Mellow Yellow 3.2ltr 24v Conversion

AudiAnt79 said

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

Ant

Brilliant, thanks Ant. How long did you own her for?

If you have more pics that would be great.

The guy I bought the car off said he would send the photos of the car when it was sprayed yellow (owner before him) but he never sent them Are you in the Derby area? I traveled up there to buy her.

Was a 1.4 16v then:

lot of great work as always Rich.
Keep it going can't wait to see it running.

Small update. Been slowly nibbling away at the things on the to do list. Should have a bigger update tomorrow hopefully.

Got the hydraulic clutch master cylinder installed. I decided to route the braided stainless steel lines in the cabin out of the way of the headers



The corrugated plastic breather pipe between the inlet manifold and the rocker cover had become brittle and broke so replaced it with a new hose



Got the radiator hoses made up. Had originally intended to go all silicone but couldn't get the right angle and the hose was bent like this so ended up cutting a section of the original coolant hose which worked a treat. This is an area I would eventually like as all alloy piping but this will get it running for now. On the lower line you can't see it but there is an alloy T pipe which goes off to the aux water pump as I'm still running this.



Started to fix the fuel line to the car. Wanted to rivet nut the fixings but my tool is too large for the location so have a smaller one coming to get in that tight space. Temporarily fixed the fuel line with a cable tie anchor. The fuel line is quite rigid and would benefit from another anchor where my hand is lower down. The fuel line will also be wrapped in a heat resistant sleeve when it's finished.

I have a quick connect fitting at the front and it's a continuous nylon line to the fuel filter fuel pressure regulator.


Tomorrow going to finish off the battery connections to the boot and possibly fill with fluids to see what happens. This is what I have to deal with lol



I opted for an 096 AGM battery which is the same that would be boot mounted from the factory for the engine. I have a battery mount tray which will fasten to the wheel well.
 

Looking great Rich, inching ever closer to the start up.

Just more wiring today lol

Only have the fuel pumps to connect and the the ignition trigger Started off laying the power and earth, wrapped in braided sleeve and convoluted tubing where it passes through the body.



Then got the final sound insulation down. Should help with the noise 

Earths sorted





 

Just need to mount the ecu and relays next. Hoping to sort that out tomorrow after work  

Looking forward to see the start up mate And wiring looking good

Where did you get that sound proofing ? And is it with a MLV layer on top ?

Hummel said

Looking forward to see the start up mate And wiring looking good

Where did you get that sound proofing ? And is it with a MLV layer on top ?

Thanks chap Hummel

Didn't think the wiring would take so long but want to get it right first time.

Bought the MLV from a UK sound deadening specialist about 6 years ago and had quite a bit left over from a previous car installation.

 I will see if I can dig it up from old emails. I installed the same stuff in my bothers MK1 GTi with the bitumen based stuff and the difference was crazy.

I have some to mount to the fire wall with double sided velcro but will leave that to the end when everything is done.

I was meaning to ask you, are you running a hydraulic clutch like me? Where are you going to hide the fluid reservoir?

Looking good.  

The attention to detail is inspiring (can also be read as mine looks rubbish compared to that and makes me kinda want to go and do it again)

Ian

borednow said

Looking good.  

The attention to detail is inspiring (can also be read as mine looks rubbish compared to that and makes me kinda want to go and do it again)

Ian

Thanks Ian, i think it's mostly down to an OCD lol

I want to get this right so I don't have to touch it for a long time and start to enjoy the car. So close now, going to get the last fuel union fitted after work today.

Not sure how fuel tight the Bosch 040 pump is in my surge tank as it was weeping the other day so have replaced the o rings so finger crossed.

Might have to buy a new carb tank and then modify it to accept a modern fuel system to reduce a lot of pipe work.

This is epic! So inspiring, well done! 

vdubber2 said

This is epic! So inspiring, well done! 

Cheers chap

Quick update and hopeful a bigger one tomorrow.

I emptied 10 litres of stale fuel from the tank and remade some lines so they flow a little easier. Will get some pics up tomorrow for that.

Today my integral fluid reservoir master cylinder arrived for my clutch.

Just quickly swapped it over and fits a treat

Your MLV/CCF is upside down, no?

the_whip said

Your MLV/CCF is upside down, no?

It was a test and you passed sir

I'll turn it around tomorrow. Should make it fit better as well  

 

Nice job shaping it. It's a pain to work with.

OK first thing I did was flip over the MLV   the_whip



Then I sorted out the fuel lines. I have a protective sleeve and a couple of mounts to put in plus a plate to mount over the connections to protect them but they are high up out of the way. Just being extra precautious.



I then attempted to bleed the clutch, boy what a nightmare. Just as the clutch was feeling good the teflon internal ruptured in the braided line and fluid went everywhere. It was where the pipe was behind the heater box in the car. I was cleaning the carpet, paint and wires  plus I used super blue dot4 (have normal coloured stuff for brake lines) as I had it a while ago unopened and at the time didn't realise it has to be a specific colour for MOT's on brakes.

Have some new line coming next week.

Then I filled the gearbox with fluid, stuck some new plugs on as well

Added the engine oil, new sump plug, washer and an alloy oil housing cap.



Then started to make a caddy for the ecu to mount to.



So very close now to a start. Going to finish the wiring tomorrow and then all I need is some fuel and off we go  

Rich. said

So very close now to a start. Going to finish the wiring tomorrow and then all I need is some fuel and off we go  

Keep us posted!

so close

Mini update,

Finished off the ecu mount and added a relay holder as the Eurowise version doesn't have any means of mounting them. Keeps them in a nice neat package all together by the fuse box.

Just need to mount it under the dash and add some rubber stripping under the ecu and the side tabs.

Also added the main boot earth. It was actually a point I used for my boot amps in the past. A captive nut in the chassis (does anyone know what its original purpose was?) cleaned it back to bright metal and then used battery terminal grease to protect it.