78 2-Door Build Thread

[dubmc]

getting there slowly now, got the manifold on last night which was bit of a job. the overall design is OK however some of the spacing leaves a bit to be desired such as not enough room to get the nuts on and i needed to grind between the two centre flanges to get the water outlet on...now i have to look into the radiator setup, setting up electric fuel pump and module for the dizzy so i can run advance...aiming to be done prior to christmas, just depends what others bit come up!

[abreut]

Carb manifold looks good, I see you ended up using the abf water outlet. Hey did the abf exhaust mani and downpipe fit ok?

[dubmc]

Carb manifold looks good, I see you ended up using the abf water outlet. Hey did the abf exhaust mani and downpipe fit ok?

yeah went with the abf outlet, it's a very tight fit so i'm hoping i can get the hose on OK once the carbs are in place! really want to avoid trying to take the manifold on and off.

the manifold bolted up nicely, and the downpipe should work fine as well! hopefully getting the carbs on tonight, once i sort these out it will be a big job out of the way

[dubmc]

bit of an update here, project was held up due to the manifold i received from Rowland Manifold in South Africa. anyone looking to do this conversion, save yourself the time and don't get a Rowland Manifold, absolute rubbish in all ways imaginable. Ended up waiting for a refund and then got one directly from Delortto in the UK which worked perfectly and it much better designed.

on the weekend we finally got the radiator in, bit of research involved here and some trial and error to find the right fit. ended up going with a 93 holden barina radiator which worked perfectly (pics below) heads up to Mikinoz (Mick) who flagged that this could be a potential option in another thread. (genuine rad was $90 and good condition bosch fan from wreckers was $50)

need to look into fuel setup and electrics now (setting up ignition module and computer). making good progress though, so will try keep this thread updated.





sits really nicely under the front slam panel for anybody looking to do this in future.

[Stiggy_21]

thats really neat!
good to know for future reference

[Peter Jones]

Coming along nicely, shout out if you need any ideas.

Saab 900 dizzy cap has 90° posts on it to clear that master cylinder if you're not using a multi coil setup.

[dubmc]

Coming along nicely, shout out if you need any ideas.

Saab 900 dizzy cap has 90° posts on it to clear that master cylinder if you're not using a multi coil setup.

thanks pete, will do! yeh i have the dizzy cap from the saab here and i'm going to use the ends off the old 8v leads to suit the plugs.

made a little more progress recently, mostly plumbing and wiring. also sorted the fuel lines - spoke to the carburetor shop near my area who are quite genius on the topic, said i could block off the return lines, any potential issues with this?

in the process now of mounting the computer and module, just making up another bracket, but slowly ticking off the to-do-list.

latest pic below - cheers!

[roccodingo]

Just asking Michael, where does the coolant bottle bottom hose lead to, as well as the outlet from the #4 end of the cylinder head ??
Pic is a bit unclear mate. Otherwise looking great

[dubmc]

Just asking Michael, where does the coolant bottle bottom hose lead to, as well as the outlet from the #4 end of the cylinder head ??
Pic is a bit unclear mate. Otherwise looking great

hey grant - bottom hose runs into the metal heater pipe whilst the hose from outlet #4 runs into the heater box inside the car...8v didn't have coolant bottle, so from speaking to people etc this is how I thought it would all work? let me know if I've got this wrong - cheers mate

[h100vw]

Do you need a set of 16v leads and a top timing belt cover? Been moving them around Australia for 7 years now, probably time I got rid?? Also got a brand new KR oil pump in the box.
Won't be expensive.

Gavin. email in my sig.

[roccodingo]

I have the correct KR water tube here Michael, I think there still available from VW classic parts. part number is 027 121 065K

[dubmc]

I have the correct KR water tube here Michael, I think there still available from VW classic parts. part number is 027 121 065K

hey grant, that's the same one as i'm using - probably just unclear in my photo, taken on the mobile!

[roccodingo]

cool, that'll be fine.

Pix 4 clix anyway



Heater valve and hose 12 go to heater inside the car, make sure you have hose 5 connecting head end port to coolant pipe.


Cheers,
Grant

[dubmc]

spending most of my time lately trying to find a place to mount the computer and module. bit of a bulky item and don't really wan't to cut a bunch of holes in the newly painted engine bay. i have decided to mount this up under the rain tray, mostly out of the weather but still with the potential of a bit of rain getting near the computer i have made up a protective case out of perspex (still haven't finished off but this is the rough idea). pretty happy with the way it came up and basically by applying heat with as heat gun you can bend/mould this however you want (pics below). also, my girlfriend's dad has made me a hose adapter on the lathe for the crank case breather hose, so i can run a 19mm hose to fit the catch can. thoughts? cheers.

[dubmc]

hey guys, haven't really updated on here for a while now. but i have essentially finished the conversion for now, obviously with a few teething issues but overall really happy with the way it has turned out so far!

I have uploaded a video below, haven't been able to drive on the road as rego ran out on Friday! (perfect timing) will get some better photos once I get it out of the garage and give it a wash etc etc



Cheers!