Harold - the T25 van (1.8T content)

[GeorgeMK1]

Quote
It's a much better outcome I think? A lot easier to install too.
Just before I put it all together, I grabbed some pliers and gave the pipe a quick roll around just to make sure the pipes don't burst off (hard to imagine with 8pis hahahaha).
Don,t be concerned with the pipes popping off with your mods VW wern't that crash hot with their high tech intercooler connections, with our 2.5 T5 they use a steel circlip to hold the section together problem is the clip is mounted onto die cast alloy and with every sudden acceleration deceleration is move minisculy to the point where it wore out the groove and would just pop off without warning with loads of black smoke and no power . A low tech repair fixed it forever , two screws one opposite each other around the collar stopped it from coming apart and cheaper than a new $600 plus part from VW . Those blue pipes remind me of my sons desire for new heater hose for his Moto Cross Race Bike , I paid for them begrudgingly as I kept pointing out to him that they looked good but did not make the bike go faster !

Haha I have claimed those c clip pressure pipes for warranty before. They are pretty rubbish aren't they!! We tend to replace a lot of the spring type clamps with screw type ones as we've seen plenty of issues with them.
Sunny you obviously don't realise that blue makes the car faster! And If your son painted the bikes callipers red, well he then would be breaking speed records in no time.

I did a quick Google search. I’m pretty sure the one that I’m thinking of is from a Mk1 Golf. I did a couple of screen shots. You might get something out of these. Enjoying your thread by the way.

Thanks for that man. I actually have a mk1 and had a look at them once you brought it to my attention, it does have a pipe that enlarges a little bit, but its still too small
Thanks for looking into it !!

[GeorgeMK1]

Small update alert.

Got my pipe back from my buddy and installed it. All the intercooler plumbing is now routed and complete! Hooray.
It’s all tucked away nicely, and I’ve also left some room for the cooler to wiggle when the engine moves side to side etc.




Here’s a wonky birds eye view.




Another small, but very vital step was taken yesterday.
I had a brainstorming sesh on Saturday and came out with a plan for the throttle cable. Essentially, the original throttle cable is too short, and I am not going to be paying for a whole new cable. So I came up with a very simple solution.
Off to the wreckers to find the longest cable I could find, and it happened to come out of a `88 DA6 Integra.




Cap removed and cut down to the correct size needed.




Cap back on, and trimmed down to a round shape.




Made a little bracket to hold the cable out of spare aluminium.




I then found the perfect spot to join the two cables. I measured then cut the old cable off here.
It was important to do it here, as the old throttle cable already had a bracket that would hold the cable in place.




Because the cable was from a different car, I couldn’t exactly just mount the throttle cable on to the flap. So I drilled a tiny hold and added a small bolt and nut to hold it all in place. Works perfect!!




Once that was set in its correct position, I ran the cable through and cut to size.
I hope it will start to make sense in these few pics below. I needed everything to be very tight and make sure nothing was loose or dangling, or there would have been too much slack for the pedal.
This was the only way I could think of without breaking the bank for a custom cable to be made up. Both new and old cables are held tightly in place by the brackets, ensuring no movement – for a perfect pedal feel.








All up the throttle cable setup cost me $16 and I’m really pleased with how it feels and works.
All the updates are getting smaller and harder at this stage of the build as it takes me 2 days to research/find parts/test fitment etc for all the tiny little things that remain.
But I’m in the home run and planning to have it running by the end of this month I HOPE.
Thanks for reading ��

[Sunny43.5]

The ultimate finish to that join would have been some heat shrink wrap .

[GeorgeMK1]

The ultimate finish to that join would have been some heat shrink wrap .

I was actually thinking about it, but then would be hard for me to inspect for any damage or wear in the future. Perhaps I can figure another cover for it somehow?

[Sunny43.5]

How about a piece of clear plastic tube just enough to cover the join cut a slit down the side and fit it over , but hey its not that big a deal I suppose . Car makers do some pretty ordinary things so up to you .

[ericcs]

i have successfully soldered cables together, the crimped single tube swages for added strength!

[GeorgeMK1]

How about a piece of clear plastic tube just enough to cover the join cut a slit down the side and fit it over , but hey its not that big a deal I suppose . Car makers do some pretty ordinary things so up to you .

That's a good idea mate, I'll have to see if I have some tube left over from an old job. Will keep the dirt away too!

i have successfully soldered cables together, the crimped single tube swages for added strength!

My dad and I were contemplating soldering it together, but wasn't sure it was possible. I was actually going to drop a blob of weld on it
Maybe I'll drop a blob of solder as a precaution. Thanks Eric!

[aprr32]

I shouldnt go anywhere, this what we used to do to make handbrake cables shorter for beach buggies.

[Sunny43.5]

We used swages for the Stainless steel cables on my racing catamaran guy wires and they held thousands of pounds of strain .

[GeorgeMK1]

I shouldnt go anywhere, this what we used to do to make handbrake cables shorter for beach buggies.

We used swages for the Stainless steel cables on my racing catamaran guy wires and they held thousands of pounds of strain .

You guys are making me feel confident the swages weren't a bad idea haha. Thanks!!


I was at WTAC this weekend so not much progress, but got back on it on Monday.
I started on the radiator. Took the van off the car ramps to level it out a bit and make it easier to work on the front end.
Radiator was pretty easy to get out took only 20 mins.

New vs. old




Fan shroud removed and installed, and also added a new genuine thermo fan switch, a bloody expensive $89.






Before I installed the radiator, I realised that each 3m rad pipe might have old coolant and other crap inside.
So I added an old coolant hose and jammed in the garden hose, then proceeded to pump it at full blast. I forgot to take a pic of all the ugly brown/green crap that came out!! Luckily I did it before adding the radiator, phew!!




Now it was time to install the radiator, but noticed it was missing the rubber dampers. So I improvised with a bit of fuel hose to add to each end, and on she went! Nice and snug fit.






On she goes




Ok, time to move onto another task I have been struggling with - intake pipe and box.
I've really been picking my brain over the past few weeks with the intake pipe and how I can make it work. The normal mk4/audi intake pipes don't work here, and I couldn't figure anything else out. Decided to order a cheapo silicone hose from ebay and chop it up for test purposes.




After cutting it and playing around with it, I realised I needed another 90deg 2"-3" silicone hose.
Ordered it, and was happy to see it had worked out in the end! A quick PVC pipe to test fit it all, shows good results




Action shot - and rough finished result.






Still very rough at this stage, but atleast I have an outline of how its going to sit, and from there I can finalise it with time.

[Sunny43.5]

Have you got a pilots license for that , because it looks from that engine the bugger is going to fly .

[kombivan]

ost site

Yeah I know mate, I've been having so much issues uploading images. I FINALLY found a site that does it, and now the images are cut in half. Grrrrr it's just so frustrating as I've got so many photos and struggling to upload haha. I've been through 5 different image hosting sites and none work aceept for ctrlq.com, but it seams to cut images for some reason. I'll keep trying

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[GeorgeMK1]

Have you got a pilots license for that , because it looks from that engine the bugger is going to fly .

Hahaha, I think it looks fast because I've used a lot of blue! But no I actually anticipate it will be pretty slow as the van is a heavy bugger.

login - cubeupload

Thanks I'll give it a try !

[GeorgeMK1]

Wiring and coolant plumbing is really the last big tasks that remain, so I figured adding fluids now is as good a time as ever.
That 5L bottle is distilled water. No, I don't really need it - but VW has recently released a bulletin with some apparent research that in different states/countries water can vary and some of the chemicals (I'm no scientist) can leave deposits and build up when mixed with coolant. I have actually noticed this on a few engines I've work over the years, so figured what's $5 for some clean distilled water.





In order to undo the drain/fill plug for the transmission - I didn't realise I needed a special hex. I didn't have one, so welded up a nut and bolt together and used a socket to undo it. Worked well.






Then it was just a matter of filling it till it overfills a tad and putting in the plug. Strange as I read that it takes 3.5L however I used almost 4L and it still didn't overflow out. I decided to stop anyhow just incase. Will have to research a bit more.




Also topped up fresh engine oil, decided to stick with genuine 5w30 for now to see how it will take it. (I used to run 10w40).

After checking atleast 5 autobarns and supercheap auto's I managed to find some rad hoses that could work.
The issue I have is the pipe that runs under the car is 40mm, and the rad pipes off the engine are 32mm.
I have searched hi and low, but without breaking the bank there is no way to get an adaptor to fit that. So I decided to settle for 40mm hoses, and just add an extra bit of hose inbetween it (I'll try demonstrate it in a pic further down.)
Found the right shapes too which was good. Just a quick test fit here.








I got some 32mm hose and a quick look to see if it fits into the 40mm hose well.




Test fitting the cut out.




.. and on it goes. I ended up putting one side on lastnight. It seams super tight, especially with a nice fat clamp. I don't think there is enough pressure for it to pop off (I reallyyy struggled to get it on). Time will tell though.




I'm very glad as this was the most cost effective method out there - I had friends suggesting to get stainless pipes made up, and then reduced down to 32mm, but that was super expensive.
Now I just have to do the smaller 90deg hose and the rad hoses are done!!

[HaydEn]

As long as it's all tight. I had to do this one a VR6 in a maccas carpark at GAD one year.

It's still going 2 years later.