Mellow Yellow 3.2ltr 24v Conversion

Sounds lovely!

Sounds really good! and not as much of a resonance around 2500 as mine…

Amazing car for sure!

paceman said

Sounds lovely!

Hummel said

Sounds really good! and not as much of a resonance around 2500 as mine…

Amazing car for sure!

Thanks guys, I'm really pleased I went this route. It's super quiet cruising and when you need it bwaaaaarp  The car is feeling planted. I haven't really chucked it around but the car feels incredibly nimble still and steering super direct.

The clutch is perfect and the gear shift is beautiful. Glad I switched it back to standard 02J shifter mechanism with all new bushings rather than short shift. Absolute pleasure to drive.

Another little snippet. - YouTube

Doesn't hang about does it!

paceman said

Doesn't hang about does it!

It would definitely be easy to lose your licence. It gets through the gears quick.

I don't generally drive around like that btw  . Demonstration purposes only.

Proper Sleeper in a Golf C

You'll never get tired of listening to that noise when you bury your foot!

Fantastic build.

Pistol said

You'll never get tired of listening to that noise when you bury your foot!

Fantastic build.

Thanks Pete.

Already through half a tank of super in 100 miles  

Update on this one .

Had a bit of an issue with the strut mounts.



The Meyle ones have only done 100 miles and gave up .

Didn't really want to go solid mount as don't want any unnecessary vibrations so decided to enhance a set of Febi ones by filling with Poly Urethane.



 

Next mission is electric windows.

I've managed to get hold of some converted stock regulators which appears to use Ford Sierra Bosch motors. Direct bolt in job.



Gave them a good clean up



What does VW recommend to lubricate the corkscrew drive? White grease?



I have mk2 Golf gti centre console switches with the harnesses so only need to route 2 additional cables per door.

This car just gets better and better Rich! Bloody awesome


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Just read your thread start to end, what an amazing job you have done, hats off to you, you have done some fantastic jobs and creative solutions to create a car you can be mega proud off

Hi Rich!

how is everything ? Still running good ? I finally upgrade my fuel pump setup, what a reflief! I can't hear the pump at all now and i can go around corners without fuel starvation I ened up with a new tank and welded a stainless plate on top to allow a complete golf mk5 fuel tank insert to fit. Maybe I upload a few pics on my thread.

anyWay I have a question, my car isn't running that great, something is keeping it back in the ECU. How did you get around the VSS signal issue ? Did you code it out if the ECU or did you put some sort of resistor or fake sensor in the harness ?  

It is the only alarm the VCDS shows me, VSS signal Implausible MIL ON :O

jakethepeg007 said

Just read your thread start to end, what an amazing job you have done, hats off to you, you have done some fantastic jobs and creative solutions to create a car you can be mega proud off

Sorry for the late reply Jake. Thank you for the kind words. Glad I got to a point where I could enjoy it this summer  

Hummel said

Hi Rich!

how is everything ? Still running good ? I finally upgrade my fuel pump setup, what a reflief! I can't hear the pump at all now and i can go around corners without fuel starvation I ened up with a new tank and welded a stainless plate on top to allow a complete golf mk5 fuel tank insert to fit. Maybe I upload a few pics on my thread.

anyWay I have a question, my car isn't running that great, something is keeping it back in the ECU. How did you get around the VSS signal issue ? Did you code it out if the ECU or did you put some sort of resistor or fake sensor in the harness ?

It is the only alarm the VCDS shows me, VSS signal Implausible MIL ON :O

Everything is great this end thanks chap. Just fine tuning everything now but really pleased with it and can't stop grinning.

Yes get some photos up on your thread, I need some tips so I can do it as well  .

So the vehicle speed issue, I bought this for that problem and it also makes my stock clusters RPM counter work https://www.vdveer-engineering.nl/index.php/en/products/can-controller

https://www.vdveer-engineering.nl/en/shop/can-convertors/can-convertor-rpm-mk1-mk2-detail

It takes the vss signal from can bus and feeds it back in so the ecu knows the current speed and you no longer have this message and there is no restriction after a certain RPM.

As well as that did you check the clutch switch wires are wired correctly at the ECU so the it doesn't think the clutch is engaged? I think I put something about this and the blocks to check in VCDS on the last page. If you can't find it let me know and I will dig it out.

Cheers

Rich

Switched over to winter maintenance.

Wanted to do some improvements such as adding a catalytic converter and additional resonator, adjust the exhaust as the tailpipe was hanging a bit low, undercoat the car as it's been a while since it was done last and switch the gearbox over to a V5 02J.

So started on the exhaust, got a new TIG torch and have been practicing as I don't want to mess up the exhaust! I have a vibrant bottle resonator and a 200 cell magnaflow sports cat.

Fortunately the resonator and cat were pretty much the same length as the existing joining pipe.

I made a v band heat sink / purging block so I can avoid distortion and ensure the inner weld is shielded as well.

Started by making some rainbow slugs on 20 gauge stainless .

Then things got serious quick  .

Started welding it up  .

Then I got everything aligned and the tailpipe in position and really happy Got a test run of the engine and sounds a bit quieter, less smelly and no leaks fortunately. Though the resonator will only really be noticeable when on the road.



 

So next the gearbox.

The o2a CCM I currently have is very tall geared due to the final drive 3.3.

I live in the Devon countryside and have beautiful fast twisty roads to use and no autobahn to cruise  .

Ideally I would swap the final drive to a 3.6 but as an interim solution I have got my hands on a FBK V5 gearbox with a 3.9 final drive. This is very short ratio'd which should make for an exciting drive but at the cost of screaming along at 70mph  .

To get round this I will be fitting a 0.717 5th gear to reduce the cruising speed. So close ratio 1-4th and a long 5th.

Eventually I will probably custom build the 02a with the 3.6 final drive and an LSD.

The box needed a good clean up but should go in on Saturday. I need to switch the refurbed end cover off my old gearbox to finish it off.