*If you're offended by cheap-assed bodgery skip straight over this post*
Well, I suspect someone somewhere was doing things properly this evening. Sadly I've been following my usual course of using the crap I've got lying around in my workshop to bodge stuff together - it saves money, which means I can do stupid stuff like this.
This evening I have mostly been bodging together a Y-piece to take the exhaust from the end of the Rallye downpipe to the original system on the car. For anyone who's not looked at this thread before - a quick catch-up - One of the big things about this project is to alleviate the restrictive downpipe scenario in the RHD Golf Syncro. So far I've hacked about a Rallye downpipe to dodge the steering column, cut out a section of the firewall and now I need to hook it up to the rest of the standard system, which isn't restrictive at all.
First of all I hacked out the 2-1 joiner from the Passat that the 2E came out of - this was just before the end of the downpipe, so flange off, then downpipes off.
Next up, I hacked apart a rather shagged T25 petrol J-pipe, as the flanges on either end are the same pattern as on the Rallye downpipe (go figure). Here is the pipe before I blessed it with the hacksaw:
I did buy a nice new pipe, but I couldn't bring myself to hack it up (come on, it had paint on it and everything!), so I've swapped it for this one and some goodwill.
I already had various random bits of vaguely-the-right-diameter pipe lying around, so I gathered them up.
Now I needed the right size pipe to fit the joiner in the standard pipework - after a bit of rummaging I found there was a salvaged front box in the workshop roof, which I'd cut the pipe off after the joiner. That came out, got separated and then got trimmed down.
I then cut a small section from some other pipe to flare the 2-1 joint down to the single pipe and then tacked together the start of the section on the workbench:
This was then fitted into the car and I rummaged through the rest of the bits of pipe to get some that were about the right length.
Before this I'd argued the motor and gearbox back into place, with the downpipe bolted up and the T25 flanges bolted to that. Now all I had to do was 'fill in the gap'. I managed to do this with assorted bits of pipe and a T25 'sealing ring' on the back of one of the flanges. Once I'd
burnt myself to pieces tacked the pipes up under the car I dropped the section out and the downpipe off, so I could give it a right dose of MIG wire on the bench, which took us from:
To
I need to drop off the downpipe and tidy the flanges, maybe do a bit of work around the 2-1 section, but it's pretty much there. It ain't pretty, but it will work and should last a while, too.
I also found out that to fit the crossflow (ABA) code head, which only has a water outlet on the end of it I really need the water pipe off a Mexican Golf, which is a bit of an arse as I can see that Heritage Bristol are unlikely to be of much use in this quest. Still, it'll be a laugh seeing if they can even find the part tomorrow - I emailed them with a list of parts, so we'll see if they even pick up their emails I suppose.
Meanwhile, the Man Who Can, over in Holland, has shipped me a lovely box of bits for the motor - inlet manifolds, G60 injectors and a few other goodies, so I need to get cracking on - this thing needs to be back ready for track action as soon as the weather cheers up a bit!