[Car_Upgrade] 1.9 Gti Rust Repairs And Bodywork

[johniban 59 1 Cars]

purchased a roll off msa spec braided teflon fuel hose, bit over the top for what i need but looks good and does the job well

test fitted them

[Lowercase 56]

if you change carbs give me a shout john could be just the ticket for my derby.

[johniban 59 1 Cars]

id love 45s if i could find them mate, im going to strip and service these first make sure they are tip top

[johniban 59 1 Cars]

managed to have a shift around in the garage and get on with the vary last bit of welding and the bit ive been dreading... the boot floor.

 

I originally wanted to keep the shape of the boot floor, but as it was all rotten, and my plan is to mount my silver top pump and a swirl pot under the car i used some flat steel,

 

 

out with the old

In with the new

 

there is rust still around the edges but its only surface so should clean up ok

[johniban 59 1 Cars]

 

all welds seam sealed ready for paint

[johniban 59 1 Cars]

couldnt find any ht leads to suit my needs so im making up my own, and works out about a quater of the price!

 

[artois7 21]

Just read through it - come a long way from the start mate! I understand where you're coming from with the carb set up - do what you want to do and make it your own; at the prices you paid you're going to profit on the parts even if you sell them on!

[johniban 59 1 Cars]

Thansk you mate, to be ohnest i haven't driven with the set up yet so ill probably end up loving it or hating it but i dont really mind as it isnt my everyday car and i have a 205 rallye to mess about in too

[johniban 59 1 Cars]

finally it seems like im getting somewhere now all the rust work and welding is done,

 

Got the back seats in and set belts, it seems ive lost all the brackets ect somewhere.

 

 

Trying to find some where to mount the silvertop fuel pump that wont look like its just been chucked in the boot

[johniban 59 1 Cars]

Then i done this..

 

 

I didn't want to just put a bent copper tube in the fuel pump, so i fitted some Torques anodized fittings, was pretty hard trying to figure out a set up so i can still keep the interior 99% standard, and keep the rear seats in and usable without crushing the fuel line.

 

 

Very expensive modification, each fitting is about £12 and i think i used about 3 or 4 and probably isn't needed but for my peace of mine i done it anyway,

[johniban 59 1 Cars]

[johniban 59 1 Cars]

I will block off the return fitting as its not used as im running carbs.

 

Unfortunately i had no choice but to cut out a small amount of the body around the fuel pump hole to get a 90 degree fitting in there, i will tidy it up at a later date

 

[johniban 59 1 Cars]

took a step back today and removed the engine, need to get some bits done that i couldnt do with the engine in.

 

My new manifold turned up, its a gti6-205 conversion 421 manifold, unsure of the make and would love to know????

 

its mild steel witch i prefer as you dont get the tinny sound with stainless steel, im going to sand it down and repaint it silver, but i will be making up a stainless exhaust system

[welshpug 1,661]

I would not be happy with a fuel pump inside the car, underneath every time.

[johniban 59 1 Cars]

I appreciate the feedback, do you think i should mount it under the boot floor?

[welshpug 1,661]

I would personally yes, its exactly where it sits on my 405, including the inline filter, less clutter in the engine bay

[johniban 59 1 Cars]

Would you be happy to take a couple of pics of your set up for me? just for inspiration

 

I kind of wish i just used normal black fuel hose instead of this fancy braided teflon pipe as its going to cost a bit now with all the fittings i need, but should hopefully look pretty good

[feb 47]

I was thinking about this the other day, so funny that this little bickering debate popped up here. All these years people have been going on about carbs being a thing of the past and you "must" have ITBs these days as they are reliable, only need mapped once blah blah blah. I'm sure there's truth in that if you get a really good quality setup that is perfectly mapped. But in the years I've been a member on here, and all the project threads I've followed, and the countless threads I've read, it seems to me that a heck of a lot of people have problems with their ITB setups on regularly used cars. Whether it be simple things like failing sensors, or things moving out of place, or somehow the map resetting itself. Seems to me that an ITB setup is not quite the robust solution that people make it out to be. Granted they do have lots of benefits, but I think people shouldn't kid themselves on that they are "fit and forget".

 

You couldn't have put it better.

 

I haven't had carbs in my GTi but I have had two cars with carbs, a 205 1.0 Trio Plus followed by a 1.0 AX, both of which were very reliable and never needed anything done to them.

 

On the other hand I had numerous problems with my 205 that had an Emerald ECU, the biggest one is the inability to control the idle properly, which ironically was one of the reasons I wanted to try an aftermarket ECU (apparently the main reason being a hardware fault with the Emerald it seems - it wasn't only my car that had such problems, there were/are others on here if you do a search on Emerald), but whatever the problem was it didn't make the car more enjoyable than my old 1.9 8V that had the s*itty Jetronic when it was running at its best the first time around I owned it.

 

Lesson learnt: unless you have the time, patience, inclination and knowledge yourself don't start messing with aftermarket ECUs etc.

 

I'll get my coat now.

Edited December 22, 2013 by feb

[johniban 59 1 Cars]

Im not really going for carbs for any reason, not saying they are better than itbs, im just interested in the old school set up on an old school car with an upto date ish engine, the joys of owning a classic car with classic parts not electronic ecu rubbish

[feb 47]

Electronic ECUs are far from rubbish compared with carbs, it is just that you need to put a lot of work into making an aftermarket one behave like an OEM one.

Edited December 22, 2013 by feb

[Reebmit 51 4 Cars]

You could have kept the original injection pump and used the filter king set at around 2.5 to 3 psi, works perfectly and very reliable

[johniban 59 1 Cars]

please keep the carbs vs injection to another thread its been argues too many times and i really dont care

[johniban 59 1 Cars]

You could have kept the original injection pump and used the filter king set at around 2.5 to 3 psi, works perfectly and very reliable

 

I want to do my car properly, i cant help but thinking that a 4 psi regulator is not designed to limit 2-3 bar of pressure down to 4psi, plus the fact i have replaced the rotten looking fuel lines with teflon braided msa spec fuel line now all the way from the underside of the boot where the knew pump now is

[johniban 59 1 Cars]

do i make a stainless system or stick to the mild steel as the manifold is? ive pained the manifold a stonechip light grey colour witch looks pretty good witch i think the system will look pretty good and maybe a silver or something for the rear box that i will have to make up.

[Reebmit 51 4 Cars]

Hi John, filter kings are fine setting down to 2.5 to 3 psi, used them for years on many cars, one of my 205's is running 45's with this set up. But you are a little way down the road with your conversion now so don't worry. Keep up the enthusiasm, worth it in the end...I enjoy reading threads like this