Turbo Diesel Cabriolet Project (with head porting pics)

[gldgti]

hehe, sorry Transporter

I should probably mention that the wife and I have been doing about 4-700km a week in the cabby of late... we've been commuting in it instead of the Skoda because my wife is still on her L's and learning to drive (and she's older than me!) and she prefers driving the cab to the Skoda. Anyway, with all these km, and taking the car up to coast periodically to visit olds and inlaws in an area with extremely poor roads... .well, that was enough.

I'd like to think I havent gone completely soft.... even if I have

[gldgti]

Update to above

Well my wife finally got her p's last week (on her first try, but after 10 years holding a learners permit) so the car really is hers now

Happy days

[DynamicDubs]

Hi Pal,

I enjoyed the read. Nice car, how's it going now?

Cheers

[gldgti]

Car is going well! We're averaging about 5.5l/100km with daily F3 runs, and a rough 0-100km/h of 8.5s. The clutch is still the biggest issue, theres just too much torque for a reasonable clutch with an 020 box.

In light of this the plans are for me to finally get the 1.6TD engine I've had apart for about 5 years back together, and swap the long block over - so I'll be keeping the turbo setup and all the accessories from the 1.9, and just changing the head and block to the 1.6. Hopefully this will mean less of a torque punch down low which is murdering the clutch, and a bit more of a revvy engine characteristic which suits the chassis and gear ratios better.

It should also help with the steering weight which is pretty heavy for my wife at the moment.

I'm also working on a set of ATS type 5's in 15x7 for the car. Should be a couple of weeks away.

[abreut]

That's awesome economy you're getting there, and still gti-like acceleration. With the clutch, I used a 5 puck ceramic clutch in my 16vt setup up until very recently when I changed to the 02A box. But that 210mm ceramic clutch never slipped. It was a bit grabby though and takes some getting used to, but it was still a sprung clutch so it wasn't ridiculous. Something to consider.

[gldgti]

That's awesome economy you're getting there, and still gti-like acceleration. With the clutch, I used a 5 puck ceramic clutch in my 16vt setup up until very recently when I changed to the 02A box. But that 210mm ceramic clutch never slipped. It was a bit grabby though and takes some getting used to, but it was still a sprung clutch so it wasn't ridiculous. Something to consider.

Thanks for that info. I did try a 6 puck organic lining setup with a sprung hub but it still wouldnt hang on. The feel was still too harsh though for a daily for my wife. I think I would live with it OK but it was just a bit nasty. That and if someone ever wants to borrow the car they end up stalling it heaps or doing nasty things to the gearbox

[EwenHayton]

You let people borrow your Golf.......???????

I wouldnt let anyone drive mine not that i know anyone who would want to lol

[gldgti]

haha - yeah mate, anyone can come and drive my cabby (or the skoda).

Ever since I sold my old mk3, I've made a point of trying to ensure that my vehicles are ok for anyone to just hop in and drive if need be. For one thing, it ensures you always have it working properly - and it also kind of helps to keep the modifications a bit sensible. Finally, it means I never have any problems getting through rego inspections. Plus, I love when people borrow the car and then when they give it back tell me what a nice car it is to drive

In the past, I've driven peoples heavily modified cars (my own included) and sure, sometimes they look great, or go fast in a straight line, but often there is something really really compromised about them - shoddy workmanship, bad ride, bad steering, bad clutch or gearshift, bad brakes, too much noise or vibration. Usually the owner overlooks all the bad stuff

[EwenHayton]

i think in the your last sentence you listed everything about my car lol!

[gldgti]

Your car is still being built so it doesnt count

[gldgti]

updated with pics....

ATS type 5's are getting tyres fitted today

crappy phone pics

[gldgti]

Front end rebuild and DIY for front wheel bearings

So as a direct result of the above post, we've been using the cabby as our daily for about 5 weeks now, doing about 140km each weekday.


This means its really racking up the km compared to before as a weekender, and some issues have come to light:

> both front wheel bearings noisy
> cv joints generally worn/noisy on acceleration
> front end bushings tired
> also noticed the rack bushings needed doing.

So, after a bit of a shop locally and with GAP (whole new driveshafts with cv's fitted!), I had some parts collected for this weekend:



I have recently refreshed the front brakes (about 10 months ago) but I have really neglected the front end of this car since we got it, what with all the attention being given to drivetrain. The only thing I've really replaced has been the passenger side tie rod (shocks and springs not counted here!)

Before shots:



For those Mk1 peeps that are new to the game, I thought I'd do a little step by step for the wheel bearing replacement.

First thing after the steering knuckle assy is removed from the car is to press out the hub from the bearing inner race.
Usually the outer half of the inner race comes off with the hub. This time was pretty typical for me - one hub basically fell out, the other one took me over 2 hours with a blowtorch and numerous screwdrivers and prybars to remove the inner race from the hub.

After the hub is out, remove the brake backing plate and then use some right angled cir-clip pliers to remove the cir-clip from both sides of the bearing. Then, set up the knuckle in your press (I have a very cheap 12tonne press that seems to do everything I ask of it with a little innovation) supporting the knuckle under outer face, and using a suitable mandrel (2.5" tube is ideal) press out the bearing:


After cleaning everything up with the pressure washer, de-greaser and then a lick of paint, you are ready to reassemble with your new bearings.

Use some spray on high pressure lithium grease to lubricate the inner bore of the steering knuckle, and insert the outboard cir-clip.

Then, press the new bearing in until its up against the outboard circlip.





Don't forget to bolt the brake backing plate back onto the knuckle, or you'll be in a mess!

Then lubricate the spigot of the hub with the lithium grease, and press the steering knuckle down onto the hub by pressing down on the inner side (the cv joint side) of the bearings inner race (VERY IMPORTANT!!!) Do not press the bearing on using the cir-clip, the bearing outer or the knuckle - this will damage the bearing!


On to the other stuff - pressure washed all this junk so I could clean it up and paint it:






After

[Water Boy]

Super sprint again this year?

[gldgti]

Yeah I reckon so. I will try to make the show'n'shine aswell.

[gldgti]

Bodi Windschott yawl!

Whats that you say? Let me show you....




and the proud owner


So, does it work? Well, incredibly, YES. Its fantasic actually, my toupe stays on all the time, even on the freeway!

More importantly, my wifes hair stays out of her face while she's driving, and no sore ears after long runs at 110km/h. So overall WIN.

I bought the kit from an ebay store and I have to say the quality is excellent, the fit is perfect, and it looks great too I reckon.