam
Fit Schrick 272 cam, replace camshaft oil seals
fit inner timing belt cover
fit waterpump - new seal
fit cambelt
fit outer lower timing belt cover
fit toothed crank aux pulley
mark tdc on outer casings and pulley in tippex
fit outer cambelt cover
fit 51mm throttle body/ported inlet - new gaskets on way
fit g60 injectors into fuel rail and refit
refit fuel lines
fit 4 branch - modify exhaust to suit
fit lambda bosses
regrease driveshafts and refit
refit gearlinkage
refit throttle/clutch/speedo cables
refit water pipes
charger pulley - fit and torque
fit charger feed lines
fit oil gauge sender and t-piece
refit mapped chip into ecu
refit loom
fluids (engine oil/water/gearbox oil)

cant think of anything else so driiiiiiiiive!
Title: Re: 1980 Golf LS Turbo
Post by: grungeisdead on April 06, 2013, 02:22:29 am
Done this eve

Fitted Schrick 272 cam, replaced camshaft oil seal
Swapped over camcovers
fitted inner timing belt cover, water pump with new seal and vernier pulley
fitted knock sensor
Fitted ISV
Wired up starter
fitted ported inlet with new gasket
Fitted g60 injectors
fit 51mm throttle body/ported inlet - new gaskets thanks for Andy (randombadger69) new VW inlet gasket
Mocked up rad with quick bracket, found suitable water hoses
Connected heater matrix hoses

(http://i134.photobucket.com/albums/q104/winter_snowball/45bb90212c96728a046e86d5bf57c0ce_zps7a6f800d.jpg)
(http://i134.photobucket.com/albums/q104/winter_snowball/2614b7691b8cc53226aaad369f003b66_zps26f82ee8.jpg)

Job's I still have to do this weekend

Cambelt - Get from TPS tomorrow
fit cambelt / fit outer lower timing belt cover / fit toothed crank aux pulley
mark tdc on outer casings and pulley in tippex
fit outer cambelt cover
Find bolts for cam cover and fit
refit fuel lines
refit throttle/clutch/speedo cables
Remove charger and mount
Mount oil cooler
Mount rad
regrease driveshafts and refit, tighten hubnuts
refit gearlinkage
fit 4 branch - modify exhaust to suit
fit lambda sensors
refit water pipes
Finish engine mount
Refit charger
charger pulley - fit and torque
fit charger feed lines
fit oil gauge sender and t-piece
refit mapped chip into ecu
refit loom
fluids (engine oil/water/gearbox oil)
Title: Re: 1980 Golf LS Turbo
Post by: randombadger69 on April 08, 2013, 05:11:34 am
Nice progress dude 8)
Title: Re: 1980 Golf LS Turbo
Post by: grungeisdead on April 08, 2013, 12:41:05 pm
Got a few hours in on Saturday

regreased driveshafts and refitted
refitted gearlinkage

Spent the rest of the time trying to separate the centre section of the exhaust and removing the lambda. Everything was mega seized. Got well annoyed with everything and gave up in favour of drinks in town and a meat feast at bem brasil. So awesome.


Got over about 3 today

fitted cambelt / outer lower timing belt cover / toothed crank aux pulley / outer cambelt cover
Found bolts for Mk2 cam cover, they a different from mk3 and mk4 bolts, thankfully found 3 that came with the g40
turbo's blue cam cover

(http://i134.photobucket.com/albums/q104/winter_snowball/temporary_zpsb483fb3b.jpg)

Started playing about with places to mount the oil cooler, it's going to go next to the fan on the rad

Modified the engine mount again, better but still touching - need to look into fitting a relay roller from a later engine on there to navigate the belt away from the mount

(http://i134.photobucket.com/albums/q104/winter_snowball/temporary_zps10b3663f.jpg)

Cut out the seized lambda and welded in a plate. Cut out a couple of bosses out of another exhaust to weld in and left it there for the day

(http://i134.photobucket.com/albums/q104/winter_snowball/temporary_zpsbfcf3543.jpg)

Finish engine mount
refit fuel lines
refit throttle/clutch/speedo cables
Remove charger and mount
Mount oil cooler
Mount rad
fit lambda sensors
refit water pipes
Refit charger
charger pulley - fit and torque
fit charger feed lines
fit oil gauge sender and t-piece
refit mapped chip into ecu
refit loom
fluids (engine oil/water/gearbox oil)
Torque hub nuts, driveshafts

Here is what I was thinking for the mount using a tension roller from a Lupo GTI

(https://fbcdn-sphotos-f-a.akamaihd.net/hphotos-ak-prn1/543785_10151564339131343_658691725_n.jpg)

But now thinking of just using the polo mount, as we have a cut up mk3 polo and even if I run a non supercharged mk1 lump I'll still be able to use the original polo mount. Good news for my unit mate as he wants the old engine mount

(https://fbcdn-sphotos-h-a.akamaihd.net/hphotos-ak-prn1/533659_10151564339346343_720412825_n.jpg)
Title: Re: 1980 Golf LS Turbo
Post by: PeteG40 on April 08, 2013, 12:45:47 pm
pm dubface - called jason as he's got a mk1 golf with a welded mount without clearance issues i think.

Pete
Title: Re: 1980 Golf LS Turbo
Post by: grungeisdead on April 09, 2013, 04:45:15 am
Cheers Pete, too late now as you'll see :)


A couple of mates mentioned cast iron being something a diy'er can't do in a garage for various reasons, So cracked on this evening spurred on by last nights research

So I set about with this

(http://i134.photobucket.com/albums/q104/winter_snowball/temporary_zps2adea647.jpg)

Which lead me to this

(http://i134.photobucket.com/albums/q104/winter_snowball/temporary_zps0f5291fa.jpg)

Then I got bored and set out for destruction

(http://i134.photobucket.com/albums/q104/winter_snowball/temporary_zps2e23668a.jpg)

About 20 smacks with a mini sledgehammer saw it crack

(http://i134.photobucket.com/albums/q104/winter_snowball/temporary_zpsacfd4f5f.jpg)

Back on the Golf - chopped chassis leg and trialling/measuring

(http://i134.photobucket.com/albums/q104/winter_snowball/temporary_zpsfe8df187.jpg)

Here's where I finished up tonight

(http://i134.photobucket.com/albums/q104/winter_snowball/temporary_zps429f00bf.jpg)

I shifted the engine the furthest to the left as he mounts would allow so plenty of room to move the engine to the right if necessary, but I'm pretty happy so far.
Title: Re: 1980 Golf LS Turbo
Post by: grungeisdead on April 11, 2013, 12:59:52 am
Engine out again, only needed driveshafts off, gear linkage and engine mounts so quick job

(http://i134.photobucket.com/albums/q104/winter_snowball/temporary_zpsfc012638.jpg)

Cleaned up the mount and surrounding area, tack welded in a couple of places before I took the engine out and started to plate it up using 1.5mm zintec sheet

(http://i134.photobucket.com/albums/q104/winter_snowball/temporary_zps1eb52880.jpg)

Only got a couple of hours on it an my lift came , Got the day off tomorrow so should hopefully be productive :)
Title: Re: 1980 Golf LS Turbo
Post by: grungeisdead on April 11, 2013, 08:57:31 pm
Decided to tax the Beemer and throw in some steel seal stuff to prolong it for a week or two as I've got errands to run that need a car!

Did some more on the mount today but ran out of gas no long after I started, knew I was running low so the Beemer will take my ass and das gas bottle to work tomorrow for an exchange.

(http://i134.photobucket.com/albums/q104/winter_snowball/temporary_zpsb635079f.jpg)
(http://i134.photobucket.com/albums/q104/winter_snowball/temporary_zps34048366.jpg)

Nowt worse than no gas on a weekend/days off next week!

Planning on a late one tomorrow night, I wanna get it finished up and in a coat of epoxy mastic, while I've got some mixed i'll give the comets newly welded panels a coat too, ready for the outer sill to go on :) bust out the seam sealer on Saturday and drop the engine back in.
Title: Re: 1980 Golf LS Turbo
Post by: randombadger69 on April 17, 2013, 10:24:43 pm
I hear your pain on the empty gas situation. Nothing worse than getting something all prepped nice then sticking a load of porosity into it!

Im always doing it with turning the bottle off, then clicking the trigger getting gas through from the line thinking sweet, arc-up to discover a fizzy mess ::)

I see you've taken a different route with the compatability, probs best if you need to change engine at a later date. Im sure with a bit of thought and the right machines a bespoke mounting bracket could be engineered for the MK1 golf for a G40 blown small block.

Nice work on the chassis, hope it all comes together. I know just what it's like needing a car everyday and desperately trying to fix the other one in the unit before the one being driven spits its dummy out.

Title: Re: 1980 Golf LS Turbo
Post by: grungeisdead on April 22, 2013, 01:43:35 am
charger mount done - far better

(http://i16.photobucket.com/albums/b12/yousafn/Saf2/WP_000886_zps87a5224c.jpg)

4 branch extended and lambda bosses welded in

(http://i16.photobucket.com/albums/b12/yousafn/Saf2/WP_000831_zpsb5d3e79f.jpg)

rad, oil cooler, lines and fan fitted

(http://i16.photobucket.com/albums/b12/yousafn/Saf2/WP_000884_zpsd949b06c.jpg)

finished up most of little jobs off this evening

(http://i16.photobucket.com/albums/b12/yousafn/Saf2/WP_000880_zps3e0b265e.jpg)


few minor jobs tomorrow

swap ecu/chip
wiring - fan / thermoswitch / alternator / starter
exhaust rubbers

and hopefully all being well it'll fire up and I can rejoice and take it into work on Tuesday :)

then theres a few jobs in the near future i wanna do, tidy up some of the wiring, get a load of grommets to replace the missing ones on the bulkhead, refit the front cage door bars, replace the centre box for a straight through
Title: Re: 1980 Golf LS Turbo
Post by: randombadger69 on April 22, 2013, 07:56:17 pm
 8)
Title: Re: 1980 Golf LS Turbo
Post by: grungeisdead on May 08, 2013, 02:19:10 am
well highs and lows in the golf saga since my last update.

that monday night I smashed it out to get the car ready to crank over and found a leak or two. one from the oil pump alloy cover and another from the block to rear water pipe, and another from various points on the sump.

turns out the previous owner decided to negate the need for gaskets in certain parts of his rebuild =/ amongst other things *sigh*

anyway oil pump cover off

(http://i134.photobucket.com/albums/q104/winter_snowball/temporary_zps8908c353.jpg) (http://"http://s134.photobucket.com/user/winter_snowball/media/temporary_zps8908c353.jpg.html")

(http://i134.photobucket.com/albums/q104/winter_snowball/temporary_zps9f07f6bf.jpg) (http://"http://s134.photobucket.com/user/winter_snowball/media/temporary_zps9f07f6bf.jpg.html")

turns out the gasket is obsolete and the jebends at elring wont reply to my query as i found their respective part number to see if they supply it, so i just used some black silicone gasket maker and sealed it that way - refitted it all

(http://i134.photobucket.com/albums/q104/winter_snowball/temporary_zpsf901ae2c.jpg) (http://"http://s134.photobucket.com/user/winter_snowball/media/temporary_zpsf901ae2c.jpg.html")

and left it at that for the day.

then we saw bye bye to another unit friend

(http://i134.photobucket.com/albums/q104/winter_snowball/temporary_zps583896d6.jpg) (http://"http://s134.photobucket.com/user/winter_snowball/media/temporary_zps583896d6.jpg.html")

removed the inlet manifold to get decent access to the water pipe, glad i did, as one of the bolts had been hero tightened and mangled so was a mare to get out. anyway refitted with a gasket and some sealant for good measure

(http://i134.photobucket.com/albums/q104/winter_snowball/temporary_zps4eee4fe4.jpg) (http://"http://s134.photobucket.com/user/winter_snowball/media/temporary_zps4eee4fe4.jpg.html")

left that to cure and then took a sabbatical from the cars whilst me and a few friends went on an epic 1400 man paintball battle.

got back on it tonight, soldered up the fan and thermo switch, and proper vw plug for the starter motor/alternator harness, tightened up the hubnuts, topped up the fluids and cranked the engine to build up oil pressure.

all good, no leaks, went to fire it up - no go.

fuel check
air - DOH - reattached boost pipe that was removed when i was fitting new copper washers

went to fire it up - no go

fuel - still check
air - check
spark - ok from the coil, no go to the plugs. scratch head - take off dizzy cap - no rotor arm - deuchebag i am!

went to fire it up - it liiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiives! so good to hear that supercharger whine again.

then sorted out the headlight wiring and went for a kfc with the boys and called it a night.

going to mess with the exhaust tomo and make this straight thru

also got these coming for the golf, as its done its time on 14 inch alloys and I've now sold the borbets

(http://i16.photobucket.com/albums/b12/yousafn/Saf2/rims_zps2700c58e.jpg) (http://"http://s16.photobucket.com/user/yousafn/media/Saf2/rims_zps2700c58e.jpg.html")

just need to get hold of some 195/45s now
Title: Re: 1980 Golf LS Turbo
Post by: grungeisdead on May 16, 2013, 12:06:51 am
[quote name='grungeisdead' date='Sunday 12th May 2013 - 11:59pm' post='2527814']
(http://i134.photobucket.com/albums/q104/winter_snowball/temporary_zpsc8f96308.jpg) (http://"http://s134.photobucket.com/user/winter_snowball/media/temporary_zpsc8f96308.jpg.html")

(http://i134.photobucket.com/albums/q104/winter_snowball/temporary_zps5d87893f.jpg) (http://"http://s134.photobucket.com/user/winter_snowball/media/temporary_zps5d87893f.jpg.html")

Straight thru done, needs some tweaking to maintain an idle long enough while I time it up, fingers crossed for tomorrows session
[/quote]


[quote name='grungeisdead' date='Tuesday 14th May 2013 - 11:17pm' post='2528585']
Got that sleeve Mikey, cheers matey.

bobbed over to unit tonight with a few jobs in mind.

Redo earthing point to charger
Replace hosing to aav
check spark plugs
Swapped out dizzy and coil
Reset co pot to 650ohms and idle screw all the way in then 2 1/2 turns out.

Refused to idle still argh.

just stuck on a spare ecu that had a ko3 chip in and that idled fine, so swapped the chips over and it seems to have solved it.

Cold and hungry by then I gave up. So tomorrow gonna swap over some wheels, run it up to temp, set timing, co on the gas analyser and the idle and take it for a spin :)
[/quote]


[quote name='grungeisdead' date='Wednesday 15th May 2013 - 10:12pm' post='2529055']
its lives, it drives =D

(http://i134.photobucket.com/albums/q104/winter_snowball/temporary_zpsaa7409ab.jpg) (http://"http://s134.photobucket.com/user/winter_snowball/media/temporary_zpsaa7409ab.jpg.html")
(http://i134.photobucket.com/albums/q104/winter_snowball/temporary_zpsb32bbf3a.jpg) (http://"http://s134.photobucket.com/user/winter_snowball/media/temporary_zpsb32bbf3a.jpg.html")

poly engine bushes - bad idea - my roof vibrates now haha
belts have slackened off slightly in my drive, think the engine mount bolts may be slightly loose =/ safffronnnnnnnn!
BTS didnt seem to make any difference when i unplugged it while it was warming up, so probably not a good sign! need to get my multimeter out tomorrow.

so 50 mile round trip to work tomorrow, bit of a tweak in the evening and then I will give the cars a full wash, polish and wax on friday ready for all types.

then its time to crack on with the comet blue as theres only a couple of weeks worth left on it. If i could get by the first week in June i would be very happy, and being half way through the year my target of getting every car working and drivable will be half way complete, with two cars left to go.

good times
[/quote]
Title: Re: 1980 Golf LS Turbo
Post by: Etches on May 16, 2013, 09:59:51 pm
Great work this Saph, loved bumping into you in the bimmer last year, such a cool motor!