Mellow Yellow 3.2ltr 24v Conversion

did you cut the lip off the scuttle panel and seam weld on top instead of filling all the spot welds?

can't see how I'm going to grind those spot welds back on mine in the corners between the strut tower and bulkhead

G60RGE said

did you cut the lip off the scuttle panel and seam weld on top instead of filling all the spot welds?

can't see how I'm going to grind those spot welds back on mine in the corners between the strut tower and bulkhead

Hi George,

Unfortunately the original spot welded section was a bit messed up when I removed it so I cleaned the edge as I only cut to where the spot welded flange folded over.

I seam welded from the top as you said. Grinding the weld in the corners was tricky but not impossible.

What you need is an air pencil die grinder with carbide burrs. This is the one I bought Sealey SA673 Air Micro Die Grinder Ø3mm Collet Sealey SA673 Air Micro Die Grinder, 203mm x 347mm x 53mm : Amazon.co.uk: DIY & Tools

Also my 9mm Makita file sander came is handy but if you haven't got one then there are cheaper alternatives now.

It's all doable with a bit of patience.

Going to epoxy prime all those bits and then filler prime and seam seal the underside before top coat

That sanding looks like fun. Take me back to when I did mine  

Ian

Rich. said

G60RGE said

did you cut the lip off the scuttle panel and seam weld on top instead of filling all the spot welds?

can't see how I'm going to grind those spot welds back on mine in the corners between the strut tower and bulkhead

Hi George,

Unfortunately the original spot welded section was a bit messed up when I removed it so I cleaned the edge as I only cut to where the spot welded flange folded over.

I seam welded from the top as you said. Grinding the weld in the corners was tricky but not impossible.

What you need is an air pencil die grinder with carbide burrs. This is the one I bought Sealey SA673 Air Micro Die Grinder Ø3mm Collet Sealey SA673 Air Micro Die Grinder, 203mm x 347mm x 53mm : Amazon.co.uk: DIY & Tools

Also my 9mm Makita file sander came is handy but if you haven't got one then there are cheaper alternatives now.

It's all doable with a bit of patience.

Going to epoxy prime all those bits and then filler prime and seam seal the underside before top coat

the belt sander looks like the way to go.

Hello Rich just read all the 18 page of your post!
What a job I love it!I have question for you.I'm making a 3.2 swap into my scirocco MK1 and was asking myself about the length of the transmission axle, can you give me the size of the 2 axle you bought on eurowise?

Thank you so much

Bergie64 said

Hello Rich just read all the 18 page of your post!
What a job I love it!I have question for you.I'm making a 3.2 swap into my scirocco MK1 and was asking myself about the length of the transmission axle, can you give me the size of the 2 axle you bought on eurowise?

Thank you so much

Thanks for the kind comment.

I must admit I'm not entirely sure how you effectively measure a drive shaft. Mine are designed for the 02a Corrado VR6 gearbox. I have measured them in a compressed state and have included pictures for reference. Take this with a pinch of salt though.

780mm for longest shaft and 460mm for shortest. I would reach out to the guys at retrofication as they make custom driveshafts for the conversion and may answer the question.

Been busy sorting out the body work. I have epoxy primed all bare metal and primed the engine bay ready for a guide coat and then finally seam seal before top coat. The electric meter certainly has been spinning getting the temperature up in the garage to paint lol



Hoping to get the top coat on early next week so the engine can go back in 

Rich. said

Bergie64 said

Hello Rich just read all the 18 page of your post!
What a job I love it!I have question for you.I'm making a 3.2 swap into my scirocco MK1 and was asking myself about the length of the transmission axle, can you give me the size of the 2 axle you bought on eurowise?

Thank you so much

Thanks for the kind comment.

I must admit I'm not entirely sure how you effectively measure a drive shaft. Mine are designed for the 02a Corrado VR6 gearbox. I have measured them in a compressed state and have included pictures for reference. Take this with a pinch of salt though.

780mm for longest shaft and 460mm for shortest. I would reach out to the guys at retrofication as they make custom driveshafts for the conversion and may answer the question.

Thank you you are so quick to answer!
Your measure are good!
I use a BHE engine from a audi TT I bought in UK and a Corrado Vr6 gearbox code CHN!
I'm using epytec engine mount but they have drive shaft pretty expensive so I Tru to find a solution….
Nice work you did can't wait to see the end.

I'm my worst enemy, wanted to get everything super smooth so got some dolphin glaze out:



Spent a day and a half sanding it back then resprayed in white primer but ran out :/

Got the seam sealer in and really pleased with the outcome. More primer has arrived now so will get it sorted this week.



So whilst I was waiting for the primer to arrive I finished the fuel system.

The lift pump in the tank fills the swirl pot using R9 rubber fuel hose. The remaining connections are using quick connect fuel fittings and nylon fuel hose.

The fuel filter / pressure regulator is mounted in the accumulator position with a stainless cradle from Crazyquiffs.

I'm going to make a change to the rubber hose connections with a 90 degree bend so there is more clearance from the wheel tub and chassis leg. The current connections are on swivel nuts so once I add the fuel line clips will pull away from any abrasive areas.


 

Final coat of primer in the bay Flat tomorrow and colour on Saturday Forgot to seam seal the rear corners under the scuttle panel where the bonnet hinges attach so did that tonight and will prime tomorrow. Hoping to get the engine back in the following Saturday and back on wheels for final assembly

No more paint to do yey Really happy with the outcome.

Going to prep the engine again for going back in on Saturday but need to be really careful I don't trash the paint on the way back in.

Bergie64 said

Rich. said

Bergie64 said

Hello Rich just read all the 18 page of your post!
What a job I love it!I have question for you.I'm making a 3.2 swap into my scirocco MK1 and was asking myself about the length of the transmission axle, can you give me the size of the 2 axle you bought on eurowise?

Thank you so much

Thanks for the kind comment.

I must admit I'm not entirely sure how you effectively measure a drive shaft. Mine are designed for the 02a Corrado VR6 gearbox. I have measured them in a compressed state and have included pictures for reference. Take this with a pinch of salt though.

780mm for longest shaft and 460mm for shortest. I would reach out to the guys at retrofication as they make custom driveshafts for the conversion and may answer the question.

Thank you you are so quick to answer!
Your measure are good!
I use a BHE engine from a audi TT I bought in UK and a Corrado Vr6 gearbox code CHN!
I'm using epytec engine mount but they have drive shaft pretty expensive so I Tru to find a solution….
Nice work you did can't wait to see the end.

I suggest you contact Dave Mac propshafts in Coventry, https://www.google.com/url?q=https://davemacprops.co.uk/&sa=U&ved=2ahUKEwiSpoSCifzmAhVwQ0EAHSaTAWQQFjALegQIBxAB&usg=AOvVaw23GA6bKwq81Vrn0Hskecdw Dave is class leading in shafts and you will deffinately get custom shafts of the best quality.
Marcus.

Rich. said

No more paint to do yey Really happy with the outcome.

Going to prep the engine again for going back in on Saturday but need to be really careful I don't trash the paint on the way back in.

Lovely job, looks mint!



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Mike 16vG60 said

Lovely job, looks mint!

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Cheers Mike, going to wet sand and compound tomorrow night to get more shine

Got the chassis reinforcement bar painted tonight

mint!

how did the chassis number come out after the top coat?

G60RGE said

mint!

how did the chassis number come out after the top coat?

Cheers chap, it came out really well.

After the white primer I pealed the masking tape off and feathered the white in to the existing yellow by the VIN with sand paper. I then masked off the vin so it was barely covered.

I applied 3 coats and then on the final coat pealed the taped off and applied a light coat.

that is coming along nicely now. Love the color.

madone_si said

that is coming along nicely now. Love the color.

Yellow wouldn't necessarily be a colour I would pick on a car but when I first saw her I fell in love with it.

Cheers

Rich

Got the suspension and wheels back on tonight and looks like i just need to lift the car a little bit more to slide the engine under on Saturday.

Going to give it a clean up tomorrow