grungeisdead - "project muppet another mk1 joins the flock"

[grungeisdead]

ended up getting a different set of webers for 20 quid more, this set was dcoes jetted for a 1.8 8v again brand new with linkage, inlet mani and trumpet, just a pump and filter king to get now when i sell summat or get my student loan on the 7th.

webers should be with me friday or monday as they are being posted out tomorrow




driveshafts just need to be removed from beena and engine unbolted and its ready to come out, im gonna paint it all up and probably replace the gearbox before it sees the muppets bay, for the time being the carbs will be going on the jb lump and see me through to all types and run to the sun then put the gti lump in after

[grungeisdead]

Got a few bits and pieces done today,

removed inlet and exhaust manifolds from the muppet, removed oil filter and a few redundant water hoses and put a new brass pipe in from the water pump to the side of the block.




fitted a mocal sandwich plate, eurosport oil cooler and new oil filter.







also fitted the speaker covers on the door pods.

[grungeisdead]

removed both exhaust systems off the car today and got the stainless steel mani on the muppet, and ordered my silver top competition fuel pump/filter king reg today so they should be here along with the carbs, woohoo!

Tomorrow only got a few jobs to do, wire up harness pre-tensioners and re-fit speaker and door cards, drain oil and re-fill, fit stainless centre pipe and finish removing the g60s as ive sold them, just replacing them with vwIIs for the time being

just a wee note of bits ive still got to get before mot

22mm master cylinder - GSF 65276
Goodridge Braided Hoses - GSF 99580
Bushing Kit - GSF 71709
Brake Fluid - GSF 98101
Backbox

Other bits i need/want

195/45/14s x 4
Polybush Kit
New Wishbones
Front Lower/Upper & Rear Strut Braces
Recaro/Bucket Seats
Golf mk2 Stub Axles/Caliper Carriers
Golf Mk4 Rear Calipers
Pressed Plates (UK English Unbanded)

[grungeisdead]

got a few things done at the weekend, harnesses are all wired up and door cards all fitted.

removed the g60 brakes and packaged them all up and put my 239mm setup back on, only to then win a 270mm tsr conversion on ebay :lol: so they will be coming off again, but its got a set of new pads,braided hoses and calipers, i dont need the calipers so ill make up a VWII G40 239mm setup for sale complete with grooved/drilled discs and new pads



also got 2 mk2 rear disc stub axles and caliper carriers ready for some mk4 ally calipers :-D



so i still need the following things for that

Rear Disc Shopping Conversion -

Golf Mk4 Calipers
Mk2 Rear Discs x 2 - GSF60340 - 15.95
Mk2 Rear Pads Pagid ( 1 Set ) - GSF64601A - 14.90
Mk2 Rocco 16v HB Cable x 2 - GSF73132 - 9.50
Mk2 Rear Wheel Bearings x 2 - GSF41311K - 5.95
Mk4 Caliper Hoses from TSR

was on a bit of a spending spree :lol: bagged this for 15 quid, debadged twin spot grille, I'm not a fan of quad lights on mk1s but cant beat that for a bit of cheapness



The Carbs arrived in the post today, so i had a nosey around to see how complete they were and what i still needed to get, trial fitted them on a spare head and found out i need longer manifold studs 50mm is too small, measured it up and i need 80mm studs so will have a gander for them.

Also needed to get a 2-1 adaptor block for the throttle cables and a 3 way t-peice adaptor for the fuel line to the carbs, got these for 14 quid through eurocarb.




anyway some pictures of the carbs, trial fitted to the spare head and car to check out any fitment issues and clearance issues especially around the MC, its tight but perfectly do-able. Ill be fitting a 22mm master cylinder I've got in the house so ill route the brake pipes accordingly.

I've decided to mount the fuel pump and reg on the scuttle panel next to the coil, it'll just make for easing routing than having it go aruond the front. Does anyway know what i do with the mechanical fuel pump on the block? do i just leave it disconnected?

trial fitting on spare head




inlet manifold




not sure of make, holes are correctly ported for the inlet holes on the head however it could seriously do with some polishing internally



a couple of randoms





them trial fitted on the car




MC clearance, good enough



sorry for loads of pics but I'm sure someone out there will apprieciate them

oh and i still need to pick up a backbox, bushing kit and brake fluid before i get anywhere!

[grungeisdead]

woohoo happy days, fair few parts came today to add to the stock pile

filter king pressure reg & and facet competition silver top pump kit



270mm discs & new pads




VWII Calipers with new seals and sliders, painted red now, painted the tips of the braided hoses too (fitted with tsr/autocavan 270mm spacer)



rear stub axles for disc brakes, cleaned up and painted



rear caliper carriers



tsr gear linkage and short shift for the relay shaft and teflon bushings. will strap a weight to the shift rod for a weighted throw



Got on the blower to GSF and got the following bits on my trade account because i spend too much money there :roll:

2 x wishbones
2 x ball joints
6 x nut/bolt/washer for above
gearbox bushing kit
passat 22.2mm master cylinder

also managed to track down some m8 x 88mm manifold studs to mount the inlet manifold.

oh and the state of my spare room at the minute! only tommys room and the bathroom remain car part free



and the reason why i'm not doing much on the motor at the minute

[grungeisdead]

boooooo today has been a  good and bad day,

got the passenger side brakes and wishbones off, got the new wishbone fitted and got the 270mm brakes and braided hoses hooked up on that side,



got round to doing the drivers side, got the old wishbone off and brakes off, fitted the new wishbone but went to tighten up the front wishbone nut (where the strut brace would attach but the bolt wouldnt tighten up for love nor money!

so whipped off the new wishbone to ensure that the bolt was actually screwing into the chassis (as it just bolt sits in the bush and tightens up into the chassis) but low and behold its not!

so im kinda stuck, pissed off and knackered!

i may attempt it one day this week but im not really sure of what can actually be done, grrrrrrrrrrrrrrrr! could this be the end of the muppet?!   i sincerely hope not!

next day -

got a tap and die set this morning and managed to sort the wishbone thread out woohoo!

so got the wishbone and carrier on, and tie rod and hub attached




disc and caliper attached




needed 3mm spacers to clear the calipay but job done, centre caps in the house



then decided to strip all the gear linkages






cleaned them up with de-gunk and a wire drill




painting them up



once theyve had a few coats ill re-fit it all with new bushes and the short shift kit

[grungeisdead]

got the shift rod linkages all painted up and sorted, just awaiting a goodie pack from missing linkz with a teflon accelerator pedal push, shift rod bush, headlight wiring relay and weighted shift rod that just takes the place

Shift rod linkages painted, all new bushes and tsr linkage




The top golden bar is being replaced with a weighted shift rod from missing linkz, also coming is a teflon shift rod bush and accelerator pedal bushing, and an uprated headlight wiring loom.

some shiney bits - top radiator cover, coil cover and brand new fuel pump (it wont be used on the engine but will just look nice and shiney on the block)



Some odds n sods, service related parts (all new bar the leads - coil, 22.2 passat mc, sparks, gaskets, tie rod ends and belts)



new water pump and 90a alternator (needs cleaning up)


Stuff to do

Stuft to get - Pre MOT

* Backbox

Brakes - Pre MOT

* Enlarge Bulkhead Hole
* Fit 22.2mm Master Cylinder
* Plumb Brake lines and brake switch
* Bleed Brakes

Other Pre MOT Jobs to fit

* Refit Gearlinkage
* Fit Coil/Sparks/Belts/Leads
* Plug Expansion Tank Hole
* Fit Facet Pump & Filter
* Fit new mech pump and block off outlets
* Fit Inlet Manifold
* Fit Carbs
* Plumb fuel lines
* Fit throttle linkages
* Mount Oil Cooler
* Change Oil
* Fit Front Splitter

turns out the new master cylinder isnt really suitable for my application and without a servo will make it harder to stamp on the brakes so teh std one just went back on.



re-fitted the gear linkage, but its super stiff now, too stiff for my liking, its coming off again, gotta do a few tweeks and rebuild teh shifter base and drill out the rivits that hold the shift rod bush in place



fitted new sparks, leads, dizzy cap, rotor arm, clutch cable, and chucked 3 litres of fresh oil in there (previously put half a litre in the new filter when that was fitted and drained the oil the other day



chopped down some manifold studs to mount the inlet manifold but two were bent and by that time i was bored so gonna chop some more up and test fit on the head in the house and have the carbs on for tuesday/wednesday. need to get some aluminium sheeting cos i want to make a bracket mounts the bulkhead where the coil resides to mount the pump/reg and coil

and the recaros came, subframes are gettin welded in the next week or so, gotta pass them on to a mate




got pally with mr hacksaw again today and cut down some more manifold bolts that werent bent this time  :oops:  fookers

bolted it up to the head in the house to check it all fitted ok, jobs a good un



you can just see to the right that I've blocked off the vacuum take off, ill be pluggin two vacuum lines into this for the vacuum guage in the car and one to the dizzy

stuck the carbs on so i could get the fuel lines measured up, the one of the left is a bit short so ill be sorting that oot.



spent a while working out where i wanted to mount the filter king for neatness of the plumbing in the bay and noticed too coincedentally placed holes, so ill be cutting the mounting plate that came with it and drilling some new holes in it to mount it to the carb, should look pretty cool when its all fitted.

means i can also retain the original coils placement and just mount the fuel pump on the bulkhead next to it.

when i get round to doing the bay I'm either going to chop out the rain tray completely or thinking of louvering the panel so its open in front of the carbs, and incorate vents in the sides of the wings to vent air into the rain tray and into the path of the carbs. not sure out much air would be sucked in from the vents being placed so far up the wing (right next to the doors/windscreen) but will be interesting anyway if i do it

[grungeisdead]

got my angle grinder today happy days

first to get chopped up was the throttle pedal for fit the 2-1 adaptor



sytec one fitted, got a weber one coming instead cos it uses grub screws instead of this one which i think uses the solderless nipples but either way its sh!te



broom broooom



drilled out the rivits for the shift rod bush





painted up the new rear ally caliper i got




whipped some bits off beena and painted them up, rear wishbone mounts with arb brackets and the rear arb and all those brackets



few bits to fit tomorrow :-

refit all the gear linkage
plug expansion tank hole
fit uprated wiring loom and smoked indis



also gotta get angle grinder happy on the short shift adaptor to shave a few mm off the edges to clear the block.

got a sheet of metal to make a bracket for the throttle cable holders, will cut that out tomorrow and drill holes for the throttle cable adjusters.

might mount the filter king and pump if i get round to it.

ordered a few more bits to finish the carb assembly, alot more bits were needed than i first anticipated but better doing it all now that fannying around later.

anyway quick list of those bits

fuel pump inertia switch
weber pedal block
heatwrap and stainless ties
2ms of overbraided fuel lines

and need to find a relay in the house to wire up the pump from the igntion, big thanks for mk1nath on the mk1 owners club for loads of advice and pictures and stuff while ive been gettin me head round this all.

woohoo

[grungeisdead]

twas raining on and off today but got a fair few odds n sods done

made up the bracket for the throttle cables and had to file a wee bit of the throttle cable hole so it fitted properly



you can just see it fitted in the far left



oil cooler fitted and a few wires tidied out the way, fitted the headlight loom






fitted the front wishbone mounts from the gti for the arb mounts, refitted the gearlinkage and shift rod bush housing, cleaned up and flushed rad, fitted new lower hose as the old one was cracked and blocked off the expansion tank hole

oh also fitted smoked indis

tomorrow i gotta

set the shift finger stop gap and fit weighted shift rod
wrap the 4 branch in heatwrap
fit pump, reg, relay and then get the inlet manifold and carbs on if all goes well

oh and chin splitter woot

still waiting on an inertia switch which should be here tomorrow hopefully.

[grungeisdead]

woopagio

picture of the throttle bracket


made a bracket to hold the pump and reg



fitted that and new coil/holder





heat wrap on



chin splittay on



and the oz routes came woot, me mams picking up some brand new yoko a539 195/45/14s for me at the weekend so i need to try and blag her into coming up to manchester to drop em off haha

tried to mount the inlet manifold but it was catching against the 4 branch, took a bit off with a grinding disc but more needs to come off tomorrow, once they are on i can get the carbs on and plumbed in, also gotta find somewhere to mount the inertia switch and then wire up the electrics for it all but thats how shes gonna sleep till wednesday after the next 2 exams