76er Swallowtail K-Jet turbo build

[velly_16v_cab]

great result guys, i will pop around for a blast some day soon tim

[gldgti]

sounds brilliant. we need a private server for video hosting

[Oneofthegreats]

Ok. Alittle update.

The car has now done 20K on the turbo setup & all has been going well until last Fri. night when the gearbox decided to start making some unusual noises which were more prominent in 2nd gear. (this is the powerskid gear, so it copes all of the abuse I dish out to it!)

I thought. Bugger it & I'll keep driving it. Whats the worst that can happen? right?

So I've been bumming around in it for the last couple of days & with a last minute decision to head upto the VW Jamboree, I was off with gearbox noise in tow.

By the time I finally got to the park, the car was making a loud enough racket that I could hear it over the engine especially in 2nd gear! Even with light taking off & babying it ,it was noisy as hell. You could even just have it idling away in neutral & it was noisy.

So after the show, we heading back to Waterboys house for a catch up & once again we were off. Well by the time I got into Melb. people were actually taking notice at how loud the noise had become in traffic! haha

But I pushed on (more like babied on!) for the 2 hour drive & finally made it into my driveway where on arrival it went ""BANG""

It locked up in 1st gear & had no drive what so ever. The noise in neutral & idle is unbelievable! Just full of bearing & crunching noises! Lucky it didn't punch any holes in the casing either. But by the sounds of it, I reckon its junk!


So I'll bang in the ever trusty diesel 4spd which I always rely on in need which has never let me down.



that is until I push god knows how much power though it! Only time will tell.

I'd post up a vid of it idling away, but I have no idea how to upload vids off the camera & they are bloody massive files too!

[Golf Loon]

Thats Gold that the old girl got you home, then died on the driveway.

I have some great TDI 020 boxes that have awesome ratios for what you are doing with it and are strong enough to hold the power. Hit me up if you feel the need.

[Oneofthegreats]

Thats Gold that the old girl got you home, then died on the driveway.

I have some great TDI 020 boxes that have awesome ratios for what you are doing with it and are strong enough to hold the power. Hit me up if you feel the need.

Thanks Matt!

Your right about getting me home & then dieing!

It broke a clutch cable last Wed. in peak hour Melb Westgate traffic & I had to nurse it over to St Kilda for a important meeting & then had to get over to Essendon through the city to replace it!
I could only manage just a tiny amount of clutch for takeoff only & had to go clutchless the rest of the trips. The pedal sank to the floor as usual!
When I removed & inspected it was fried to the max & only was holding together by 2 strands!

I reckon I've replaced more clutch cables & components in Mk1s than I have replaced brake pads, discs & also any light globe in a mk1! They are bloody terrible! But that's the joys of running a heavy duty clutch!

I'll definitely keep this in mind, but I reckon the TDI boxes may put alittle too much load on very tired old engine under long periods of boost.
I'm not really into crazy long ratios or top speed.


You can only do 100, but its more about how fast you can get there, or turn the tyres trying! haha.




I might just try the stock old 4 spd for the time being, as I'd really like to hopefully get some sort of movement on the custom auto build up

[GRN_VAGN]

Will have to come and have a look when im in Melbs in couple weeks.

Thats pretty awesome about the box lasting the 2 hour trip home haha!! good work VW!

[Jarred]

Funny how your cars always seem to get you home isn't it Tim?

the old 8V and now the gearbox finally!

[Oneofthegreats]

Funny how your cars always seem to get you home isn't it Tim?

the old 8V and now the gearbox finally!

True!!!!


It must just be that the car knows that I'll look after it & if it gets me home it will get good going over.

The 6 hr trip home from wagga with a severely blown head gasket comes to mind!

http://www.vwwatercooled.org.au/newforum/upload/showthread.php?t=38088&page=2

Post #17 onwards





Funny. My old silver banger was a jealous bastard!
When ever I'd get another car, it would chuck a hissy fit & either start playing up or jinx the other car!

Especially when I swapped a spare mk1 for a 350ci Landcruiser "shorty" to be my daily & it blew up the first day I got it!

[Oneofthegreats]

Masters of Destruction

Well I finally got enough motivation to get out into the shed & carry out what I thought would be a straight gearbox swap.

Not too be.

Once I removed the gearbox, I found bits & pieces of metal fragments inside the bellhousing & scratch marks all around the flywheel!

So off with the clutch & with a light I also found not only did I destroy the gearbox, I also destroyed the clutch drive plate!!!!!!

On with the pics

Think of your clutch plate drives your gearbox input shaft & from friction material drive section (outer section) is drives through a set of dampening springs & onto a metal star shaped item which then drives the input shaft.

Well I smashed up the metal star drive plate & nearly stripped out the dampening springs out of the housing too!
















So after having a bit of a "what the f$#k do I do now?" moment, I moved onto stripping the gearbox to have a "captain cook"

What I found was no great surprise to me by the sounds the old gearbox was making but...

It stripped both 2nd gear driver & driven gear & also mashed up the layshaft out support bearing!














So all in all, pretty much screwed! No signs of the diff rivets letting go or any other bearing marks from little metal fragments getting through the oil.


So for now, I'll source another HD clutch hopefully this week & refit the trusty old diesel 4spd which I always resort too in times of need!

[Water Boy]

Nice effort on the clutch Timmy...

[Oneofthegreats]

Nice effort on the clutch Timmy...

Cheers dude

Who was to know.

I've never seen a clutch let go like that. Not even reading through all the drag & horror stories on vortex!

This was also a HD Sachs clutch with the 3 drive tabbed pressure plate!

Depends on what I can get, but may just bang another HD one in. Don't have time to get one in from the states, as much as I'd really like to!

I was hoping the clutch would have lasted until I finally had the auto up & running, as there was no point buying a solid centred 4 puck racing clutch & only having it in there for a few month's!

[Peter Jones]

MIG the centre soild CIG clutch FTW.

Nice effort, I only managed a pressure plate.



Pete

[Oneofthegreats]

MIG the centre soild CIG clutch FTW.

Nice effort, I only managed a pressure plate.



Pete

hahahaha

didn't really think of this! Mmmmmm

Nah better not.

Remember the clutch spins at double engine speed (ie double the tacho reading), so if it was to let go, it would let go in a BIG way!

Plus I reckon the balancing will be way out!


I can be dodgey, but not "that" dodgey! I don't mind welding up diff centres though! hahaha

[Peter Jones]

Or to be a little more serious

Call Jim Berry.

PHONE: 07 3847 9999
ADDRESS: 26 GLADYS STREET
STONES CORNER QLD 4120
CONTACT: JIM BERRY HOURS OF OPERATION: Monday-Friday: 8.30 a.m. – 5.00 p.m.

Apparently he can make just about anything and is highly regarded.

http://www.motorsportworld.com.au/outlets/raceclutch/index.htm

Pete

[Oneofthegreats]

Or to be a little more serious

Call Jim Berry.

PHONE: 07 3847 9999
ADDRESS: 26 GLADYS STREET
STONES CORNER QLD 4120
CONTACT: JIM BERRY HOURS OF OPERATION: Monday-Friday: 8.30 a.m. – 5.00 p.m.

Apparently he can make just about anything and is highly regarded.

http://www.motorsportworld.com.au/outlets/raceclutch/index.htm

Pete

Thanks heaps Pete.

Think to save myself some time I may just order a clutch plate from work seeing as VW don't do kits for anything these days incl. headgasket VRS sets, I can just get a replacement disc.

Hopefully be Tuesday!

I would've loved to get a spec stage 4 solid centred setup. But I really need this thing going again ASAP