[Car_Upgrade] 1.9 Gti Rust Repairs And Bodywork

[johniban 59 1 Cars]

Test fit bonnet with trumpets on, not much clearence at all so not sure what todo here

 

 

new wing, its a base model and looks identical to a gti wing just doesnt have moulding holes

[johniban 59 1 Cars]

 

hub assembly refitted with brake hose

[welshpug 1,661]

Test fit bonnet with trumpets on, not much clearence at all so not sure what todo here

 

 

shorter trumpets and lose some grunt, or get a Satchell inlet manifold, costs the same as the jenvey/maniflow one that doesnt fit anything very well.

 

miles stocks them afaik.

[jackherer 543]

Is the gearbox mount only held on with two bolts? Do you think it'll be strong enough?

 

I'm currently building a 205 for a friend that has had the same thing done to the battery tray and I was planning on replacing it as it doesn't look like enough to me.

[welshpug 1,661]

Good spot keiran, I would say most certainly not strong enough, I have seen many bent and almost sheared battery trays from missing bolts.

 

yes the 306 mount looks similar, however it has an extra plate over the top with 4 more bolts.

[Mac Crash 78 1 Cars]

Should have 4 bolts as standard, yes?

[jackherer 543]

Yes, the top layer that the battery normally sits on has been removed and it should bolt onto the top of the chassis leg where a power distribution block has been bolted

[Mac Crash 78 1 Cars]

Thanks... one last question on this man's thread if that's okay... regarding braided brake lines... can the copper brake pipes be done away with in their entirety and replaced with braided hoses throughout the whole car? or do you think this will cause loss of feel, too much expansion in the hose for the brakes to operate correctly? don't mind the expense as I have access to unlimited amounts of the stuff, just wondered if this is feasible due to the need for ridgid pipe to make hydraulics work?

[jackherer 543]

I've run braided hoses the whole way before and it works fine, it's just normally very expensive! Make some extra sets and I'll take 1 or 2 off you if they are a reasonable price.

[Miles 331 1 Cars]

Looks like the box still has the 06 stud, You'll need to change this for the 05 stud as it will wobble around big time inside the bush

Also the fuel rail as I see you have gone for the good fittings is that the middle has a habit of leaking around the O ring seal, A single piece rail is more reliable

Edited July 7, 2014 by Miles

[johniban 59 1 Cars]

Looks like the box still has the 06 stud, You'll need to change this for the 05 stud as it will wobble around big time inside the bush

Also the fuel rail as I see you have gone for the good fittings is that the middle has a habit of leaking around the O ring seal, A single piece rail is more reliable

funny you should say that miles as i need to get a new o ring for one side as i caught it pushing in the pipe, i didn't no you could just fit the one piece onto anything as the injector spacing would differ from engine to engine?

[johniban 59 1 Cars]

Is the gearbox mount only held on with two bolts? Do you think it'll be strong enough?

 

I'm currently building a 205 for a friend that has had the same thing done to the battery tray and I was planning on replacing it as it doesn't look like enough to me.

 

The gearbox mount i have modified, its been cut down and seam welded all the way around, its held on with two allen head bolts cant remember the size but they look up to the job, i can make the mount so that it bolts up onto the top two original bolt holes but i really don't see it being a problem.

 

maybe ill fab up something later on if it is a problem

[johniban 59 1 Cars]

I had made this previously from 2mm mild steel, but it was heavy and seemed over the top so i didnt bother with it.

 

[welshpug 1,661]

You do need it to tie in to the bolts on the top, or weld the whole thing on.

[johniban 59 1 Cars]

really think i need a different inlet manifold, maybe a longer one with more of an angle to it, not happy the way they are at all

 

 

Going to make up a front slam panel to house the rad, oil cooler and to fit around an air filter

 

[johniban 59 1 Cars]

I bought this little kit, although its from a 106 turbo i thought i could use it on the gti6 engine, when it turned up i found up the braided pipes are really long and i cant loose any pipe anywhere without looking stupid and it looks like AN-12 with i think is way overkill for an oil line!!

think im going to keep the mocal oil fiilter relocater as it has an output for a turbo feed witch i shall ad an oil pressure switch/light too instead.

 

The sandwich plate doesnt fit though as the gti6 engine has a long inner bolt thats way too long

 

http://s13.photobucket.com/user/johniban/media/Mobile%20Uploads/D2B6BB44-BAFA-4C44-AB52-B56DC067BFE2_zpswhmgiarn.jpg.html?sort=3&o=2

 

Unsure weather to just sell the kit on again to someone looking to turbo a TU engine or take the bits out i want and sell the rest,

[welshpug 1,661]

You could just shorten the lines, no special tools needed, and get a shorter bolt.

[johniban 59 1 Cars]

the lines have crimped ends theres no easy way to just shorten them

[Mac Crash 78 1 Cars]

the lines have crimped ends theres no easy way to just shorten them

 

Pirtek or Hydrasun will easily re-end those hoses for you, or send them up to me for the postage costs and I'll have it done for free.

[johniban 59 1 Cars]

cheers fella but id rather downsize the hose to maybe an-10 then i can make it up as i go along

[welshpug 1,661]

whoah, DOWNSIZE to -10?! -10 is pretty big as it is 16mm o.d for -10, -12 is nearly 20mm!

 

though for oil, not hat big I guess, but still.!

Edited July 10, 2014 by welshpug

[johniban 59 1 Cars]

ive got AN-8 and 6 on the 106 for fuel lines, the hoses i have on this oil cooler kit are massive ive not measured yet but they look really too big

20mm sounds about right!

you can see the size of the hose compared to the oil filter, the turbo feed hose with the removable fittings is an-6

[johniban 59 1 Cars]

think im going to sell the sandwich plate, lines and cooler together as one package and keep the oil filter relocater as they seem pretty hard to find

[Miles 331 1 Cars]

You can see the solid pipe on mine,

 

Just ring up Jenvey and ask them for one, you will need to measure the centres for the injectors thou

[johniban 59 1 Cars]

This came through today, pretty impressed with it, looks awesome and is pretty compact,

 

 

return line started

 

 

regulator fitted in place, bracket looks tacky so want to make up a new one later on, but theres plenty of room around it

 

 

need some of them clamps that join the two hoses together to neaten it up a little

 

 

lines fitted under the car

 

 

ill add a fuel filter in the line somewhere at some point