Mellow Yellow 3.2ltr 24v Conversion

That's a bloody great idea Rich. Great fab work.
I've been wanting to do the same but wasn't sure if it would fit but now I'm definitely do this.
Do you have any dimensions I could use to get this cut from a machine shop?

77mk1_R32 said

That's a bloody great idea Rich. Great fab work.
I've been wanting to do the same but wasn't sure if it would fit but now I'm definitely do this.
Do you have any dimensions I could use to get this cut from a machine shop?

Thanks chap. I wouldn't want to give specifics as it depends on the pump unit used and tank. You just need to be careful you have the height for the sender unit and this can be lowered further by shortening the cradle guide rods and spring.

Also you need to be wary of the recess for the tank strap as you don't want the pump sitting on this. Any good fab company should be able to sort this out for you with just the pump unit and tank.

I haven't removed my old tank yet so not 100% sure of the position  .

You won't be able to remove the pump unit from the back seat inspection hatch unless you want to cut it up. I'm not going to cut my rear bench but will replace the pump in the cradle with a new one and test before fitting as bit of a mare to remove the tank on a mk1.
 

Been a little while, car has been in hibernation and will soon be coming out for it's MOT.

I bought a Vibrant Ultra quiet resonator a while back and wanted to fit that. I just want to remove a bit more drone at low revs, it wasn't terrible before and I actually fitted a vibrant bottle style resonator but this is the bigger brother and just fits!

So in order to fit it I had to move the v band on the downpipe back a bit so the lip of the resonator doesn't touch the bottom of the shifter mechanism.

Made the necessary cuts and tacked everything in position.

Then final welds. Please excuse the tig welds, still learning .

Back in place .

So next was making sure the gearshift cables don't touch the new resonator. So made a bracket .

Then a final adjustment:

Finally new wheels .

With obligatory exhaust sound video. Definitely quieter with a slightly deeper growl.

 

Rich. said

With obligatory exhaust sound video. Definitely quieter with a slightly deeper growl.


 

Awesome sound. Nice one!

Nice update Rich. What is left on the list till your happy with it ?.

FXTURE said

Nice update Rich. What is left on the list till your happy with it ?.

What do you mean  . Everything I'm doing is fine fettling. When you carry out a conversion like this there is no handbook on how to do it, you need to make do with what's available and make parts to work. Half the fun is improving and optimising what you have.

Trip up to Stealth Racing this summer so Vince can work his magic. Probably an LSD next.

Then come 2030 when fuel is £5+ a litre, electric conversion  .

Rich. said

Then final welds. Please excuse the tig welds, still learning .

I'd be happy with those welds. I've only got a MIG welder. TIG welds are so much nicer.  

Lhasa2008 said

Rich. said

Then final welds. Please excuse the tig welds, still learning .

I'd be happy with those welds. I've only got a MIG welder. TIG welds are so much nicer.  

Thanks chap, starting to get it now. So much hand, eye and foot coordination with TIG welding oh and getting comfortable for a smooth hand motion.

A lot to process at once and a lot of tungsten grinding to start with   .

My Wording sometime's😄As you say with a project Like yours there is no manual.

Update time Car is now historic tax status .

Few improvements to the fuel system, nothing was wrong with it but I thought there was an opportunity to simplify it drastically.

Bought a gti/diesel repro tank (the one with the cylinder baffle inside to emulate a mk1 gti swirl pot).

Now I've managed to get this working using a deatschwerks dw100 fuel pump on the end of my late cabriolet lift pump hanger. I used a flexible ptfe corrugated line which allows you to place the pump in the cylinder so you have some form of swirl pot.

The issue now is the fuel level hanger float gets in the way of the lines that return to the top of the swirl pot.

No problem turn the hanger so it's facing the other direction. The only issue with this is the feed line is in the wrong position but I made a bend out of fuel line to return the line in the other direction. I capped the return on the hanger and used the side feed on the tank as it returns to the same location .

The next issue is the stock inspection hatch doesn't fit as the back of the tank comes up to the floor and the lines coming out of the hanger are taller.

No problem, fit a cabriolet inspection hatch as it has a raised section in the middle .

Finally the fuel filter with new ptfe pvc coated stainless braided line to the fuel rail. All quick connect as well for quick filter changes.