Quick catch up - Lots done over the past week or so.
We now have the pressure pump and wiring fitted under the floor:
This is a sight many GTI drivers will be familiar with, to a point - you can see the independent rear suspension subframe in the photo. Thankfully the supplied pump was from a continental Syncro, so it had the right length pipes - something that actually 'bolts right up' - shocking. To compensate I'll be needing to make up the wiring to power the electric lift pump I've fitted in the tank - the carb Syncro doesn't have one. Thankfully the Rallye does:
Rallye unit on right, with lift pump.
Now, I was going to be using the 2E management and wiring loom, but it has a fifth injector, which ain't gonna just fit up to the crossflow inlet manifold (which is not designed for a cold start injector), so it looks like I'll be falling back on chipped G2 digifant management, although to make sure we fuel correctly I'll be using a Euro loom, so it runs with a lambda and hopefully gets the mixture about right. Although I'm running with G2 management, I still need to use the 2E throttle housing, as this bolts up to the square hole on the crossflow inlet manifold. In comparison the G2 GTI throttle plate housing is rectangular and will not fit at all, being both narrower and longer. The kicker is that the 2E uses a potentiometer, whereas the G2 uses closed and wide open throttle microswitches. I've now converted the 2E housing from this:
to this:
Which seems like a right old retrograde move, as surely a potentiometer will work better for injection, won't it? Well yes, but only if the system you're using works with a potentiometer!
Because the throttle damper has now gone it's meant I can mount the square any which way I want, meaning it's been a lot easier to figure out the mounting for the throttle cable. Might turn out after all.
This week has also bought a few parts:
A Techtonics 268 cam, to spice things up a little. This might seem a little tame, but given that the head is being breathed on it should flow better, giving sensible gains overall. This was bought and shipped in from the USA at a total cost of $210 plus £30 duty on arrival. It was either that, or £220 plus shipping for a Kent GS2, which will do the same job (tough choice).
To cater for the crossflow head I've purchased new a hose from a 2002 Golf cabriolet. The crossflow has no water outlet on the front surface of the head, so the cooling arrangements are substantially different to the GU carb motor. This hose also means I can run a radiator without the stupid bleed hose at the top. The radiator is still to buy - a G3 unit, as this omits the bleed tube.
I had to pick up a bracket for the cable-change mounted transfer box, as it's different to the rod-change one. £5 on Fleabay. That's now with me.
I'm still waiting on the Euro loom, the chipped ECU, a Rallye rear engine mount (to miss the 100mm CVs) and a remote oil cooler. These are coming over from Holland in the next couple of weeks. The head eventually left for work, but it wasn't alone - it has the flywheel with it, which is going to be losing 3 out of 9kg.
A little while ago I painted the new plated section in silver Hammerite to give it a fighting chance of survival. It's under the car, so no point worrying about the paint match. The underside might even get a little stonechip on it, although to be honest it would make more sense to fit up some heat protection.
I spent this evening putting the heater and dash back in, which have gone back in quite nicely, without too much arguing.
The flywheel and head should be ready for pick up the weekend after this, so it looks like I should
really get a scoot on with the rest of the car, especially as we're looking at a trip to the Eiffel Mountains in May.
