Mellow Yellow 3.2ltr 24v Conversion

Hummel said

I really want a picture on how your fuel system setup gonna be Mine also had DSG and with my current file I'm having a non smooth torque curve, so I might need a expert handling my maps  .

when you drive it up to him he will re map on dyno. right?

and then we need numbers!   

That's right a remap and on the dyno, need to get the MOT first though  Little diagram for you  

Just read through this whole thread! Great work and props on doing it yourself at home!

Quick Q, Are you using the Eurowise stage 2+ kit? If so, did you have issues with customs duty when you ordered it/got it delivered?

Praks

G60Praks said

Just read through this whole thread! Great work and props on doing it yourself at home!

Quick Q, Are you using the Eurowise stage 2+ kit? If so, did you have issues with customs duty when you ordered it/got it delivered?

Praks

Thanks for the kind words. Yes a Eurowise kit.

You will have to pay customs on items from America.

Just thought I'd share my new downpipe which has been made for the mk5 manifolds 😁

77mk1_R32 said

Just thought I'd share my new downpipe which has been made for the mk5 manifolds 😁

Very nice, I can only see one lambda bung. Are you going to weld 2 more on the branch from cylinders 1-3 and cylinders 4-6?

I certainly will mate and just put a bung in the bottom one. Not sure why they do that 🙄

Sorry for the lack of content, had a holiday break with the family. Managed to get some work done this week.

Made up a joining section from the manifold to the Miltek exhaust with a flange mating joint.



Also mounted the radiator and oil cooler. Welded up some stainless brackets (I'll get some pics up when I take them off to clean them up.) The bottom bracket utilises the stock radiator mounting point. I've welded a stainless bolt to the bottom of the bracket and then fitted a nylon stepped bush in to the mounting hole to reduce vibration.

 

Tiny update

I got fed up with falling over stuff in the garage so had to sort it out. Built a work bench with some left over wood from the roof so proper overkill 

Then general clean up.





As you can see from the work bench I've amounted a collection of brake bars . As luck has it another member on the forum shepp has sold me a South African Brake Bar setup so won't need to take my life in to my own hands with the welding This weekend I'll get some proper updates.

This afternoon managed to get a bit done.

Jerry rigged the inlet manifold to a bumper stand.



Got some plastic primer on



Tomorrow I'll give it a light wet sand and get some top coat on 

Got some anthracite base coat on this morning. Really please with how it went on. Will get some clear on later in the week 

New toy arrived

‘

Mike 16vG60 said

Rich. said

New toy arrived

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Lol that’s the one I sold to Shepp a couple of years ago when I was thinking of selling up. I’ve since had seller’s remorse and bought another one from abfmk1.
Looking forward to seeing how it fits-still need to get my new one on the car


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Mike 16vG60 said

Mike 16vG60 said

Rich. said

New toy arrived

Sent from my iPhone using Tapatalk

Lol that’s the one I sold to Shepp a couple of years ago when I was thinking of selling up. I’ve since had seller’s remorse and bought another one from abfmk1.
Looking forward to seeing how it fits-still need to get my new one on the car


Sent from my iPhone using Tapatalk

Ha small world   

Having the remote dual circuit servo, a CQ brake bias setup and then rear disc conversion I think was a recipe for disaster with all the different ratio's and proportioning valve.

The SA version is more minimalistic and efficient than stock so happy to go that route plus I will re instate the scuttle and heater vent once I have the engine running  

Got the inlet manifold flatted down yesterday and this afternoon and coated it up with clear

Tomorrow I'm going to bite the bullet and put the heater hole back in and if I get a chance put the scuttle back but not sure how restrictive it will be with the engine in  I stored both the heater hole and scuttle carefully so I could revert back if I wanted.


 

Started on the heater blower hole. I could still see the welds underneath from where I covered the hole. i drilled up in several places underneath and then placed my cut out on the top in the engine bay and marked it's location. I hope the tolerances aren't too tight as it might be a millimeter out here and there .

I will dig out the heater system tomorrow and try underneath before finally seam welding just to be sure.

I've placed the rain tray in position, I can see where the spot welds are where it mounts to the wing. Needs a good clean up and gentle manipulation but not too bad. I'm thinking about stitch welding from the top as most of the lip where is was spot welded is gone.

Couldn't find my heater unit. Hidden away in a big pile of boxes but still have my old Gti unit which I trial fitted. Looks good I'll get the tack welds ground down and seam welded this week 

Marked up the rain tray to restore it and weld up some unused holes. Noticed I marked the speedo cable hole as weld oops 

Looking good, great to see some progress.

How come you've decided to put them back in after all that work & finished painting the bay?

Super_ted said

Looking good, great to see some progress.

How come you've decided to put them back in after all that work & finished painting the bay?

Cheers chap.

I wanted the VIN number back where it should be and also a decent heater. The BMW electric heater was never going to be great. Plus it keeps it all original  

It gave me the opportunity to clean up the section under the scuttle and remove the sound proofing and give is a smooth finish so nothing lost there.

I will need to respray the rain tray and under it to the seam and probably both inner wings but they just need a scuff up and blow over. I sadly enjoy that sort of thing  

I'm going to get that done in the next few weeks and then back on to the fuel and brake system