Helios Blue Campaign

Man Flu is stopping play at the moment  :cry: BUt here are a few things I got done before I went away for a bit…

Here is a pic of those pesky rubber washers that sit on either side of the engine mounts, the ones I forgot to put back in   Managed to get them in now though. Im sure it would of been fine without them, but may aswell put them in as I have them!



Also, Got my standard exhaust fitted, turned the back box slightly so that the tailpipe sat at a nicer angle.











Im pretty happy with it! I do have a piece of 2" stainless pipe which I was going to slip over the top of the tailpipe and tack into place but looking at the standard tailpipe I quite like the size of it! It looked a bit big with the 2" on it tbh!

Anyway, it'll do for now, if I feel the need to change to a bigger pipe I always can at a later date.

Then I moved on to finishing the brake lines. After a few hours  :roll: of working things out I managed to get it looking fairly neat. I was trying to avoid having any copper brake pipe on show, I had 3 green pipes left to work with, of various lengths. Im happy with it anyway!



You can see the two brake light switches here. The only piece of copper pipe I used was down here just to extend the pipe so that the brake light loom would reach the switch.



And the one t-piece out of the master cylinder is hidden once the fluid reservoir is fitted.



It got a little windy down in S.Wales a few weeks ago! So windy that it blew a piece of my roof off!!





Made a slight flood, lol.



Luckily there was no damage to either of the mk1's!

A quick botch up and she was right as rain so to speak



Once we had fixed the roof, I riveted on my vin plate and bonnet catch



While the rivet gun was out, I riveted the ignition module back on the bracket

Whilst  had a bit of spare time on work, I turned my attention to my grille trim. I had tried to refurb my existing one but had a little accident which ended up in them being bent beyond repair  :redfaced: Luckily though I won a chrome grille on the bay for 20 bucks, I took the trim off and painted it up!

First I cleaned them up with a very soft wire wheel…





I then noticed a little dent,



So out came the filler!!



Gave it a quick skim



And sanded it up once it had gone off…



I then wiped them with panel wipe and used masking tape to stick them down to a piece of wood for painting.



Gave a coat of high build to fill in all the little imperfections and pits..



After a quick rub down once dried, gave a coat of red primer…



Then came the mars red…



And finally, a quick coat to 2pac lacquer to protect..





Also painted up the chrome badge to black. Cant believe I managed to get the badge free from the grille without breaking the tabs, I usually break em!!



Before…



Primer…



Black paint, finished with matt lacquer for protection from stones etc



Thats it for now. Hopefully have the engine done soon so I can start on the interior!

fab work as always.....

Swallowtail_uk said

fab work as always…..

Thanks Bob!

Hows yours coming along?? Last post I saw on your build was of your washer bottle motor.

Who knew someone could turn a washer bottle motor into a work of art!! Top work. Your car is going to be OTC  8)

Top notch mate. Excellent work. :clap:

smudger1980 said

Top notch mate. Excellent work. :clap:

Thanks  

rosie81 said

Nice explanation I think we all appreciate the effort taken with your reply especially when about to paint up a box like I am soon.

Great job

Sorry Rosie81, must of missed your reply! Glad my babbling is of some use  

About time for an update I suppose! Here are some pics of the grille finished





Finally received my fan cowling from CrazyQ, so I could build my fan back up!



It was the last piece of the engine puzzle, once this was fitted I managed to get the engine running! Very lumpy at the moment and wont idle, but it starts and you can rev it  so thats a good start! Will finish the rest of the build then take it to a k-jet expert. Anyone have any tips on how to set up the k-jet properly?

Heres a couple of the engine







I turned my attention to the rest of the car. Started with the headliner  lol

Turned out pretty good, managed to re use the original one so it was pretty simple, I guess after 30 years of being in the car it was moulded to the shape of the rood so putting it back in wasnt that difficult!

Raided the office in work and home for every bull dog clip I could find 













And the finished result, sorry about the rubbish pics…





Tailgate went on…



And windows went in, bar the windscreen as I ran out of time!

Also got the sunroof in…





Scratched it when putting it in cf_emoticons__BangHead:

Absolutely gutted, wil have to blow this in when shes finished!

Stuck my new badges on..



Also got some new bits delivered..



Including a new seal for the drivers door as mine had shrunk about 5 inches!

Bought some second hand mirrors of funk-star on here, top service and mint wing mirrors! Cheers.



Unfortunately one of the remote threads was cross threaded, but my mate lent me this rather handy tool!



A thread cleaner! Worked a treat. Will be buying one of these as soon as possible, great for the toolkit.

I am missing loads of pics, I have rebuilt all the doors now, took the regulators out and greased them so the windows work nice. All other locks and moving parts have also been greased.

Fitted the rear seat belts and shelf supports…



And fitted the spare wheel and genuine wheel strap..



Then fitted the carpets…





SHould hopefully have the interior finished off this weekend, hopefully if she will drive enough I can take her to be tuned next week Well see! haha.

wow looking great brillaint job you doing . i just love this colour

peterg60 said

wow looking great brillaint job you doing . i just love this colour

Thanks Pete, cant wait to get her on the road now!!

absolutly awesome build and in the best colour!! top work!!

Great build! Love Helios, such a good colour. Gutted about the scratch but sure it will fix up no problem.

Have to say I've never seen so many bulldog clips in once place before!  

mk1_FSI said

absolutly awesome build and in the best colour!! top work!!

Cheers, I love the colour too. My fav!

Hairyarse said

Great build! Love Helios, such a good colour. Gutted about the scratch but sure it will fix up no problem.

Have to say I've never seen so many bulldog clips in once place before!  

It is a shame about the scratch, siht happens though I suppose! It was never intended to be a show car, just a like new daily driver! So it was always going to happen sooner or later!!   Will have it blown in when funds allow!

I had to chuckle myself with the bulldog clips! I raided the office at home and work and bought about 100 off ebay!  

I do have an update coming soon! Kinda got carried away with her as things are picking up pace now!

But Ive hit a snag with the front wipers!! I fitted a mk2 wiper motor, but when they 'park' they stop in the middle of the screen!! And the very fast mode doesnt work at all. Ive only got two settings, intermittent and normal speeds.

Here is a video in intermittent mode…



As you can see they park in the middle of the screen!??

Could I have wired them up wrong? All the mk1 wires were same colours as the mk2 ones and I even used the mk2 plug too to make it look factory. Or have I lined the mechanism up wrong??

Anyone else converted to a mk2 wiper??

As you can tell from the above post I have the windscreen in!   And the front end on! Will post some pics up soon!

pet73r said

I had to chuckle myself with the bulldog clips! I raided the office at home and work and bought about 100 off ebay!  

You'll have to rent them out to club members - 'Headlining fitting kit'  

im jealous, love a helios blue one

Wonder if anyone following the thread can help me?? I have also made a post on this in the technical area but the more answers the merrier!!

---

My plan was just to get her to a drivable state so that I could take it to a specialist to be set up properly. But at  the moment I struggle to get it started.

The engine is a 3A block, with a Late Cabriolet head (i think) part number on the head is 026 103 373 H, Im using an Audi 2.2 throttle body and WUR plumbed in to the vacuum system. I am using the k-jet injection system off the DX engine that originally sat in the car. Infact, everything on the engine apart from the aforementioned parts are from the DX engine.

Where I could I have used new parts, such as leads, dizzy, rotor arm, plugs, all filters, new injectors with new rubber seals, all new seals and gaskets for the block, washers nuts and bolts etc! Everything that could be replaced without massive cost has been replaced.

Timing is set up correctly following the guide on this forum. So it is currently set at 0 degrees as I have had no way to warm the engine up to set it to 6 degrees. And there is a good strong spark from every plug.

When I try to start, engine turns over for about 20-30 seconds before even thinking about firing. Eventually it will fire but then it will be very lumpy and rough and will just stall unless I keep my foot on the throttle. It will not idle. If I allow it to cut out, its the same when trying to start it up again. Takes ages cranking her over for her to start, sometimes it wont even start.

I decided to try and warm the engine up a little and see if it would run better as it has just been rebuilt and may need to be run in a little?! So I kept it running with my foot on the throttle for about 3-4 mins before I decided to slowly let foot of throttle to see if it would idle. It didn't. It cut out straight away. But upon trying to restart it, it fired first time of the key idled for about 1-2 seconds and then cut out again, I tried this a few times but it kept doing the same, idling for 1-2 seconds and then cutting out, it wouldnt even let me rev it up. By this point I noticed that the fuel pump had become noisier than usual, a mate said that it may be low on fuel, which it was, so I chucked in another 5 litres of fuel after about 20 mins and tried again. This time it went back to its old tricks… Taking about 20-30 of cranking before it would even think about firing! When I pulled the plugs out, this is what I saw….



Very wet (petrol) with carbon like deposits. So I assumed that it was probably running rich, so I adjusted the CO screw anti-clockwise to lean the mixture a little. This had minimal effect. Car doesnt even fire now! I made sure that the cylinders were not flooded when I tried to start again.

So, ive got a spark, Ive got fuel and it runs (just about ) So where do I start to look to diagnose whats wrong with it?! I am fairly new to k-jet having always owned carbed mk1's before and only ever owned 1 mk2 16v with k-jet which actually ran like a dream so I never had any issues with it, thus, didnt learn much about k-jet! All other VW's have been DigiFant. So Im a bit stumped.

Im sure its something simple, but I really have no idea where to start looking??

Flap in metering head moves freely, I know that much!  And was fully cleaned before being re-installed.

Any info on how to diagnose my problem would be greatly received!! Many thanks for your time, if I have missed anything that may help you geniusus please let me know!! 

Could it be a vacuum leak?
Where did you buy the exhaust system from?