Scotty's MK1 Golf.......D.I.Y Extreme Edition

[thestu]

Hell yeh! Looking good!

[funkamedic]

looks tops man. superlites are rad. you've done heaps in such a short amount of time too!

[ScottyMK1]

Thanks for the kind words guys. I'll be sure to keep updating it each step.

If I miss any questions in my reply just jog my memory haha.

Been working on it for 3 weeks George, Trying to do as much as I can before someone complains that I'm making so much noise in my front yard..This way I'll have lots done when the council send me a letter lol. The rain never helps painting though.

Josh, I'll try post up as many descriptive photos as I can. I often forget to take photos midway through doing something which sucks. The wheels are 13 x 7 with 175/50 tyres. There is no offset stamped but I was told it was around 0. I'll measure it next time the wheel is off.

I understand your pain Henry, Spacers won't really be an option and doing an upgrade such as you have done looks like the go.

Jarred, Logically I knew upgrading the braking system would need to happen, Would have been nice when things just work hey? Hehe. Haven't done anything with the strut mounts yet. Thanks for bringing it to my attention. I'll investigate it a little when they come back out.

Hey Jace, I think shaving the retainer is a feasible option. I need close to 25mm though which unfortunately won't be easy. I could take out the back of the wheel spokes a little also but new brakes will be my first choice.

Uploading a few more pictures of today shortly.

[GRN_VAGN]

Try a Mk2 front brake setup, the caliper is ALOT slimmer ... but the pad contact patch is bigger.

Superlites looks great, what primer is that on them? the beige looking colour, looks sick that colour :O

[ScottyMK1]

It's Protec Parafill HS primer. I also thought the colour looks rad haha. The car is going to be a WRX mica blue in a Satin finish. So high gloss white I decided would look best.

Woke up this morning and decided I wanted to hear the car at least idling consistently.

My first mission was to do a compression test. The old owner had just got the head reconditioned, ground, shaved etc by the torque team in Brisbane so I was confident it wouldn't cause me any problems. Not doing things yourself you can never be to sure though.

115,115,115,115...While the numbers seemed low I was pretty stoked with the consistency. I did however pre-empt these figures as bolting on a turbo to a high compression engine usually doesn't end well. I have been told that the engine build consisted of Mahle low comp pistons which would explain this figure. It's pretty hard to confirm this without having them out but I am leaning towards this being true.

Gah.. I hate posting engine bay pictures due the fact how ugly it currently is. Anyway, the half dead battery went in and turn went the key. Started up after a few tries.



I got the car to idle and rev(roughly) to about 3000RPM. The battery soon died before I could throw the timing light on and really have a play. Another day I guess. I plan on getting it to a stage where it will run OK before I pull the whole thing out again for paint and a general clean....

Battery went on to the charger so more body work it was.

I figured by the end of the day I would fill all the holes down the middle of the car as I wont be reusing the chrome strips any more.

It's here I learnt a very valuable lesson in Murphy's law. 90 Minutes later and the guard FINALLY came off. I literally had to cut through the sikaflex type bondo sealing the sucker on. I felt battered and it was now mid afternoon but I continued as the show must go on.



Filled the first 5 holes and 1 minor rust hole. I decided to shave the aerial as well but I'll need to fill that in with a bridging piece. Hopefully a tomorrow job. Started to take a few more pieces off that need to be removed for when I paint..









Stay tuned for tomorrows updates.

[Jace]

So you're one of those super-motivated guys huh? Killin it.

[dubmc]

ahah they were my superlites...bout time someone put them on a car

good luck with it all.

[GoLfMan]

So you're one of those super-motivated guys huh? Killin it.

x2! Dam man looking the goods!

[ryana89]

This thread is a GREAT subsitute for TV during the run up to X-mas
I'll definantly be watching this.

[ScottyMK1]

I'd probably work on this during Christmas day if I could escape the relatives haha. No doubt I'll change conversation towards the golf many times.

Last couple days have been fairly slow. I think I have looked at the car and pondered more than doing any work. The tedious job of welding all the chrome strip holes etc continues. I think I've still got 20 odd holes to go. You don't need any more pictures of that lol..

My mate dropped around yesterday. I'm lucky he's a bit of a VW fanatic as the advice and help I got was pretty sound. We tinkered with the engine a little more but were no closer to getting it run any smoother. Any large amount of throttle given will stall it straight up. I still have a few variables to consider (Clean fuel, dirty carb, vac, pressure etc)but I'm starting to think it may be something more sinister.

After gaining a better understanding of a blow through turbo system, to me it looks like it was never really set up correctly to begin with. I have a fairly sound knowledge of turbo systems on injected vehicles but this carby was a first to me.

Firstly the Jet seems huge. It literally pours fuel even at idle rather than spraying a fine mist. My fuel pressure into the carby was hanging at around 15 PSI. I only plan on running 8PSI ish through this turbo so I could probably get away with 12PSI pressure at max boost. I had a feeling it may have been over fueling on throttle which would make it stall. To check this I reconnected the mechanical pump which is still in my block to see if dropping the pressure would make a difference. No such luck, Not even when I ditched the turbo feed pipe and let it just suck air.

I've read that a possible cause of this could be a split diaphragm which again makes me think the Webber wasn't completely set up to hold that kind of pressure.

The other discouraging things I've noticed is successful blow through set ups have dual butterfly's and a excess fuel return to the tank/surge tank etc. That excludes me on both counts. Sigh...

Even if this car was running perfect at some stage I highly doubt it would have had the best of both worlds. ie. good idling and hauling at full boost. Being my future daily driven car this has to be corrected.

While I am going to try all possible solutions and seek further help before I start ripping it out. The words MegaSquirt have quickly made a solid mark in my mind. I've started to map out a stand alone fuel injection system. DIY extreme mode of course.

Fuel system how it currently sits all messy and ugly in the boot. Repco primer feeding an external VL Turbo pump. This should be more than enough.

[ScottyMK1]

I have also put into motion a cold air box to house the pod filter. I was originally going to have the pod near the ground and create some kind of fresh air duct but due to the lowness and position of the turbo this wont be feasible. Locating it here is better than having it suck hot air directly beside the exhaust manifold.

I was unsure of the legality of cutting a hole into this area but I don't think it's classed as part of the firewall? Welding a small piece in will maintain the strength (if any) while giving it a professional feel.

However if I get pulled up that will be the least of my worries haha.



That's it for a couple days. Hope everyone has a good Christmas.

[ryana89]

MK2's and I think injected MK1's (please correct me if I'm wrong) suck their air in from behind the right headlight.
Just a possibility if you decide not to cut the scuttle tray.

[Preen59]

I'm confused.. You say that it's overfuelling, but when you apply more throttle it stalls? If you have a carburettored engine, and it's rich at idle.. Generally (and i'm being very broad here) when you apply more throttle it will clean up until the airspeed increases and it progresses to the main jets..

What I'm saying is, it stalling when you apply throttle from idle and it overfuelling at idle don't really seem to me like the same problem....

[ScottyMK1]

Whoops I left out a critical piece of the puzzle. I forgot people can't read minds haha.

My fuel system includes a rising rate regulator with a ratio of 1:1.7 My original thoughts were that if it's over fueling at idle then as soon as demand increases significantly it's going to dump nearly 2 times the amount of fuel in causing it to literally drown. While I agree with what you say about it choking until fuel matches the volume of air to an acceptable rate I just wasn't 100% convinced.

You are correct in saying it's 2 different problems though. I just had to confirm this by using the mechanical pump temporarily. Without checking the other things I mentioned earlier this leads me to think it could possibly be a diaphragm problem if it's stalling so significantly even as a NA setup?

I'm by no means a carb expert so anyone with knowledge or even advice feel free to post it up It's currently rocking a Weber 34 ICH.

[Preen59]

Basically, until it makes boost it's still technically an NA setup, as everything is still running at atmospheric pressure. With a carbie, throttle position does not equal fuel delivery. Throttle position combined with air speed equals fuel delivery.

A split pump diaphragm could definitely cause a drastic over-fueling problem.

A rising rate FPR works on vacuum, so at idle, with no boost and bugger all throttle %, I don't really see how it could be affecting your mixture.

I hope i'm not confusing you, i'm just throwing out my opinion based on my knowledge and the information you have provided.