Author Topic: MK1MADJ - mk1 16v  (Read 29836 times)

Offline Mk1Mad J - 16v

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Re: MK1MADJ - mk1 16v
« Reply #10 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.



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.


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:


It might look a mess but at least it cleared the linkage  :smiley:



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:
« Last Edit: 18 July 2006, 02:01 by Mk1 Mad J - 16v »

"Ever since I started to surf, I have realized that golf is for people who don't know how to surf."  -- Tiger Woods.

my dub project:-
http://www.golfgtiforum.co.uk/index.php?topic=35338.0
http://www.youtube.com/watch?v=WyEUOoH_xxo

Offline Mk1Mad J - 16v

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Re: MK1MADJ - mk1 16v
« Reply #11 on: 07 May 2006, 20:12 »
When my battery melted it took out my main battery cables (along with many others  :rolleyes:)



So.....

I made these yesterday when it started raining  :cool:

"Ever since I started to surf, I have realized that golf is for people who don't know how to surf."  -- Tiger Woods.

my dub project:-
http://www.golfgtiforum.co.uk/index.php?topic=35338.0
http://www.youtube.com/watch?v=WyEUOoH_xxo

Offline Mk1Mad J - 16v

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Re: MK1MADJ - mk1 16v
« Reply #12 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:

"Ever since I started to surf, I have realized that golf is for people who don't know how to surf."  -- Tiger Woods.

my dub project:-
http://www.golfgtiforum.co.uk/index.php?topic=35338.0
http://www.youtube.com/watch?v=WyEUOoH_xxo

Offline Mk1Mad J - 16v

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Re: MK1MADJ - mk1 16v
« Reply #13 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:


"Ever since I started to surf, I have realized that golf is for people who don't know how to surf."  -- Tiger Woods.

my dub project:-
http://www.golfgtiforum.co.uk/index.php?topic=35338.0
http://www.youtube.com/watch?v=WyEUOoH_xxo

Offline Mk1Mad J - 16v

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Re: MK1MADJ - mk1 16v
« Reply #14 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

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:)



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:
« Last Edit: 17 May 2006, 21:37 by MK1MADJ »

"Ever since I started to surf, I have realized that golf is for people who don't know how to surf."  -- Tiger Woods.

my dub project:-
http://www.golfgtiforum.co.uk/index.php?topic=35338.0
http://www.youtube.com/watch?v=WyEUOoH_xxo

Offline Mk1Mad J - 16v

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Re: MK1MADJ - mk1 16v
« Reply #15 on: 16 May 2006, 22:35 »
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

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:)



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


 :grin: :grin: :grin: I should be driving again by the end of the weekend  :grin: :grin: :grin:
« Last Edit: 20 May 2006, 22:07 by MK1MADJ »

"Ever since I started to surf, I have realized that golf is for people who don't know how to surf."  -- Tiger Woods.

my dub project:-
http://www.golfgtiforum.co.uk/index.php?topic=35338.0
http://www.youtube.com/watch?v=WyEUOoH_xxo

Offline Mk1Mad J - 16v

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Re: MK1MADJ - mk1 16v
« Reply #16 on: 17 May 2006, 21:46 »
hats off to www.potn.com  - It came  :grin:

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


 :embarassed: I haven't tightened one of the nuts - it was getting dark.   :nerd: better check them all tomorrow.

"Ever since I started to surf, I have realized that golf is for people who don't know how to surf."  -- Tiger Woods.

my dub project:-
http://www.golfgtiforum.co.uk/index.php?topic=35338.0
http://www.youtube.com/watch?v=WyEUOoH_xxo

Offline Mk1Mad J - 16v

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Re: MK1MADJ - mk1 16v
« Reply #17 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:




 :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


« Last Edit: 20 May 2006, 20:33 by MK1MADJ »

"Ever since I started to surf, I have realized that golf is for people who don't know how to surf."  -- Tiger Woods.

my dub project:-
http://www.golfgtiforum.co.uk/index.php?topic=35338.0
http://www.youtube.com/watch?v=WyEUOoH_xxo

Offline Mk1Mad J - 16v

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Re: MK1MADJ - mk1 16v
« Reply #18 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:


 :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:
« Last Edit: 18 July 2006, 02:05 by Mk1 Mad J - 16v »

"Ever since I started to surf, I have realized that golf is for people who don't know how to surf."  -- Tiger Woods.

my dub project:-
http://www.golfgtiforum.co.uk/index.php?topic=35338.0
http://www.youtube.com/watch?v=WyEUOoH_xxo

Offline Mk1Mad J - 16v

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Re: MK1MADJ - mk1 16v
« Reply #19 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:




« Last Edit: 18 July 2006, 01:51 by Mk1 Mad J - 16v »

"Ever since I started to surf, I have realized that golf is for people who don't know how to surf."  -- Tiger Woods.

my dub project:-
http://www.golfgtiforum.co.uk/index.php?topic=35338.0
http://www.youtube.com/watch?v=WyEUOoH_xxo