Mellow Yellow 3.2ltr 24v Conversion

Rich. said

@DaBullCam bit confused chap you linked to the first page and now we are 22 pages on. I sorted out wiring some time ago

 Hehe, yes wrong end of the thread! I'll grab a look at how far the car has come now.

Busy busy today but seem to have more questions than answers. Please can any of you helpful people shout out if you have any answers as I'm stumped.

Any who re made the reinforcement bracket for the brake bar. Added a bend to relieve the pressure from the bolt holes in the thin sheet metal in the rain tray area:




So first issue, the head shield for the exhaust manifold. I wanted to keep the stock one but unfortunately I discovered it's designed for the mk5 triangular headers not the mk4 hexagonal headers.

It seems to hit the header closest to the passenger side.



So a bit of manipulation with a hammer and dolly



Doesn't foul now, need to add more to the back of the engine to provide additional heat protection in due course.

Added some brake line clips:



So got the servo in and I have some clearance issues The shifter cable bracket hits the bottom of the 9" servo so I attempted to grind the bracket down a bit and without the rubber bushings and it has about 5mm clearance. Not sure if that will be enough to clear with engine movement. Does anyone know know of a more compact bracket that will fit an 02a corrado box or even an alternative?



As I had the opportunity I gave the bracket a refresh:



So the next problem was the top of the servo, well the brake filler reservoir.

Can you see the problem 

Does any one know of a shorter reservoir that fits the mk2 golf gti 16v master cylinder. I don't want to fit a mk1 gti servo to get round this issue but might have to it I can't figure it out.




 

I've found this brake reservoir from a mk1 scirocco 16v part number  533-611-301 which looks a lot shorter but discontinued

With being home bound I've managed to give the garage a good clear out Think I have a solution for the brake fluid reservoir, should arrive next week. Re the abutment that holds the shifter cables on the gearbox I'm not happy with the 5mm clearance so have started to make something out of stainless.

Due to the thickness (maintaining the thickness where the cable passes through the bracket) I have decided to make it in 2 parts and then weld together. I have also simplified the design by removing the third support leg like the 02a design. The part is a further 10mm lower so 15mm should be plenty. I will maintain the angles so should work fine.





 

I managed to mock up a bracket tonight. Just tacked in place at the moment because it needs some final fettling tomorrow.

 

Managed to get a couple hours in this afternoon. I took the wiper assembly apart, cleaned it up, re greased it and installed it. Got the heater unit in as well. Might need to adapt the hoses that come out of the heater matrix as the top hose is clashing with the brake bar.





Started to look at the wiring. Oh boy this is going to be interesting lol



Test fitted my new scuttle tray cover, really pleased with it. It's from SWG motorsport. Needs a bit of fine adjustment but should do the trick



 

Finished Tidying up the interior wiring this evening. Wanted to be sure everything was right before introducing the standalone loom for the engine.



Got a replacement brake fluid reservoir from a Mk4 LHD Golf which fits directly to the 22mm 16v master cylinder. Its a lot shorter than the Corrado / Mk2 reservoir. Got a brake fluid level cap on the way.



Now the air filter fits  got a silicone hose on order to space it away from the coolant reservoir
 

Starting to really come together Rich, well done!

Liking the look of the new rain tray, was it expensive?

Super_ted said

Starting to really come together Rich, well done!

Liking the look of the new rain tray, was it expensive?

Cheers bud, the only positives about Covid-19 is that I can home work and spend lots of time on the Golf. Off Friday until the day after the bank holiday so should be able to work solidly on it.

Have most things now to finish the project.

It cost £99 but is made of fibre glass. It's never going to break as it's rock solid unlike the OEM plastic versions which are pretty expensive. Buy once never replace again

I've been putting this off for a while now. Trying to get the wire through the bulkhead I started by getting the engine ecu connector through as this was the biggest one and it was a tight fit! Then the other side of the ecu loom from the interior, involved de-pinning some of the connectors. Then mk1 D loom. All I have left is the light loom which I will try to get in tomorrow and the main power and earth from the battery.



Once everything is in place and working I will tidy the loom under the chassis leg. The heat shrink on the grommet can shrink from 40mm to 20mm so should snug the wires nicely.

Fitted the dash top and made sure everything aligns properly. All good, proves I welded everything in the right place 

Got the heater grommet back in but pretty tight against the brake bar :/ needs some creative thinking to get round that.

Hey Rich,

I really like that heat shrink able thingy that your using to  your wires through the bulkhead

Just a side to that, when I did the feed through, I deplugged the ECU connectors as well, this allows me to use a very small hole thorugh the bulk head  

I tried to answer your question in a PM, put I couldn't, i dont know why ?  

So first question about battery and altenator B+, I run one from B+ to main starter, and then one from starter to battery in trunk. I'm also planning on taking a main + to everything else from the starter

I'm using a alloy pipe from throttle body to filter with no outlets fro anything, so just bung it I bunged to outlet on the back of the manifold, so only using one to brake and one to vacuum.

Hope this helps

It is def,. an earth connection, I believe mine was connected to the chain cover somewhere next to the fuel rail, seems like yours is suposse to be another place though.

Hummel said

It is def,. an earth connection, I believe mine was connected to the chain cover somewhere next to the fuel rail, seems like yours is suposse to be another place though.

Thanks chap, I spoke with rubjonny this morning and he confirmed it as the coils earth so have looped it round to a stud where the wire loom bracket mounts to.

Just trying to figure out where to mount the horn, an ideas don't want it super visible.

Getting close now to a start up . In the next few days I'll get some fluid in the gearbox and engine.

Just been waiting for some bits and pieces to finish various things off. I have some velcro style heat sleeve coming which will wrap the looms in to a nice bundle under the chassis leg out of view.

Mounted a distribution terminal for starter and alternator. It was great there was a hole in the servo bracket to mount it to

Starting to look presentable. I didn't want to do a full wire tuck. I just want this on the road now as she has been off for a while now. The look I wanted is clean and easy to work on.



And finally the car has a face again 

Thanks to Hummel and especially rubjonny for the relentless questions. John is a legend and probably quite fed up with me by now.

No worries mate, just happy to help.. And to see this amazing build come together.... It is nice to see others with the same project and the same issues..

Hey Rich. Can believe my first ever car is still on the go. It's changed alot from the blue 1 litre golf it used to be.
Looks great now though

AudiAnt79 said

Hey Rich. Can believe my first ever car is still on the go. It's changed alot from the blue 1 litre golf it used to be.
Looks great now though

Cheers Ant,

Unfortunately with the 2 engine conversions In my ownership I think it's been off the road more than on

Looking forward to getting it on the road for the summer assuming things improve in the UK.

Do you have any pics of the car when it was blue

Managed to get a few hours in this afternoon and hopefully a full day tomorrow.

I've finished the engine bay wiring apart from the fan control but that will all be based in the engine bay. Would've preferred to use the stock mk1 thermo switch but unfortunately the radiator has a 3/8th npt thread so not compatible with a mk1 switch being metric.

Got the horn mounted, think I might move it behind the VW sign but that would be a nice to have.



Got the light loom tucked away. Just need some clips to fasten it to the valance area.



Also hid the window wiper motor loom and routed it with the main dash loom. Just needs clipping in with the other wire bundle.


 

Massive disappointment today, I was eager to get a test start so checked the fuel by running it out from the lift pump  but as I thought 2 years in the tank has taken it's toll.



 This was super unleaded as well but the bad thing is I think the tank is pretty much full :/

The tank was brand new a couple years ago so it doesn't have any particles in, its just orange with oxidisation :/

I think I have enough containers to drain it in if it's not more than 20 litres but what the hell am I supposed to do with it  

I noticed that the surge tank was leaking where the pump joins the case so have some O rings on order that should hopefully arrive later this week. Then I can try again! Plenty more to do though

 

Hey Rich. Found this one just for now taken in 2001

Ant