Slight change of direction due to budget
I expected to have a little more cash to be finishing this project with :dapprove: It's got a bit silly now and i'm having to make cutbacks wherever I can. I won't be using the conrods I've got for this first build of the car. I literally can't afford to take the pistons out of the bores as then I'd need to replace the rings and re-hone. I plan to drop the compression later on anyway with some forged pistons as the AGU 20v compression is sadly very high at 9.5:1.
Also in the budget cut is clutch. I rang helix and they'd want £470 for a paddle clutch to do the job. Another company called CG motorsport do a cheaper one, but I still can't afford that really. So I'm going to run a VR6 clutch which are rumoured to handle the peak power of a K04 (audi TT turbo) ~280lbft/280bhp.
So the peak power the car can make is coming down, but I wouldn't say the new figures are going to be boring.
Driveshafts
GB engineering in nantwich are SLOW. I've now been promised free delivery on my custom shafts and he's said they will be with me by friday next week (18th)
Back to actual pictures and stuff.......
So, firstly, here's the gearbox, same colour as the engine. Nice and practical so I can see any oil spills. It's an 02J
Fitted the new oil pump (GSF) with pickup pipe (VW)
And fitted with plastic sump baffle:
My engine clearly came from a car that had a crash. There's evidence around the oil filter housing (now replaced) and on one of the OEM driveshafts. This is another place where it's had a knock. The crank alternator belt pulley. I looked into a VW replacement....but no....they are around £170
I just neatened it up delicately with a very thin grinding disk and sprayed a small amount of paint on. Took away the sharp edges and I think it can defo be used now.
I'm quite please that the donor car met it's death by crash really, it means that the engine was working when it was crashed.
Got the manifold back.
Built in 316 stainless by Jon Deeley.
[Plug]
Wolfy's Workshop NN13 5NU 07767743715
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The guy is ex pro-drive and made the exhausts and manifolds for the batmobile (tumbler or whatever) in the 2 new batman films
I'm really pleased with it. The engine flange was laser cut using a gasket, which makes them bigger than the actual ports on the head. So I have some porting to do, see further down.
Wanted to sort out the head with new valve stem seals and now also needed to port it so the valves had to come out.
Cams coming out
Rocker cover had a clean
Tried a couple of borrowed valve spring compressors but neither worked properly on this head so made by own :approve:
Had all the valves out in an hour (there are 20 ffs!)
Head went into the dishwasher
Came up nicely
This is my mum on the left catching me trying to sneak the head back out to the garage. She wasn't pleased :dapprove: lol
Tonight I pretty much finished porting one cylinder (to match the new exhaust manifold). I'm no expert (i'm a beginner h'actually
), I'm just using a die-grinder to gradually bring out the port smoothly.
OEM size
Ported
That one is almost done i think.
Whilst i've been waiting for tools/part/etc, i've been strengthening the engine mounts.
VW bolted down these mounts in the OEM cars with 3 bolts, so I thought, for what it's worth I would too. I just used some bar to contruct a little setup on a plate and then weld it up.
Drivers side:
The top is the tapped with an M10 thread and it bolts down like this:
Passengers was done in a similar way and welded down to the car. (primered).
That should give the engine mounts extra support.
I think that's it. atm am porting the head out. Anyone know of a G60 Flywheel for sale let me know
Cheers,
Mark