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Model specific boards => Golf mk1 => Golf mk1 gallery => Topic started by: jv on 02 March 2006, 13:12

Title: MK1MADJ - mk1 16v
Post by: jv on 02 March 2006, 13:12
here you go :)
Title: Re: MK1MADJ - mk1 16v
Post by: Mk1Mad J - 16v on 02 March 2006, 14:05
Cheers JV :smiley:

Here's my mk1 the day i brought it, i got it from my mates mums boyfriend who bought it from a lady living opposite - she bought it from the 1st owner who only had it 6 months!!! so although i dont have any history i know where its been and thats all that matters  :smug:

The car had been stored in a garage for about 9 years and was looking pretty shabby, the paint was covered in all sorts of cr@p including bits of concrete  :sad:.  1st stop Bromley Hand Car Wash for a full valet  :cool: 

(http://i22.photobucket.com/albums/b336/MK1MADJ/GALLERY/door.jpg)
(http://i22.photobucket.com/albums/b336/MK1MADJ/GALLERY/front-1.jpg)
Ripping off that horrible red thing round the lights moments after this photo was taken and throwing it in the bin was 1st "mod" I made :grin:

The interior looked like the car had been parked in a pond as there was loads of mould all over the seats dash & carpet :sad:

(http://i22.photobucket.com/albums/b336/MK1MADJ/GALLERY/seats.jpg)
(http://i22.photobucket.com/albums/b336/MK1MADJ/GALLERY/dash.jpg)
It cleaned up really nice and best of all i found absolutely no rust whatsoever!!!

(http://i22.photobucket.com/albums/b336/MK1MADJ/JasonsWagen.jpg)


As this is my 4th mk1 gti I already had plenty of shiny bits to put on, steering wheel/door pins etc... and after all the trouble i had with my last one it was really nice to spend the last 2 1/2 years just driving it!!!

RIP YDF 700Y - It looked great on the outsite, shame it was held together with mastic and bubblegum :cry:
(http://i22.photobucket.com/albums/b336/MK1MADJ/ydf700yrear.jpg)

After 10 years behind the wheel of stock 1600 gti's the time finally came to up the power a bit  :evil:

I kind of blame this thing  :rolleyes:
(http://i22.photobucket.com/albums/b336/MK1MADJ/mk5.jpg)
I hired it in spain & bought my 16v lump the first payday after returning - I like turbo's  :laugh:
Title: Re: MK1MADJ - mk1 16v
Post by: Mk1Mad J - 16v on 02 March 2006, 14:37
Since i started driving I've always wanted to do an engine conversion, back in the day a 16v was the only real choice for a Mk1 - unfortunately, as a struggling trainee accountant, i could never afford it.

then along came the 20v turbo - 150-210HP out of the box with loads more available from a remap - it seemed to be a gift from heaven - when i looked further into it i realized just how much it would cost £5000-£6000  :shocked: are you mad????

over the last few years I've been seeing a lot of 16v turbo's, which seem to be the favored engines of the germans & Americans, i looked into the price and all things considered it appeared to be around the same cost as a 20v but with more power available  :grin: then i heard vw were ditching the 20v in favor of a 16v turbo in the new Mk5 - thats it i thought, if its good enough for vw its good enough for me.

So here's the plan

Fit 16v engine, gearbox & brakes

uprate suspension, fit strut brace & replace all the bushes (& maybe some uprated anti-roll bars)

get bodywork sorted - its so close to perfection that a blowover will make it mint  :smug:

add a turbo kit from USA or Germany


I've already got my scirocco inlet manifold - this is what you want if you're doing a 16v turbo as it leaves plenty of clearance for the boost pipes  :grin:  £95 delivered from USA

(http://i22.photobucket.com/albums/b336/MK1MADJ/myhead.jpg)


I found my engine and brakes on e-bay and they'll be delivered within the next week or 2 - auction ended early for £280 inc. delivery  :grin:

http://cgi.ebay.co.uk/ws/eBayISAPI.dll?ViewItem&item=8040566729&rd=1&sspagename=STRK%3AMEWA%3AIT&rd=1

And I've got a TSR 1.9 bottom end which i'll also be using  :evil:


Next step is to whip out the wimpy little 1.6 and clean up the engine bay ready for the new engine  :drool:


Title: Re: MK1MADJ - mk1 16v
Post by: Mk1Mad J - 16v on 05 March 2006, 22:14
(http://i22.photobucket.com/albums/b336/MK1MADJ/eusa_dance.gif) My Engine (http://i22.photobucket.com/albums/b336/MK1MADJ/eusa_dance.gif)

(http://i22.photobucket.com/albums/b336/MK1MADJ/6e_12_sb.jpg)



The Donor Car  - for sale if anyone wants it - may need some welding  :laugh:

(http://i22.photobucket.com/albums/b336/MK1MADJ/f315edtEDIT.jpg)


The Future (http://i22.photobucket.com/albums/b336/MK1MADJ/cool4.gif)

(http://i22.photobucket.com/albums/b336/MK1MADJ/db_16v_turbo_usa4.jpg)

Picture stolen from www.grasshopperdrag.de/ chelk it out its a wicked site
Title: Re: MK1MADJ - mk1 16v
Post by: Mk1Mad J - 16v on 04 April 2006, 14:28
Update - April06

 :rolleyes: What started as just giving the inlet manifold a bit of a polish has now turned into an obsession with most of the aluminium parts under the bonnet now getting the same treatment - Its going to slow the conversion down a bit but it'll be worth it in the long run  :grin:

Aside from the polishing i've cleaned the block & head and given the block a fresh coat of matt black lacquer, i'm in two minds whether to paint the head or not  :undecided: - Once it was nice & clean i gave it a good check over with my feeler guages and there's no signs of any serious wear  :cool: I'll be putting it all back together soon once i've got my new gaskets from vw -  i'll post a pic or two when its finished.


Plans have also changed slightly - I'm going to fit the standard 1.8 16v and get it all running sweet, then sort the rest of the car - brakes/suspension/blowover etc...    In the meantime i'll get another head, gasflow it etc... rebuild the 1.9 with that and swap it for the 1.8 - then its Megasquirt time http://www.megasquirt.info/v22manual/mtune.htm

Once the 1.8 is back in the garden i'll be stripping it down for a rebuild - as a turbo motor  :evil: :evil: :evil:
Title: Re: MK1MADJ - mk1 16v
Post by: Mk1Mad J - 16v on 04 April 2006, 22:17
Before

(http://i22.photobucket.com/albums/b336/MK1MADJ/db_2.jpg)

After

(http://i22.photobucket.com/albums/b336/MK1MADJ/HPIM0311.jpg)

 :cool:

Title: Re: MK1MADJ - mk1 16v
Post by: Mk1Mad J - 16v on 27 April 2006, 22:20
The engine as it looks now  -  i decided not to paint the head, it'll get an acid bath after the gas-flowing so i'll just have put up with it the way it looks for now  :sad:
(http://i22.photobucket.com/albums/b336/MK1MADJ/HPIM0318.jpg)

gearbox....
(http://i22.photobucket.com/albums/b336/MK1MADJ/HPIM0319.jpg)

Metering head....
(http://i22.photobucket.com/albums/b336/MK1MADJ/HPIM0322.jpg)

and dials  :cool:
(http://i22.photobucket.com/albums/b336/MK1MADJ/HPIM0320.jpg)


not long now (http://i22.photobucket.com/albums/b336/MK1MADJ/bounce.gif)
Title: Re: MK1MADJ - mk1 16v
Post by: Mk1Mad J - 16v on 01 May 2006, 19:24
Yay i've finally made a start   :grin:

here's the old engine just before i pulled it out - look at it, it's go no idea whats coming  :laugh:

(http://i22.photobucket.com/albums/b336/MK1MADJ/HPIM0323.jpg)


how it looks now, an empty engine bay  :sad:

(http://i22.photobucket.com/albums/b336/MK1MADJ/hpim0324.jpg)


I've fitted the ecu thing :smiley:

(http://i22.photobucket.com/albums/b336/MK1MADJ/HPIM0326.jpg)


and the coil, 16v servo & master cylinder

(http://i22.photobucket.com/albums/b336/MK1MADJ/hpim0325.jpg)


 :embarassed: silly me, I reconnected the battery when the engine was out so the alarm LED would still flash  :rolleyes: should of made sure all the live wires weren't grounding out anywhere first, DOH!!!! - i've replaced all the melted wires with some of the mk2 loom  :wink:

I should be able to get the bonnet sprayed before i've finished the conversion, i've borrowed another bonnet off a mate to use while mines getting sorted.

(http://i22.photobucket.com/albums/b336/MK1MADJ/HPIM0327.jpg)

I think i might need a new battery though :lipsrsealed:

(http://i22.photobucket.com/albums/b336/MK1MADJ/HPIM0329.jpg)


 :angry: You'd think my car would be glad of all the love & attention its getting, but no!!! it bit me - with the engine of all things, it really hurts  :cry:

(http://i22.photobucket.com/albums/b336/MK1MADJ/HPIM0328.jpg)
Title: Re: MK1MADJ - mk1 16v
Post by: Mk1Mad J - 16v on 03 May 2006, 22:36
 :sad: I haven't been able to do anything for the last couple of days as my hands still really hurting  :cry: 

heres what happened:-   my mate who was operating the crane must have got bored of going slow as the engine shot up about 2-3 inches while I was trying to pull the gear box away from the chasis leg, it took a while to register that he was crushing my hand   :angry: after lots of screaming and swearing he dropped it a couple of inches, the engine swung and caught my hand again before i had a chance to pull it free, again this took a while to register but he finally ditched the engine on the ground (f**kwit  :rolleyes:) I'm really lucky no bones were broken - and he's really lucky he didn't damage my baby

but..... My brothers coming round on friday evening to help me get the 16v in (he's the only person I trust to operate the crane now  :lipsrsealed:) once thats in I should be able to do some wiring and stuff even with my crippled hand  :cool:
Title: Re: MK1MADJ - mk1 16v
Post by: Mk1Mad J - 16v on 05 May 2006, 23:21
Yeah baby - finally got it in about 10pm  :grin: :grin: :grin: :grin:

(http://i22.photobucket.com/albums/b336/MK1MADJ/HPIM0343.jpg)

(http://i22.photobucket.com/albums/b336/MK1MADJ/bounce.gif)(http://i22.photobucket.com/albums/b336/MK1MADJ/bounce.gif)(http://i22.photobucket.com/albums/b336/MK1MADJ/bounce.gif)(http://i22.photobucket.com/albums/b336/MK1MADJ/bounce.gif)(http://i22.photobucket.com/albums/b336/MK1MADJ/bounce.gif)(http://i22.photobucket.com/albums/b336/MK1MADJ/bounce.gif)(http://i22.photobucket.com/albums/b336/MK1MADJ/bounce.gif)(http://i22.photobucket.com/albums/b336/MK1MADJ/bounce.gif)(http://i22.photobucket.com/albums/b336/MK1MADJ/bounce.gif)(http://i22.photobucket.com/albums/b336/MK1MADJ/bounce.gif)(http://i22.photobucket.com/albums/b336/MK1MADJ/bounce.gif)(http://i22.photobucket.com/albums/b336/MK1MADJ/bounce.gif)(http://i22.photobucket.com/albums/b336/MK1MADJ/bounce.gif)(http://i22.photobucket.com/albums/b336/MK1MADJ/bounce.gif)(http://i22.photobucket.com/albums/b336/MK1MADJ/bounce.gif)(http://i22.photobucket.com/albums/b336/MK1MADJ/bounce.gif)(http://i22.photobucket.com/albums/b336/MK1MADJ/bounce.gif)(http://i22.photobucket.com/albums/b336/MK1MADJ/bounce.gif)(http://i22.photobucket.com/albums/b336/MK1MADJ/bounce.gif)(http://i22.photobucket.com/albums/b336/MK1MADJ/bounce.gif)(http://i22.photobucket.com/albums/b336/MK1MADJ/bounce.gif)
Title: Re: MK1MADJ - mk1 16v
Post by: Mk1Mad J - 16v on 07 May 2006, 19:33
EDITED 20th May 2006

I was going to make my own exhaust using the mk1 & 2 downpipes but after 5 hours of messing around with it i've decided to get a 4-branch instead  :smiley: SCRUB THAT - I did make it   :laugh:

I just can't deal with an arc welder, how do you line the rod up with the stupid mask on  :undecided: if you try and get it lined up without the mask then flip it down when it starts welding (like i did) you end up with sore eyes, a headache & a messy weld.  I need to learn how to use a proper gas welder  :nerd:  (Thats still true  :smiley:)



Heres how  :smug:     far I got if anyone wants to attempt it, it was pretty closley lined up but i'd taken a little too much off (about 1cm) so patching in a bit to replace it was just too much of a pain  :sad:
 

1. I started by chopping the flange off the mk1 downpipe, I cut the pipe as close to the flange as possible, also in the pic is the extra bits I chopped off later.
(http://i22.photobucket.com/albums/b336/MK1MADJ/HPIM0359.jpg)


2. I then cut the flange off the 16v downpipe (just before the pipe loses its shape) fitted it to the 16v manifold and offered it up to the head with the mk1 downpipe already in place.  I found that there was too much tubing for the 2 exhausts to meet so i chopped a little bit off the mk1 pipes (too much  :rolleyes:). then I offered it up again, it went in but was fouling the gearshift  :sad: i had to cut it down quite a bit to get the clearance as you can see in the pic.
(http://i22.photobucket.com/albums/b336/MK1MADJ/HPIM0360.jpg)

I welded it up a bit where i'd cut but its full of some kind of mesh which the arc welder thoughly enjoyed melting (lots of sparks  :laugh:) - this is about as good as i could get it  :embarassed:
(http://i22.photobucket.com/albums/b336/MK1MADJ/HPIM0361.jpg)

It might look a mess but at least it cleared the linkage  :smiley:
(http://i22.photobucket.com/albums/b336/MK1MADJ/HPIM0362.jpg)


The side opposite the linkage could have been welded at this stage (if there was access) but where i'd cut too much off the side seen in the pic above it was about 1cm apart  :angry:.

 :rolleyes: I didn't think to take any pics of how it eventually looked, my eyes were hurting and i had a headache so I had to go for a spliff  :drool: I'll try and remember to take a couple before i bin it.

Someone with better welding skills than me & ideally a lift or a pit (rather than lying in a main road with busses going by) should easily be able to do it   :wink:


TO BE CONTINUED......  :smug:
Title: Re: MK1MADJ - mk1 16v
Post by: Mk1Mad J - 16v on 07 May 2006, 20:12
When my battery melted it took out my main battery cables (along with many others  :rolleyes:)
(http://i22.photobucket.com/albums/b336/MK1MADJ/HPIM0364.jpg)


So.....

I made these yesterday when it started raining  :cool:
(http://i22.photobucket.com/albums/b336/MK1MADJ/HPIM0366.jpg)
Title: Re: MK1MADJ - mk1 16v
Post by: Mk1Mad J - 16v on 11 May 2006, 12:27
 :angry: Grrrrrr me not happy....

After waiting 3 days for the money i put on my c/card to clear (  :undecided: a barclaycard & i bank with barclays so why does it take so long???) I was finally able to place my order for my 4-branch.

I'd found one on "were-all-cu^ts-bay" called the number to check they had one, waited ages to find that no they dont!!! (so why are you advertising 3 of them you prick???)  he told me ashley had 1 in stock and it was on hold for him - i hit the buy now button and found gay-pal have decided i've overspent my limit or some boll0cks and i have to varify my bank account?  -  so i've spent over £500 with the same credit card over a 6 month period and not one of the transactions has been disputed so now your getting suspicious??? wheres the logic in that????

I rang Ashley direct and they informed me that the mk1 16v conversion exhaust is now a special order part (due to lack of demand) and will take around 10 days to make - so why do you advertise it with free next day delivery you fuc&ing idiots????

I rang proven products who suppied my last 4-branch - they didn't have any in stock but reckoned they could get one in from ashley in a couple of days, i informed him of the fact that its now special order - he started arguing with me so i called him a w@nker & hung up


Looks like its back to the cut-n-shut job  :sad:
Title: Re: MK1MADJ - mk1 16v
Post by: Mk1Mad J - 16v on 11 May 2006, 16:56
 :smiley: I've ordered my Ashley Manifold direct from the factory - it won't be here til the end of the week  :sad: but i've got a feeling that'll be quicker than:-

the_trickydicky (AKA Internet Auto Spares Ltd) - EBAY SHOP advertising 3x manifolds with buy now - he doesn't even have any  :angry:  - you'll be waiting a while for your payment you prick!!!!!!! (hey isnt richard another word for DICK!!!!)

Proven products - advertising "free next day delivery" on their website (what is it with people advertising stuff they haven't got??? idiots)

the various other people I phoned, chatted too - then insulted  :laugh:

Title: Re: MK1MADJ - mk1 16v
Post by: Mk1Mad J - 16v on 14 May 2006, 11:00
 :smiley: I've calmed down now, what is it with these suppliers  :rolleyes:

I've realised that if I get everything other than the manifold done this week I should be able to get it started next weekend (http://i22.photobucket.com/albums/b336/MK1MADJ/eusa_dance.gif)

Got all my fuel lines in, well sort of  :rolleyes: - i'm using mk1 lines for now which are really dodgy as they touch the inlet manifold  (they've wrecked my paint-job  :sad:) - once the cars back on the road the first trip will be to a breakers to find some better lines off one of the many other k-jet cars out there.

Most of the breathers are in, i had to chop the err..... pipe thing that goes from the airbox to inlet quite a bit and getting a feed to the ISV was interesting but i'm really pleased with how that came out - I think it looks quite factory :cool: (but where do i put my K&N sticker now  :undecided:)

(http://i22.photobucket.com/albums/b336/MK1MADJ/HPIM0392.jpg)

As the crankcase breather exits to the left (where the airbox would be on a mk2) i spent quite a while trying to get it running over to the right but wasn't very sucessful - then i had a eureka moment - run it to the left and stick a K&N breather filter on (Added bling for my bay, nice  :smug:)

I got all my plumbing done yesterday -  :sad: the pipes to the heater matrix on a mk1 are much smaller than a mk2's but I got there in the end with various off odd pipes & tubes  :smug: - just got the rad & expansion tank to go in but i'll leave that till the wiring's finished.

The wirings not quite as easy as i first thought, I've sorted a couple of exits/entrances for the wires to go through to the inside of the car and i've got most of the wires worked out now (just a couple i'm unsure of) it's working out how to route them around the engine bay thats a bit tricky  :undecided: they're in but theres no insulation -  I'm going to get all the wiring done, check its all working ok then worry about insulating it  :smiley:



I Went out in my mates mk2 16v on friday night so I asked him to remind me why i'm going through all this grief -  :grin: :grin: :grin: :grin: :grin: :grin: :grin: :grin: :grin: :grin: :grin: :grin: :grin: :grin: :grin: :grin: 16v's rule  :cool:
Title: Re: MK1MADJ - mk1 16v
Post by: Mk1Mad J - 16v on 16 May 2006, 22:35
(http://i22.photobucket.com/albums/b336/MK1MADJ/bounce.gif) My manifold is coming tomorrow - I phoned to check it was going to be here by the weekend and they said it went out today (http://i22.photobucket.com/albums/b336/MK1MADJ/bounce.gif)

I took the day off work yesterday and got quite a bit done on my wiring :cool: I've got the ISV & the er?...other relay ( :undecided:) attached to the fusebox, all the connectors to the bits and bobs in the engine bay are connected and wired in through the bulkhead and i've just got a few wires to identify and i'll be ready to put my recently donated battery in

THANKS FOR THE BATTERY ASH  :kiss: (the hand crushing incident is forgotten  :wink:)


(http://i22.photobucket.com/albums/b336/MK1MADJ/HPIM0393.jpg)
Spagetti Anyone???  :laugh:

 :angry: See the remains of the triangle on the seat - I put it out in the road when I was under the car and some **** drove over it - that could have been me  -  Blind?  :undecided: or stupid? either way get off the road you ****ing idiot!!!



So I've only got to ...

finish the wiring (I'm halfway there, I know what they are but they go through the fusebox  :undecided:)
refit the vacume lines (they were getting on my nerves when i was wiring so i took them out  :grin:)
fit the manifold ( :evil: the extra power its going to give has really helped me get over the hassle of getting it)  :angry:
fit the 16v Inner CV joints - I picked up new boots yesterday 
fit the radiator & expansion tank and fill them
fit my freshly charged and un-melted battery

And I'll be ready to fire the beast up (http://i22.photobucket.com/albums/b336/MK1MADJ/eusa_dance.gif)


 :grin: :grin: :grin: I should be driving again by the end of the weekend  :grin: :grin: :grin:
Title: Re: MK1MADJ - mk1 16v
Post by: Mk1Mad J - 16v on 17 May 2006, 21:46
(http://i22.photobucket.com/albums/b336/MK1MADJ/eusa_clap.gif) hats off to www.potn.com  - It came  :grin:

how keen am I - I fitted it this evening in the rain  :rolleyes:

(http://i22.photobucket.com/albums/b336/MK1MADJ/HPIM0391.jpg)
 :embarassed: I haven't tightened one of the nuts - it was getting dark.   :nerd: better check them all tomorrow.
Title: Re: MK1MADJ - mk1 16v
Post by: Mk1Mad J - 16v on 20 May 2006, 19:42
Well I got back to work on the car yesterday and in the daylight I was able to see that
the Ashley manifold IS A STEAMING PILE OF DOG TURD!!!
its about as much use to me as a c0ck flavored lolly-pop  :laugh:  :laugh:  :laugh: It'll be going back on monday for a refund.  :wink:

As you can see from the pictures below it doesn't fit - the worthless pile of sh!t hits everything it possibly could :rolleyes:

They're upside down as I was lying on my back under the car to take them  :smiley:
(http://i22.photobucket.com/albums/b336/MK1MADJ/HPIM0396.jpg)(http://i22.photobucket.com/albums/b336/MK1MADJ/HPIM0397.jpg)
(http://i22.photobucket.com/albums/b336/MK1MADJ/HPIM0398.jpg)(http://i22.photobucket.com/albums/b336/MK1MADJ/HPIM0399.jpg)


 :shocked: You may wonder why i'm in such high spirits about this - I was never happy about paying for the manifold in the first place, I want a turbo and the 4 branch will be useless for that, plus.......

Whilst sat about feeling miserable I had one of those moments that needs a lightbulb on head smiley (JV :smiley:)

I knocked up a sleve using a bit I chopped off a spare

.
.
.

My curry just got here (http://i22.photobucket.com/albums/b336/MK1MADJ/bounce.gif)


Title: Re: MK1MADJ - mk1 16v
Post by: Mk1Mad J - 16v on 20 May 2006, 20:45
mmm, yum... sorry about that  :grin:

right yeah, I cut the joint end off a spare backbox I had kicking about and used it as a sleeve between the 2 parts of exhaust and it was a total success  :cool: trouble was I only had one spare back box  :sad: I called around my mates but nobody had an old backbox i could have  :cry:

(http://i22.photobucket.com/albums/b336/MK1MADJ/HPIM0409.jpg)
 :nerd: If you're wondering about the screwdriver, the pipes wanted to play with each other so I wedged it in there to temporarily separate them  :smiley:


I sat about again for a bit and turned my attention back to to the wiring and worked out a couple more  (the ignition fed ones :wink:) then I had another "missing smiley" moment  :laugh: - use the reducer sleeve that I had made (Thanks Paul  :kiss:) to join the standard exhaust to the c0ck lolly  :laugh:



Job done - Just need to get it welded by a pro  :wink: :cool:
(http://i22.photobucket.com/albums/b336/MK1MADJ/HPIM0411.jpg)
Title: Re: MK1MADJ - mk1 16v
Post by: Mk1Mad J - 16v on 22 May 2006, 11:39
Fitted my homemade downpipe yesterday, it fits a treat  :cool:  I'll take some pic's after the monsoon  :laugh:



The long awaited pic's (sorry for the delay dude's  :embarassed:


(http://i83.photobucket.com/albums/j284/jasonmk1j/HPIM0481.jpg)
(http://i83.photobucket.com/albums/j284/jasonmk1j/HPIM0479.jpg)
(http://i83.photobucket.com/albums/j284/jasonmk1j/HPIM0478.jpg)
Title: Re: MK1MADJ - mk1 16v
Post by: Mk1Mad J - 16v on 23 May 2006, 15:01
 :embarassed:  :rolleyes: AAARRRGHHHH I'M SUCH A TW@T!!!!!

I was feeling pretty lucky lastnight so I thought i'd put the battery in and see what happens, I put it in turned the key to the first position and the battery light came on (http://i22.photobucket.com/albums/b336/MK1MADJ/eusa_dance.gif) good start..... so I turned the key further to crank the engine and nothing  :shocked: had another go.... nothing.... I can hear a coulpe of relays clicking but thats it???  :huh:

A bit fazed I thought i'd better check the diagrams again but everything seemed to be in order  :huh:.  I didn't touch the cars original starter motor circuit so why wouldn't that work? I could understand the sensors and things, maybe i'd left a wire off but the starter? that should be working damn it!!!


I just had a poo (nice :evil:) and whilst sat there I had another of those flash moments of pure genius  :cool:

Remember my lovely painted gearbox, i'll remind you
(http://i22.photobucket.com/albums/b336/MK1MADJ/HPIM0319.jpg)

See that bit on the right hand side where the ropes are going through, its just where the engine mount goes right? WRONG!!!!  its also the earthing point for the engine... and i've bloody painted it!!! (http://i22.photobucket.com/albums/b336/MK1MADJ/banghead.gif) So now the engine isn't earthed  (paint doesn't conduct electricity  :rolleyes: )  I've painted both sides of the mount too, doh!!!!!

I'll be looking for another earth point tonight  :wink:
(I'll try and get those downpipe pics sorted too)
Title: Re: MK1MADJ - mk1 16v
Post by: Mk1Mad J - 16v on 20 June 2006, 10:19
Its been a while so you're probably wondering why I haven't posted pics of my completed conversion yet? - the engine was siezed   :cry: why I didn't check it I'll never know  :rolleyes:

I had a parrafin/oil mix soaking in the bores for a few weeks but it still didn't shift so I took the head off on friday to see exactly whats going on -  the rings had stuck to the bores so I've started rebuilding my other engine with the head & polished bits off the siezed engine, which thankfully is ok, :cool:

(http://i22.photobucket.com/albums/b336/MK1MADJ/HPIM0470.jpg)


I'm not worried about this one siezing, I'm more worried about how it'll start with all that oil in it - its dribbling out  :undecided:
EDIT: It started spluttering after 2-3 turns and started after 4-5  :smiley:

(http://i22.photobucket.com/albums/b336/MK1MADJ/HPIM0434.jpg)
Title: Re: MK1MADJ - mk1 16v
Post by: Mk1Mad J - 16v on 22 June 2006, 01:17
A Couple more Pic's I'd forgotten about, they were on my new phone so I'm well impressed with the quality  :smiley:

Off with its Head!!!
(http://i22.photobucket.com/albums/b336/MK1MADJ/Image008.jpg)


The working Bottom End after painting
(http://i22.photobucket.com/albums/b336/MK1MADJ/Image006.jpg)
Title: Re: MK1MADJ - mk1 16v
Post by: Mk1Mad J - 16v on 28 June 2006, 09:56
 :grin: The seized bottom end is finally out, just got to swap the mounts/gearbox & polished bits over to the other lump now - I should get it done in time to re-fit it over the weekend.



Thats Dave (AKA MK2MADMAN) and his dodgy beard striking a pose for the camera -   :laugh:
 I received a complaint about Daves's beard, the offending material has now been removed   :smiley:
(http://i22.photobucket.com/albums/b336/MK1MADJ/jhgg.jpg)
Title: Re: MK1MADJ - mk1 16v
Post by: Mk1Mad J - 16v on 17 July 2006, 10:03
(http://i22.photobucket.com/albums/b336/MK1MADJ/SMILEYS/cheerleader.gif) ITS (http://i22.photobucket.com/albums/b336/MK1MADJ/SMILEYS/cheerleader.gif) A (http://i22.photobucket.com/albums/b336/MK1MADJ/SMILEYS/cheerleader.gif) 16V (http://i22.photobucket.com/albums/b336/MK1MADJ/SMILEYS/cheerleader.gif) NOW (http://i22.photobucket.com/albums/b336/MK1MADJ/SMILEYS/cheerleader.gif)

(http://i83.photobucket.com/albums/j284/jasonmk1j/rear.jpg)
(http://i83.photobucket.com/albums/j284/jasonmk1j/side.jpg)
(http://i83.photobucket.com/albums/j284/jasonmk1j/FRONG16V.jpg)

 :cool: It works too
(http://i83.photobucket.com/albums/j284/jasonmk1j/th_HPIM0488.jpg) (http://s83.photobucket.com/albums/j284/jasonmk1j/?action=view&current=HPIM0488.flv)

Title: Re: MK1MADJ - mk1 16v
Post by: Mk1Mad J - 16v on 18 July 2006, 01:41
The siezed lump should free up after some heat, boiling oil & a bit of hammer action - I had great fun heating it on Sunday, who ever said oil doesn't burn was wrong  :wink:

(http://i83.photobucket.com/albums/j284/jasonmk1j/HPIM0482.jpg)

Once the pistons are out and its been checked and honed I'll start collecting my bits so I can build my turbo engine  :evil:


Suspension & Bushes next so stay tuned  :smiley:


EDIT: It's free'd up nicely and it doesn't look like there's any damage  :cool:
Title: Re: MK1MADJ - mk1 16v
Post by: Mk1Mad J - 16v on 13 November 2006, 15:04
 :rolleyes: This things got well out of date, naughty me  :grin:

All was going really well, the engine was in, brakes set up, wires tidied away and it was ready to test drive.   I went to drive down the road but as soon as I went for 2nd gear there was all sorts off misfires & electrical noise going on  :sad: what now  :rolleyes: .   The distributor cap had made contact with the brake  light switch in the master cylinder  :angry: it smashed the rotor arm to bits...

I replaced the rotor arm and the cap looked ok so put it all back together, but ditched the brakelight switch by replacing it with a blanking plug which has now given me plenty of clearance.  Whilst sorting that lot out I had another battery incident  :embarassed:  some of the fuel injector lines touched the possitive terminal and promptly got red hot and started to melt  :huh:  :angry:  :rolleyes: will this fecking car ever be finished.....


After months of searching I finally got some Scirocco 16v injector lines, fitted them and went to start it .... aarghhh flat battery  :rolleyes:

So yesterday, armed with a freshly charged battery and some sparkly bosch super4 sparky plugs, I walked up to the garage (Its been in hiding since the tax ran out) put the battery in, fitted the plugs and turned the key..... oh come on ....  :shocked: oh is that ......  :sad: no ......  :huh: hang on .......  :rolleyes: petrol????


Shot down to the petrol garage for £5 of shell's finest, back to the garage .... where's the feckin funnel  :rolleyes: Mr Organised does it again....

back to the car with a can of juice & a funnel, poured it in, turned the key halfway.... left it a second to prime.... turn the key some more ..... YAY!!!!!! first click and she's purring  :cool:

I Took it for a little drive around the flats where its parked and the grin on my face was starting to hurt.... I'm quite amazed I managed to resist the urge to take it out onto the main road and give it a blast, must be getting better behaved in my old age  :nerd: 10 years ago I'd have been on my way to the coast  :laugh:

Just got to sort out the brakelight switch, either using a t-piece (if I can find one) or a micro-switch on the pedal box.  and fit a new fan switch as the old one got broken during the second engine fitting - then its off for its MOT

If all goes well you can hope to see it at the next no-rice  :cool:

(http://i22.photobucket.com/albums/b336/MK1MADJ/Image036.jpg)
Title: Re: MK1MADJ - mk1 16v
Post by: Mk1Mad J - 16v on 15 November 2006, 20:08
A few more pictures I took today

The Business end, it still needs a bit of tidying and the polished bits don't look so polished  :sad: but overall I'm well pleased  :smiley:

(http://i22.photobucket.com/albums/b336/MK1MADJ/16V/Image039.jpg)


Its still a bit of a mess inside, but nearly there...

(http://i22.photobucket.com/albums/b336/MK1MADJ/16V/Image042.jpg)



(http://i22.photobucket.com/albums/b336/MK1MADJ/16V/Image040.jpg)

The clocks were a bit of a nightmare to fit but I got there in the end... I couldn't leave them standard  :wink:
(http://i22.photobucket.com/albums/b336/MK1MADJ/16V/Image043.jpg)

And at night  :cool:
(http://i22.photobucket.com/albums/b336/MK1MADJ/16V/Image044.jpg)

You can't do a photoshoot without a sexy ar$e shot  :grin:

(http://i22.photobucket.com/albums/b336/MK1MADJ/16V/Image041.jpg)


 :sad: Its SORN at the moment but that should be sorted over the weekend, I can't wait to drive it  :evil:

Title: Re: MK1MADJ - mk1 16v
Post by: Mk1Mad J - 16v on 23 August 2007, 15:03
 :undecided: It feels like forever since I posted in here now, I got made redundant in November and I've been temping since so not really had any spare cash to throw at the car  :sad:

I've had a few bargains come my way recently and now things are moving on...

1. A mate bought himself a Range Rover, when I saw it for the 1st time I noticed a head unit I'd secretly wanted since I 1st saw them, but never really thought I'd be able to afford/justify the £500 price tag - imagine my joy when he informed me that it would be coming out to make way for his Pioneer  :cool:

just £60 and it was mine :grin:
(http://www.caraudiocentre.co.uk//productimages/full/kdavx1.jpg)


2. Same mate told me of a friend breaking a late cabrio, white unfortunately but I had the bonnet anyway, I've cleaned the small amount of surface rust & stone chips and its all ready to go for a paint in a week or two, no more bubbly bonnet  :grin:

3. When I went to pick up the bonnet I got offered some Koni Coilovers, so I had them too, along with the hubs/carriers/caliper/drivershafts & wishbones - I'm picking up a full set of Powerflex bushes on saturday then I'll be fitting the lot, so I'll post some pics up of that once they're done   :smiley:


Also bought a set of Goodridge brake hoses, the cars going to be so much better next week, infact it'll be ready for the track  :evil:

 
Title: Re: MK1MADJ - mk1 16v
Post by: Mk1Mad J - 16v on 27 August 2007, 22:32
Got the whole lot fitted today without too much hassle, in fact there was only one difficult brake pipe which eventually came free after a bit of swearing and grunting  :cool:

The old shocks were well and truly knackered, one of them was leaking quite a lot and the top mounts were past their use by date, as for the bushes  :lipsrsealed:


BEFORE:-

Yucky 25 year old shocks and standard brakes
(http://i22.photobucket.com/albums/b336/MK1MADJ/16V/Imagej.jpg)

Discs and pads are still in really good condition
(http://i22.photobucket.com/albums/b336/MK1MADJ/16V/Image001-1.jpg)

But look at the state of this wishbone bush  :shocked: I knew it was bad as I got an advice on it on my MOT but  :undecided:
(http://i22.photobucket.com/albums/b336/MK1MADJ/16V/Image002.jpg)

Ah thats better
(http://i22.photobucket.com/albums/b336/MK1MADJ/16V/Imagem.jpg)

KONI Coil overs, new top mounts, Powerflex Wishbone Bushes, Red Dot Racing Brake Discs & Pads, Goodridge Brake Lines, Late Cabrio Driveshafts, Late Cabrio Calipers & Carriers Freshly Painted & Lower Strut Brace - Not bad for a days work  :smiley:
(http://i22.photobucket.com/albums/b336/MK1MADJ/16V/Imagem.jpg)

Its sitting nice and low now, I could go loads lower but I'm waiting for my new wheels before I mess with them again, It feels so much better and I haven't even had the camber set yet, I just set them both in as far as they go  :undecided: I reed to get that done ASAP

(http://i22.photobucket.com/albums/b336/MK1MADJ/16V/Image004.jpg)
(http://i22.photobucket.com/albums/b336/MK1MADJ/16V/Image003-1.jpg)

Next week:-
Powerflex Anti Roll bar & Steering rack bushes
Wheels 

:smiley:
Title: Re: MK1MADJ - mk1 16v
Post by: Mk1Mad J - 16v on 15 December 2007, 12:04
I still havent got the bonnet painted, its in the garden covered in tiny foot prints and scratches from next doors cat  :angry:  I was browsing ebay about a month ago and I saw a really nice shiny black bonnet, but it was £345  :shocked: why???  ahh... carbon fibre...  :shocked: CARBON FIBRE   :drool: 

 :cry: I should be posting pics now but it hasn't turned up yet, its been 5 bloody weeks  :sad:

EDIT: I canceled the order in the end and eventually got my money back  :rolleyes: Lesson learned, I wont be using ebay for this kind of purchase anymore  :smiley:

So I spent the money on some wheels instead  :cool: I'm off for a drive through the countryside tomorrow so I'll find a nice spot and take a few piccies.
Title: Re: MK1MADJ - mk1 16v
Post by: Mk1Mad J - 16v on 28 April 2008, 15:37
 :sad: stupid rain spoiled my plans of a little photo shoot in the countryside, here's a pic I took lastnight after I'd given the car a clean

Before (its a bit high at the front as the picture was taken when the engine was out) :-

(http://i22.photobucket.com/albums/b336/MK1MADJ/16V/02052006.jpg?t=1209393393)

After:-

(http://i22.photobucket.com/albums/b336/MK1MADJ/GALLERY/Image001.jpg)

(http://i22.photobucket.com/albums/b336/MK1MADJ/16V/Image011.jpg)
Title: Re: MK1MADJ - mk1 16v
Post by: Mk1Mad J - 16v on 05 May 2008, 19:15
Car looks really sad in this one  :cry: I need to get it painted real bad...
(http://i22.photobucket.com/albums/b336/MK1MADJ/16V/Image012.jpg)
Title: Re: MK1MADJ - mk1 16v
Post by: Mk1Mad J - 16v on 04 May 2009, 13:30
This is starting to become a yearly update by the looks of things  :rolleyes:

I didnt realise it had been so long since my last update, oh well  :grin:

Driving back from cornwall lastyear my downpipe broke at the flex joint, after lots of umming and arring i finally deceided to stump up for a stainless 4 branch, I got one from HOT TUNIG in belgium via their ebay shop  :cool:

(http://my.frooition.com/070297/images/MK116VManifold.jpg)

once that arrived i realised it wasnt really gonna work with my standard exhaust, so i took the car down to my local Powerflow spcialist for a full 2.5" system  :cool:   i've got an MOT soon so I'll get some under car pics when its up on the ramps  :wink:



I've also darkened up the front end a bit more, I brought some tinted X-hair headlights and spots but found that the spots wouldnt fit into the mk1 grill   :undecided: I'm using a clipper grill for now but I really dont like it, I'm going to work out how to get the spots into the mk1 grill somehow  :wink:      (Its suitably LOW I'm only just able to get a clipper lighter under the front  :cool: )

(http://i22.photobucket.com/albums/b336/MK1MADJ/front-1.jpg)

The bonnets all sorted now, but i've still got that stupid bit of white on the wing  :rolleyes:  I'll get to it eventually  :laugh:


What else  :undecided:

 :evil: Bit more bass......

I've replaced the Silverstone tyres that came on my wheels with Yokohama AS01's all round  :smiley:


I think thats about it really, no breakdowns, nothings needed fixed, it doesn't need anything else doing to it  :grin:   well not yet anyway, i still think about turbo's quite a bit :evil:


I'm planning to get out to a few shows/drag strips and track days this year so updates should be a bit more regular soon  :smiley:

(http://i22.photobucket.com/albums/b336/MK1MADJ/edited-2.jpg)
Title: Re: MK1MADJ - mk1 16v
Post by: Mk1Mad J - 16v on 01 April 2010, 13:46
Wow, nearly a whole year since my last update... in the last year ive done, well nothing really just washing it & and driving it, nothings broke or worn out, loves it  :grin:

Just had to do a list of mods for my insurance so thought I might as well post them here aswell:

Engine/transmission
1989 Mk2 Golf 16v (KR) Engine (bored to 1.9l)
1989 Mk2 Golf 16v (2y) Gearbox
Raceland Stainless 4 Branch Exhaust Manifold
Powerflow Stainless Exhaust (2.5" Full System with 3" Tip)
Scirocco 16v Inlet Manifold/Fuel Injectors & Injector lines
Crazy Quiff Stainless Braided replacement fuel pipe set
Late Mk1 Golf Cabriolet Driveshafts & CV Joints
Mk2 Golf 16v Fuel distributor mounted to original airbox
K&N Panel filter


Chassis/brakes

Koni Ride height adjustable Coil-Over set up
Mk2 Golf 16v Brake master cylinder & servo
Late Mk1 Golf Cabriolet Front wishbones/front hubs/brake carriers & calipers
Red Dot Racing Cross Drilled & Groved Brake Discs & fast road pads
Goodridge Stainless Brake hoses
Powerflex Bush Set (Complete)
EMPI Front Lower strut brace
15" Ripspeed 5 spoke Alloys with Yokohama AS01 tyres


Bodywork/Exterior
Mk2 Golf 16v front lower spoiler
Mk1 Golf Clipper front Grill
Smoked Cross-Hair Headlights & Spot Lights
Smoked fronf indicator lenses
Zender side skirts
Kamei roof/boot spoiler
Scirocco 16v tail badge
Hi-level window mounted brake light strip

Interior
Mk2 Golf 16v Dashboard cluster (white dial kit) & all associated wiring inc. MFA, Knock-box etc…
Mk2 Golf 16v Indicator/wiper + MFA Stalks
VDO Voltmeter in centre console + additional VDO oil temp guage used to monitor water temp
Unbranded aftermarket steering wheel - hand polished alloy centre with Wolfsburg badge
Karman Ghia chrome interior door pulls & surrounds
Chrome Window winders
Trimsport Alloy golfball gear knob
Trimsport Alloy Door pins (wolfsburg)
Trimsport Alloy Mirror Adjusters (wolfsburg)
EMPI Alloy hand brake cover
Leather gearstick & hand brake gaitors
Crazy Quiffs dashboard vent inserts
Child booster seat upholstered with original mk1 seat fabric to match interior
Ripspeed alloy pedal covers


Security

yep  :lipsrsealed: