Skip navigation

Mk1 16vg60 build, slowly but surely

Post

Back to the top
Managed a little more progress with the help of the bodyshop.  They have yet to get started with prepping and painting the car but ive managed to get a few more things sorted in the engine bay.  Started with the G60 airbox;









  Its going to be tight with the serp belt but should fit.  Need to weld three lugs on so i can secure the airbox properly with the rubber bands that hook on.



  Attached the fuel pressure regulator.  Quite tight again but should work ok.  Will have to make an adaptor hose up to connect the gauge to it for setting the fuel pressure up.




  Routed the fuel hose, just need to get some tabs welded on to secure them properly.


  Fitted the fuel filter bracket, just need to fit the wiper motor to make sure everything is going to fit ok.



  Had another trial fit of the intercooler and radiator as the bodyshop had fitted it in the wrong position whilst i was away.  Just need to raise the intercooler up 20mm or so to get some more air flowing over it.



  Got the engine back from the engineering shop after having the bores rechamfered and rehoned, block blasted and painted again as wasnt happy with it and a helicoil fitted to the crank oil seal mounting bolt hole.  Going to start rebuilding it tomorrow.  Slow progress but hopefully going to take shape soon.

Last edit: by daniboy123

Post

Back to the top
Looking good.

Don't raise the intercooler too high otherwise the bonnet catch will not engage and you will dent your intercooler when it tries !

Cheers,
Ade

Banner


Post

Back to the top
 I hadn't even thought of that ade! Spunds like the voice of experience talking there lol
  Would there be any chance you could measure how far across your serp belt  is from the inner wing so I can gauge what kind of clearanceill have with my air box?

Post

Back to the top
Yep, first fit brought it to light !!

It is about 52mm from the edge of the belt to the centre ridge on top of the chassis rail.

A couple of pics:

C:\fakepath\image.jpg C:\fakepath\image.jpg

Cheers,
Ade

Banner


Post

Back to the top
Excellent thanks for that. I'd say it should fit but I'll take some measurements next time I'm at the body shop to make sure along with fitting the bonnet catch.
  I'm unsure what to do with the fuel supply pipe that goes straight to the injection rail. From memory there isn't really anywhere to secure it is there?

Post

Back to the top
 Thought I'd make a little update after chatting with the body shop. They agreed to let me come in and work on the car to save myself some money. I started another thread about the cost of my respray which was looking to be around 7K. I'll save myself a good bit by stripping the car myself. We decided to take the majority back to bare metal as there were a few suspect looking areas.


 The N/S quarter had a load of filler hiding quite a nasty dent which ive been told can be pulled out;



  A combination of paint stripper and a heat gun and many hours scraping and washing paint stripper off my skin got me here;



  You can just make out how the arch has been modified in this picture. The return has been removed and a section added to bring it out further, should avoid any clearance issue with my bigger wheels.

  I continued onto the front wing which thankfully wasn't hiding anything sinister;




  Here's a few pictures of some of the repairs that have been done so far, I only got a few yesterday but ill get some more next week;





 Scuttle area had to be cut out and repaired;



Other side;



 I've stripped the sill and made a start on the scuttle panel.






 Plan is to bare metal everything apart from interior, engine bay, door and boot shuts which are all looking ok. Main things that bothered me are ripples in the rear quarters and doors so hopefully we should get it a lot flatter this time.

   The biggest repair was to the sunroof area. We ended up removing the cassette completely so the the roof skin could be repaired properly, and the cassette also  repaired, shot basted and primed then fixed back in place. It will need a skim of filler but I'm happy with the way it turned out, will get some pictures of this area next week.

  I've decided I want to relocate my filter to the engine bay from the scuttle area as the way i had it one of the fuel lines was going to be using the hole for the scuttle drain tube. I was thinking about this location;




  There are 3 holes here and I can't remember what they are for? I don't think there is any reason I couldn't put it here put I need to look at my mates mk1 to be sure.

I want to weld a few tabs in to secure my fuel lines along their new route and also remove any unused tabs from the bulkhead and inner wings. I can't for the life of me remember which tabs are needed and which arent;




My plan was to run hard pipes into the engine bay and up behind the steering rack then onto braided hose, just need to figure out a good route and secure them properly.

  Not much of an exciting update really, my hopes for bringing it to the NEC stand are well and truly dashed now and I've set my sights on trying to have it finished before my 40th  birthday at the end of may next year.
  More pictures to follow :).






Last edit: by daniboy123

Post

Back to the top

Mk1 16vg60 build, slowly but surely

Coming on, lots still to do though !!

Those holes were used for the coil mount, I had my boost pressure sensor mounted there as it is external to the Emerald ECU

Cheers,
Ade

Banner


Post

Back to the top
Cheers ade, yes still plenty to do, feels good being able to get stuck into it on the body shop front. Next I need to ask him if he minds me doing a little welding in there as I've well and truly blown my budget and it's not in paint yet!.
  So that area looks a good bet to weld the brackets for the fuel filter then. I'm planning on attaching my map sensor to the ECU bracket I'm making which will all sit in the scuttle area.

Post

Back to the top
A quick update although nothing drastic. Car is STILL in the bodyshop due to work drying up for a while and lack of funds, ive managed a little progress including completely stripping the floorpan.  Ive just started seam sealing it and prepping it for body colour stone chip.  Ill get some pictures up soon when im home from work.
  I have a quick a question if anyone can offer any advice.  After speaking with a 16vg60 specialist i had fittings welded onto my rocker cover, crankcase breather plate (where the rear charger bracket would normally bolt to) and onto my sump.  The plan was to pipe the crankcase and block to my catch tank and then pipe this back to the sump.  Having spoke with the specialist again i was advised this is not the best set up for this engine.  Has anyone much experience of this or any suggestions on how to imrove it?  Thanks.

Post

Back to the top

Mk1 16vg60 build, slowly but surely

I wouldn't pipe it back into the sump as what you get in the breather is emulsified oil that you really don't want back in the engine. I had a rocker cover breather for a while, but I deleted it as at high revs oil would was pushed down it and filled the catch tank rapidly.
I just run a single pipe off the front of the block to a catch tank, seems to work well.


Sent from my iPhone using Tapatalk

Cheers,
Ade

Banner


Post

Back to the top
Thats what i was worried about but i was assured that what moisture there was would soon burn off as soon as the engine was upto temp.  I think the problem is when you dont drive the car and get the oil upto the correct temperature.  Where did you have the fitting on your rocker cover just out of interest?  Sounds like i may have to blank that off at least if i get the same issue.

Post

Back to the top
When I clean out my catch tank I am glad that it is not drained back into the sump!

On the rocker cover I had a beetle breather that replaced the oil fill cap, I think that there is just too much thrashing about from the twin cams and that coupled with the crankcase pressure that the 16V develops when revving.

Cheers,
Ade

Banner


Post

Back to the top
Well ill keep a close eye on it and just run with what ive got.  Going by what you have said ade and after reading around, venting the crankcase seems to be the answer to any breathing problems.  Ill just blank off the sump return and rocker cover should they prove to be more of a hinderance than a help.
 On another note Ill be running a cabrio tank with lift pump which will feed a swirl pot, fuel pump, fuel filter then engine and i want to tuck all of this underneath the car.  Obviously the lift pump is in the tank but i need to find a space for the filter and swirl pot.  Be interested to see how others have done this if anyone has any pictures.  Im thinking of mounting the swirl pot in the accumulator bracket then maybe the filter bracket onto the fuel pump bracket.  Be interested to hear/see how others have done it.
  Ade have you done much to yours of late?  Any spaces on the NEC stand this year if i can get mine finished in time?

Post

Back to the top

Mk1 16vg60 build, slowly but surely

Mine uses a standard 1983 GTI tank, the one it left the factory with :-) My fuel filter is in the accumulator position.

I have fitted pop out rear windows :-)

NEC spaces are usually filled with winners from the AG in July. CabrioAnna deals with that


Sent from my iPhone using Tapatalk

Cheers,
Ade

Banner


Post

Back to the top
Yea id have stuck with the original tank as that has a built in swirl pot but mine was no good and the replacements dont have an integral swirl pot.  I didnt realise the NEC spaces were filled with the AG winners, id best get cracking then lol.  I do like the look of those pop out windows,  Eye wateringly expensive going by the last prices i saw for them.

Post

Back to the top
Going to be plodding on with this again soon. Where have people routed their hydraulic clutch pipe? I notice there is a hole near to the steering rack that I could route it through although it would mean the pipe would run under the carpet.

Post

Back to the top
Anymore up dates dan

Nas
0 guests and 0 members have just viewed this: None.