Mk1 16v Project

[Golf Loon]

Are you doing this to a 4 door??
Schweet, there are not enough 4dr 16vs.

[Preen59]

Are you doing this to a 4 door??
Schweet, there are not enough 4dr 16vs.

Gees Matt, you didn't JUST notice that did you??

Yeah i'd like to do a 2 door one day but too many people do 2 doors because its "the go". I thought i told you i had a 4 door? Maybe not..

[Jarred]

year 4 door FTW, i like em, in fact I didn't even want a 2dr. I just happened to get one. thats all. besides that. It's looking good, and flag mirrors are scweet too!

[Preen59]

Yeah i decided the big mirrors were too bulky and the drivers side one was old and the passenger side one was an aftermaket one and it was just crap and i was unhappy with it, so i though stuff it. They're going.

I wanted to put the flags back on it to neaten it up and keep with the subtle thing i've got going.

Unfortunately it will only be subtle when its stationary and the engine isn't running.

[twin eng, twin turbs]

Ok, well i'd like to get over 200 at the flywheel, which should be achievable.

Yeah the rods are 450 grams total, and the L19 bolts should be more than enough. Usually the bolts break before the rods if you don't use good stuff..

Yes the exhaust valves are swirl ground and inconel.

Silky said with a 4 cyl you don't need to balance the crank with bob weights, so the crank will be balanced static (its going to be out by HEAPS after i knife edged it). I will be getting the rods balanced to within .1gm and the flywheel/clutch will be balanced, obviously. I'll be getting silky to organise all that because (as you would appear to have enough knowledge to know) an awesome engine that has been badly balanced can turn into a real heap real fast.


Oh, and i don't mind sharing, we aren't competing in the same racing class in which i need those extra couple of tenths over you.. (Ah, the ways you learn to keep secrets in kart racing...) Ask me anything and i'll answer honestly. Thats why i like this forum, everyone is eager to help eachother.

You sure will have to have your crank and flywheel balanced after lightening and knife edging. Of the three cranks i have knife edged ( i did my forged stroker crank yesterday he he) they were all out at least 30 grams and the flywheels a similar amount! But static balancing is not enough it needs to be dynamically balanced properly at 500 rpm. If it is out you risk bearing damage at high rpm or in the worst case sinario a spun main and ka boom! Interestingly i have run four 86.4mm stroke cranks on the balancer and from the factory they were within 3 grams out of balance! You only need bob weights on 6 and 8 cylinder cranks

[Preen59]

You sure will have to have your crank and flywheel balanced after lightening and knife edging. Of the three cranks i have knife edged ( i did my forged stroker crank yesterday he he) they were all out at least 30 grams and the flywheels a similar amount! But static balancing is not enough it needs to be dynamically balanced properly at 500 rpm. If it is out you risk bearing damage at high rpm or in the worst case sinario a spun main and ka boom! Interestingly i have run four 86.4mm stroke cranks on the balancer and from the factory they were within 3 grams out of balance! You only need bob weights on 6 and 8 cylinder cranks

Sorry static i meant as in no bob weights (because like you said you don't need them on a 4 cyl), Silky is going to get everything dynamic balanced in Canberra.

[twin eng, twin turbs]

You should post some pics of your engine goodies like bonks head job he gave you he he on your cylinder head that is! So do you want a ride to the nats this year guaranteed we will get there fast! Ill even let you drive the turbs mk2. Is tom coming?

[Preen59]

You should post some pics of your engine goodies like bonks head job he gave you he he on your cylinder head that is! So do you want a ride to the nats this year guaranteed we will get there fast! Ill even let you drive the turbs mk2. Is tom coming?

Haven't got the head back yet, otherwise i would have many pics so i could boast about having one of the best 16v heads in australia . I'm taking the Karmann Ghia to the nats this year, but i'll take you up on the drive. .

Got my bearings today (again, thanks Andrew!) and fitted my rod bearings. I'll fit the mains next week and mic everything up so that i can get the crank individually ground to exact size to give it top tolerance (highest) clearance on each journal, a must for a high revving engine.

I've also been offered a part time position as Race Engineer for a guy who runs a V8 supercar in the Fujitsu series, which should be some fantastic experience aswell as a good boost in my weekly income.

[GoLfMan]

I've also been offered a part time position as Race Engineer for a guy who runs a V8 supercar in the Fujitsu series, which should be some fantastic experience aswell as a good boost in my weekly income.

dude mega jealous of you right now!!!!

i wanna see this car when im up in sydders and have a few cold bevvies mulling over it

[Preen59]

dude mega jealous of you right now!!!!

i wanna see this car when im up in sydders and have a few cold bevvies mulling over it

Its JUST a mk1 4 door you know? I like it and i'm happy with what i'm doing, but its nothing that flash. Except the donk, it'll be pretty serious. Once i'm finished i'm going to build a full on race 1.8 16v. Solid lifter head light weight everything 9500rpm type stuff.

Edit: Having said all that, i'm glad theres other people that like it too. Thanks for the complements.

[GoLfMan]

Its JUST a mk1 4 door you know? I like it and i'm happy with what i'm doing, but its nothing that flash. Except the donk, it'll be pretty serious. Once i'm finished i'm going to build a full on race 1.8 16v. Solid lifter head light weight everything 9500rpm type stuff.

Edit: Having said all that, i'm glad theres other people that like it too. Thanks for the complements.

deerrrrr its just a mk1 4 door, i just love the serious engine prep thats going into this 16v, its old school cool with some nice engine building and engineering going into it, not just bolt on sh$t
to hell if its a 4 door, extra practicality

[Jarred]

I too like what you're doing with your mk1. taking the time to do it proper and making it look pretty sweet along the way. lookg forward to more updates for sure!

oh, and well done with the future job prospects!

[twin eng, twin turbs]

I'm taking the Karmann Ghia to the nats this year, but i'll take you up on the drive. .

Thats awesome your taking the karmann ghia it should be shown off more often as it is probably one of the cleanest ive seen! But it stiill dosn't have water cooling.... As yau know we have the same supertech oversize valves but did you realise that they are boardering on to big on the exhaust side and almost require new oversize seats aswell! See how yours go when they are cut and you'll no what i mean.

[Preen59]

I'm taking the Karmann Ghia to the nats this year, but i'll take you up on the drive. .

Thats awesome your taking the karmann ghia it should be shown off more often as it is probably one of the cleanest ive seen! But it stiill dosn't have water cooling.... As yau know we have the same supertech oversize valves but did you realise that they are boardering on to big on the exhaust side and almost require new oversize seats aswell! See how yours go when they are cut and you'll no what i mean.

Hmm interesting. I think bonk is getting G and G to do my head so i'll just have to see how it goes. The head is a 9a head and was very low K's when i got it, not that it makes much difference. Bonk said that .5 out of the throat of the insert should be fine, i hadn't taken a look though, because the head had no cams in it so all the valves were shut.

[Preen59]

More progress today.. Slightly.

MIC'd up the big end and main bearings.

The rods varied .02mm between them, but the mains were all within .005mm, which is 3/8ths of a mickey hair of stuff all. So i'll get the mains on the crank ground all to a set size and i'll only worry about individually sizing the big end journals.

Here's a pic when i was doing it, obviously i've left the bearings in the rods and the mains i have kept them in sets and numbered for the corresponding cap.



Oh, and i worked out why the 16v's and later have 3 piece centre bearings too. Making the centre thrust bearing in 3 pieces enables them to use a normal bearing for the journal and 4 thrust bearings that are all identical.

What this does is allow them to only have to tool for the 2 bearings, which is far cheaper and less complicated with no need for changeover etc, but also it means that on the production line they only need to have the 2 types of bearing available, this reduces logistical and mismatched part issues, which lowers the chance of running out of the parts on the production line.

You may not think that's interesting but i do.