ManicGTIs 9A Convn update: On the Road!

Spiffing work done there!

 

good work

 

Can't find any small drill bits (seem to have broken them all) and have run out of solder....



Tbh that kinda puts a dampener on wiring the thing up!...



Am thinking of doing a few more small bits and cleaning up. Its a
shame I havent been able to complete it this week but nevermind, i'll
have to come back up to parents house next weekend, maybe try and take
fri off and come back early.



I think there may be a few wiring questions that need resolving anyway,
I thought I was clear on it but have found have had some
conflicting advice from people on the 16V loom...thats one for the
elec/engines section though.



edited....as keep noticing glaring spelling mistakes.



Edited by: ManicGTI

 

time for a well earned beer!

cracking write up

 

Well done mate. I really should start mine. You make me feel lazy

 

great thread - well done!

 

nice one dude, good work, I'm sure loads of people on here know excatly what your going through, I certainly do and you've really captured the whole conversion progress, including all the good days and the bad it'll all be worth it in the end

 

yep yep yep

 

Cracking mate
You done great work on your car and this thread is one of the best i have read

 

Well done matey

 

cheers for support guys, appreciated.



all I wanna do now is sack off work and get back to it...got so close...



Not much point in putting up any pics from Sunday, as changes barely
noticable (ie details with wiring etc). I'll try and do another update
just before I 'try' and fire her up. Will be really happy if I can get her up and running next weekend, and potter down to No-Rice on wed.



Longer term, once i've replaced the mk1 bits with KR bits, I guess a
trip to Stealth maybe in order, have never actually had an engine i've
thought it worth tuning before.

 

going really well by the sounds of it! not long now

 

Have just had a chat with oplaii, he pointed out that my braided fuel
lines are probably low pressure jobbers. Did a bit of research and
found them for sale at rally design and they are indeed, so will have
to swap them for high pressure inj hose before starting up! Think I
have some in Garage anyway...

 

Right another update!!



...At this stage changes are less obvious, a lot less photos taken so i'll cover the whole weekend



During the week I had the exhaust section sorted out, the manifold
bottom section flared and a larger bore of pipe welded to the other
side of the flexi-joint.



As I found out on sat however it was not
quite big enough. In the short term, to get running, I butchered the
new bit of pipe to let it go over the existing system. As it
stood the section fitted and lined up nicely at the engine end, but
only over lapped about 3mm at join with existing system. I'll
wrap it up so this will do temporarily, i'll have to take it to an
exhaust place within the first few days to get this part adjusted to
fit properly.

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Changed remaining gearlinkage bushes, mainly ones around the gearstick:

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I went through the existing mk1 loom, checking what it used to
connect
to where it should now go (from my notes and all 3 haynes mk1, mk2 and
passat!), and checked connectors. Most were tired to say teh least so
replaced spades, soldered on multiplugs from the passat loom where
appropriate, and in some cases traced the wires back to the loom
insulation, cutting back and soldering new wire in (then insulating and
then covering back into the main loom). I did try and keep
colours of wires the same although had to compromise in some places,
ideally should have used shrink wrap, but I'll i'll be re-tidying the
wiring at some point soon anyway.

Soldering in new wires:

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Triple insulation, lol:

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Once existing loom sorted out I tackled the mk2 16V KR ECU and TCI
loom. One connector was taped out of the way as not required
(part of mk2 ISV circuitry)and the rest run from the mk1 TCI position
out into the engine bay. Rather than cut the loom I made up extensions
to go to the coil, then connected the others as they would be in a mk2.


I chopped the mk1 tci off its heat sink and luckily the mk2 tci had
some screw holes that lined up with random existing ones, abeit facing
other direction to not foul on pop rivets (so stays in contact
metal).

mk2 TCI:

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Fiddled with ECU and realised to should fit on same
bracket, so took the mounting plate off the mk2 bracket, drilled and
screwed it to the back of the mk1 tci bracket, then screwed ecu on.

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Seems to fit pretty well and to be honest by facing in the odd direction it takes
up the slack in teh mk2 loom perfectly, allows it curve round gutter
section from bulhead hole without kinking. May bag it up for protection
but shouldn't get wet.










The brake fittings were bottoming out on the new 3 way adaptor, so cut
pipes and wacked on new longer end pieces, flared pipes and plumbed
in. The reservoir from the Passat required some adjustement
before fitting as I had fogotten that it had a feed to the hydralic
clutch system. Superglue a random plastic stopper and a screw and
that was plugged. As can be seen from the images clearance with the
dizzy is marginal, had been warned about this previously by people anyway:





Plumbed radiator in (cutting random pipes to fit, picked from the
passat and mk1 bits!). And filled Gearbox and Engine with
appropriate fluids.



At this stage a few of the lads appeared, Rich(Git), George(16Vmk1) and Gem(MrVWagen). With
them loitering around pressure was on to try and get her started.
After an initial 'turn' a few fuel lines ends and a water pipe leaked a
bit, nipped them up and tried again but of course battery didn't have
the legs. Conencted up to Gems mk1 and started pretty much on the
button!



At this stage was worried as hell, engine was making a racket and
smoking! Of course smoke was just the paint and heat wrap on manifold,
the squeaking being overtight cambelt, not a big problem will just have to
adjust before driving anywhere.



Anyway, running, and idling straight away at spot on 1K! Brilliant! Was well worried wiring woul dbe wring or something.



It'll all need adjusting and didn't run it for too long.
I'm aware the conversion has been done a million times before, and
probably a lot quicker, but still fecking pleased with myself at this
point!



I owe tons of people thanks, but i'll reserve it until I drive down the road and I know it works properly.



Decided to chill out after that, cleared up some of the mess I had made
and realised I would have to come back just to clear up, even if I
finished up on the car. So decided to take it slow, tidy some
bits up
the lads had pointed out (rubbing pipes etc) and prepare everything for
next Sat. Besides had to get back to Reading to do some work for the
next morning.



Left to do: Change the fuel extensions I used for injection rated line,
fill and bleed brakes, change acc'r cable for mk2 16v cable, fit front
wash fluid tank and fit hub nuts. I think thats it...Theres prob
some things i've forgotten. Assuming of course that it runs! its
still on stands so won't know whether clutch/gbox set-up is all ok
until its down next weekend.



Dave







Edited by: ManicGTI

 

Nice work mate cant wait to hear the next instalment

 

Good job

 

dave fancy comming and finishing mine??

Bloody well done by the way

 

well done m8.

 

Excellent work


For a first time effort that is some achievement.