Shed-esque Golf2 Syncro

[danny_p]

am now feeling very very very knackerd

[Diamond Hell]

Epic day.

Lots done, got some pics, but no time to put them up.

More later in the week.

[Hurdy]

Sounds like some serious work going on down in the bowels of the DH garage.

Fingers crossed all goes to plan for you from now on

[VeeDubGTI16v]

is this what they call a blessing in disguise?

so what happened tuning the 8v then?

[danny_p]

it was allways planned for it to go 16v, just not at this exact moment.

[Diamond Hell]

so what happened tuning the 8v then?

Got hot, some mis-firing and then no compression on 2 and 3 and no electrodes left on those plugs.  Pre-ignition or detonation.  Not lifted the head yet so don't have full diagnosis.  Anyone want to buy a 268 8V cam?  Head's probably OK, so anyone want to buy a breathed-on crossflow 8V head?  Anyone need a Rallye exhaust manifold?  210mm (or 215mm - can't remember) 6kg lightened flywheel and clutch?

ABF now in, with homebrew tubular manifold and a fabrication job on the transfer box bracket.  Danny's wiring skills have been tested and delivered top class. Went out for a quick test last night.  Runs sweet, but the clutch on the engine is shot away.  That was at 22:30.

Got the front off the car, everything disconnected before I went home at 23:30.  Just needs a quick lift out and clutch change on Thursday evening.

Time and money are running short.  Levels of epic are running dangerously high.

[Khare]

Bummer to hear about the 8v  Could be head gasket and new plugs all it needs maybe, but then again it could be bigger. As you and Danny said though, your car was always made with an ABF in mind anyway. Did you use Russ' ABF?

Just needs a quick lift out and clutch change on Thursday evening.

Typical you DH 

Just a quick lift out, as if it was an almost relaxing task 

Classic example was when we did my CV boots, test drove it and there was a griding noise from the o/s/f brake. So I pulled into the barn and within a minute the car was up in the air, the wheel was off and the caliper and pads were out  Turned out to be the dust shield.

[Diamond Hell]

Meh - it's just a consumable.

Yes, we're using Russ's ABF.

Last seen doing this: http://www.youtube.com/user/DiamondHell#p/u/1/6lgnxcaJgOc

Guess we'll find out whether all that red-line action has caused any damage!

I have video footage of the shell being lifted off.

[Khare]

that was one lightweight mk3 

[Diamond Hell]

This is Danny reading a Golf3 its last rites:



8V: sick



The 16V must have the Golf3-ness cleaned off it:



ABF blocks have this pesky rib down the bottom of the block.  This means we need to butcher the ultra-rare Rallye transfer box mount like this:



This is then re-worked to feature a new securing lug on the underside of the rib.  Pics later as I don't have any now.

No one makes a 16V tubular manifold to suit a Syncro, so we're going to make one with loo-roll tubes and cardboard.  This is the flange being cut.  Flange.



I have been saving VW downpipes for about two years, in readiness for this occasion.  I still have spare.  Here are some that aren't spare any more:



9" FTW when cutting pipe - straight through, no messing.

Fits where it touches: