Mellow Yellow 3.2ltr 24v Conversion

Update time I made up a bracket to ensure there was no chance of contact with the heater hose:



Fitted a variable heater valve, it allows the coolant to flow in to the heater matrix in varying levels or being completely redirected to the engine.



Then trial fitted the air filter housing. It's a good fit and a change to the radiator support bracket will be a good place to get cool air in but Houston we have a problem.

The air box is sitting too high . I reckon I can change the first silicone over to a 15 degree bend lowering it quite a bit as I'm going to have bonnet fouling issues otherwise. One is on order.


 

Once the fitment has been sorted for the filter housing I need to heat protect wiring, bundle them and protect a few hot spots with all this.



That will finish the engine bay and on to the new exhaust and finish the brakes

Fitted a 15 degree 83mm silicone elbow and the air filter housing sits perfectly with no contact. Unfortunately the world has a shortage of black hose at the moment.

I can wait out and see if I can get hold of a black one or change the coil covers to blue and possibly the elbow to the air box housing but I think that will also be a tricky one to find. What do you guys think?

Also played around with the brake fluid reservoir position. Just need to work out a good location. Might look for a prettier brake fluid reservoir with dual outlets.

Looks really neat! If it was me I’d look for a black version of the silicone hose, but having it all working with the blue one wouldn’t keep me awake at night. The positioning of the brake reservoir looks good in the last photo-with the air intake in place it fades into the background a bit. All in all very functional and clean in my opinion (much more so than my bay!) Great work.


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the_whip said

Ha that's a bit ballsy for my liking

Mike 16vG60 said

Looks really neat! If it was me I’d look for a black version of the silicone hose, but having it all working with the blue one wouldn’t keep me awake at night. The positioning of the brake reservoir looks good in the last photo-with the air intake in place it fades into the background a bit. All in all very functional and clean in my opinion (much more so than my bay!) Great work.


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Cheers chap, I just got an email from ash silicone to say they only do them in blue now. Can't find anyone who can make them black 15 degree and 83mm ID.

Can get 80mm and 89mm but that is far too small and large

the_whip said

Can you photoshop the coil covers as blue please

the_whip said

Cheers chap.

I don't think that looks too bad. I think I'll make the change to blue coil covers as a nod to the R32 and if I can find a black silicone change it over.

Nice work figuring out the fluid reservoir  

Go on, go pink  

Ian

Red is obviously tempting, but blue and yellow are complimentary colours so very pleasing from a designer point of view:

the_whip said

Red is obviously tempting, but blue and yellow are complimentary colours so very pleasing from a designer point of view:

Yes I agree. I looked at the prices of the coil covers and they are £70 from Germany for 6 pieces of plastic : O.

I forgot you can get non adhesive silicone repair tape in loads of different colours including black. I think I will give that a go and re wrap the surface. If it looks naff I can peel it off.

It's worth a shot as looks more OEM.

I say more OEM with a massive forge carbon canister

Yeah, you've actually managed to make that engine look small  

Rich. said

I just love the quality of the images you post. Spot on that man. This is probably one of my favorites of any recent ones you have posts.

That engine looks insane squeezed into that humble MK1 engine bay. Makes my TFSI engine look positively spacious 

Lhasa2008 said

Rich. said

 

I just love the quality of the images you post. Spot on that man. This is probably one of my favorites of any recent ones you have posts.

That engine looks insane squeezed into that humble MK1 engine bay. Makes my TFSI engine look positively spacious 

Ha it looked much smaller without all the stuff added. I guess most people go for a shaved bay look and compromise on brake servo, brake bar and the heater.

I've managed to retain all the goodies but has made it a bit tighter at the back. Loads of room at the sides of the engine though.

Managed to put in an hour after work today but hope to bleed the coolant system, finish the front brakes (waiting for rear proportioning valve to arrive from Germany) and fit the new exhaust tomorrow.

Started by removing the surface rust from my brake disc's. They were new on at the beginning of this never ending project and during the garage build where the car wasn't in a climate controlled building.

Broke out the Deox C, soaked them for 20 minutes and then cleaned and zinc primered.


 

Then sorted out the silicone hose. Really pleased with the finish. Bit shinier than the other silicone but will do the job for now.



And a teaser of the brake calipers 

"It will remove very heavy corrosion, but is safe to use on even the most delicate items"

Really? Brake servo?

the_whip said

"It will remove very heavy corrosion, but is safe to use on even the most delicate items"

Really? Brake servo?

Been using Bilt Hamber products and this for years. Normally leave it over night but it came off super quick. Always works brilliantly especially for old crusty calipers.

Confused about your question? are you surprised people run without servos? I obviously have mine and a big one European LHD Golfs are lucky as servo off the brake pedals in the ideal position. Some people are crazy, I wouldn't run without one!

Ah sorry. It was Kinda meant as one question…

It seemed like quite a bold claim, as though it wouldn't damage anything. So I was wondering if you could just submerge an entire brake servo without damaging the diaphragm etc.