1980 Yellow Golf LS Turbo

Thursday 3rd January 2013
Some pictures from last year





Latest happenings in the Golfies world :-

Got a K03 turbo and mani to try out to see how it stacks up against the T25
Full stainless exhaust to fit
Track day in February
Blat about until next winter where it gets some much needed restoration in some key areas to preserve it for a bit longer.

Looking at the pictures, I miss it daffodil loads, but that being said, if anyone wants to try me with swaps, I'm always open to a bit of bartering!



Tuesday 26th February 2013 -
Decided I've spent far too long having not driven a VW so I needed to rectify the situation and with the start of a month looming its the perfect time to tax and insure it.

Got a small list of stuff to do before Friday,

Replace a fuel line
Replace passenger pre tensioner for harnesses
Fit the stainless exhaust - which involves rewelding the factory hanger back on as I cut it out previously as it was intruding on my pikey'd centre box.
Refit the cages door bars and windscreen bar - bought a step drill bit to make neat holes for the cage leg on the passenger side floor pan, which was replaced when I welded it up earlier last year
Go drive

Today I cleaned up swapped out the ecu and cleaned up the loom contacts, they got grotty from when the scuttle cover was cracked and letting water into the loom

Interim plans for this which will proceed when I've finished the comet blue

been measuring up a stainless rad I picked up a while back ( need to get azbar to flip round the water outlets as it was designed for a big block golf engine ) and measuring up the intercoolers I have with metal end pieces so I can decide what needs welding for the tidiest routing of boost pipes, and then I will set out making brackets to neatly hold the rad, intercooler and oil cooler in place.



ko3 conversion is just awaiting getting the manifold flange machined flat and sorting out a chip, either the origins of mine, or getting one from PPP, picked up a stainless downpipe from Jose and a gasket and stud set



The rocker cover is being sent away to be powder coated along with a load of engine parts for the comet blues engine, there's also a single wiper there too =D

Wooooop woop golfie times



Thursday 28th February 2013

Set about fitting the stainless exhaust this eve,

Welded in a flexi and a sleeve for a reducer




Back box on,  tailpipe will get changed at some point but in no rush



Gotta get 3 new rubbers for the backbox and whip the flexi centre section off, reduce the size of the slits in the flexi with a copper backed weld, and make a new centre hanger, I've got some 8mm rod and a 6n exhaust rubber so should be able to make something up that will take the impact when the centre box invariably catches.

Nice update mate. I love the colour of your MK1, don't see many of them at all.

Good luck getting those bits sorted   

Woohoo



Pidge spotted a new fuel leak between the pump and accumulator, short length of hose later and that was sorted. Was bogging down massively under any acceleration but tweaking the co pot got it drivable. Will take it to the unit one evening so it'll be nice and warm and set base co, then timing, idle and co pot on the gas analyser and then keep refining it till its sweet.

Feels so wierd driving it again after the beemer! Can't wait to proper start driving it again

Get her indoors in the warm  

Looks like a blast to drive.

  Nice bimmer, what's the vraic with that one then  Saf?

It's already spent long enough indoors haha!

Leaks like a sieve and needs welding but if I start on it I want to give it a lil resto so I wait till later in the year, for the meantime it can just get used and abused!

Ian, bought the Beemer last year October I think, meaning to go out and buy a reliable modern tdi daily I ended up with a 30 year old rear wheel drive zimmer.

 There a build thread on club polo and retro rides!

Got bored today



Needed toothies again in my life



Azbar finished the mod to the ally rad



And started chopping up the two engine mounts to make a new one

Great update matey. What you sticking in there now??

Rebuilt G40 lump, with a supercharged setup (got 65mm toothed belts, 51mm throttle body, shrick 272 cam, ported inlet manifold and a PSD stainless 4 branch) it was RR'd at 170 bhp at Awesome GTI a couple of years back in my Grey G40, was then transplanted to my yellow mk2 polo but thats undergoing a mini resto due to tin worm so I thought I would be all viva la supercharger.

Got a few hours on this tonight.

Did some research into swapping over the driveshaft flanges over from a mk3 box, to fit the 6n box but turned the mk4 flanges and the box wouldnt move, neither would the output shaft! span them on my 2 ATV's and they were fine, albeit a bit noisy. so whipped the 6n box off and stuck another ATV on there. Had to change the guide sleeve on the box, as it had previously broken and ruined the splines on a clutch in the process

so if anyone has number 7 - part #     085141181 from the below diagram off a broken 5 speed gearbox, i would be much obliged it you would part with it for pennies



Gave a box a quick clean up, and dropped the engine in the bay and fitted all the mounts - some of which are now polybushed, tightened up and off the crane



Finished chopping the mounts up, now I can get a jack supporting the engine in the correct place, and mock up the and get the final cuttygrindymcweldy on its ass. bearing in mind that I need to keep enough room for the charger belts in between the mounts otherwise it'll be slappy slappy



That'll be tomorrows mission, anything else done will be a bonus

You don't hang about mate do you. Nice engine. Bet it won't hang about when it's up and running. Looking forward to more updates.  

I go through phases, normally where theres no decent computer games out to divert my attention. spent most of my weeknight evenings at the unit for a solid three months now after one of my best mates who was also a mad car nut passed away, kinda spurred me to just crack on as he would, all the time.

Bit more chopping and grinding saw something close



Bit of weldy weldy



Bolted up the charger and alternator so i could put a belt on, tension up the charger and check for belt clearance



that's a no then haha



so with that all mocked up nicely, i set the job of addressing that to another day this week.

next job was boost piping - nothing to change on the outlet side of the intercooler so that was all sweet, so just the charger->intercooler jobbie.

armed with a box full of assorted boost pipes from my cupboard of joy, a handful of head scratching and a hacksaw, twas sorted.



tomorrow I wanna

Make a bracket for the bottom of the intercooler
mount the oil cooler off the lower bracket
mount the rad and make brackets


Job's I still have to do

Finish engine mount and paint
Cambelt - Get
Remove std G40 cam
Fit Schrick 272 cam, replace camshaft oil seals
fit inner timing belt cover
fit waterpump - new seal
fit cambelt
fit outer lower timing belt cover
fit toothed crank aux pulley
mark tdc on outer casings and pulley in tippex
fit outer cambelt cover
fit 51mm throttle body/ported inlet - new gaskets on way
fit g60 injectors into fuel rail and refit
refit fuel lines
fit 4 branch - modify exhaust to suit
fit lambda bosses
regrease driveshafts and refit
refit gearlinkage
refit throttle/clutch/speedo cables
refit water pipes
charger pulley - fit and torque
fit charger feed lines
fit oil gauge sender and t-piece
refit mapped chip into ecu
refit loom
fluids (engine oil/water/gearbox oil)

cant think of anything else so driiiiiiiiive!

Nice little list to keep you going mate pending the release of a new game.

Sorry to hear about your mate.    

Yeah gutting

Anyway I'm hoping to be done by Saturday and back on the road. Then its back to finishing the welding on my blue mk2 coupe polo and putting it all back together and through an mot.

Then it'll be time to pull the head off my e21 and see the damage as it start to mix oil/coolant

Done this eve

Fitted Schrick 272 cam, replaced camshaft oil seal
Swapped over camcovers
fitted inner timing belt cover, water pump with new seal and vernier pulley
fitted knock sensor
Fitted ISV
Wired up starter
fitted ported inlet with new gasket
Fitted g60 injectors
fit 51mm throttle body/ported inlet - new gaskets thanks for Andy (randombadger69) new VW inlet gasket
Mocked up rad with quick bracket, found suitable water hoses
Connected heater matrix hoses




Job's I still have to do this weekend

Cambelt - Get from TPS tomorrow
fit cambelt / fit outer lower timing belt cover / fit toothed crank aux pulley
mark tdc on outer casings and pulley in tippex
fit outer cambelt cover
Find bolts for cam cover and fit
refit fuel lines
refit throttle/clutch/speedo cables
Remove charger and mount
Mount oil cooler
Mount rad
regrease driveshafts and refit, tighten hubnuts
refit gearlinkage
fit 4 branch - modify exhaust to suit
fit lambda sensors
refit water pipes
Finish engine mount
Refit charger
charger pulley - fit and torque
fit charger feed lines
fit oil gauge sender and t-piece
refit mapped chip into ecu
refit loom
fluids (engine oil/water/gearbox oil)

grungeisdead said

Cambelt - Get from TPS tomorrow

I've got the cambelt in the car ready to give you!

Looking great mate, I remember seeing the pics of the Muppet years ago on Club Polo. Bad times, but at least you've got a beast on the way!

Nice work dude. Not long to go now and the speed you work

Got a few hours in on Saturday

regreased driveshafts and refitted
refitted gearlinkage

Spent the rest of the time trying to separate the centre section of the exhaust and removing the lambda. Everything was mega seized. Got well annoyed with everything and gave up in favour of drinks in town and a meat feast at bem brasil. So awesome.


Got over about 3 today

fitted cambelt / outer lower timing belt cover / toothed crank aux pulley / outer cambelt cover
Found bolts for Mk2 cam cover, they a different from mk3 and mk4 bolts, thankfully found 3 that came with the g40
turbo's blue cam cover



Started playing about with places to mount the oil cooler, it's going to go next to the fan on the rad

Modified the engine mount again, better but still touching - need to look into fitting a relay roller from a later engine on there to navigate the belt away from the mount



Cut out the seized lambda and welded in a plate. Cut out a couple of bosses out of another exhaust to weld in and left it there for the day



Finish engine mount
refit fuel lines
refit throttle/clutch/speedo cables
Remove charger and mount
Mount oil cooler
Mount rad
fit lambda sensors
refit water pipes
Refit charger
charger pulley - fit and torque
fit charger feed lines
fit oil gauge sender and t-piece
refit mapped chip into ecu
refit loom
fluids (engine oil/water/gearbox oil)
Torque hub nuts, driveshafts

Here is what I was thinking for the mount using a tension roller from a Lupo GTI



But now thinking of just using the polo mount, as we have a cut up mk3 polo and even if I run a non supercharged mk1 lump I'll still be able to use the original polo mount. Good news for my unit mate as he wants the old engine mount

Which oil cooler are you giong to use mate? Will be fitting one to mine in due course. Nice update btw.