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Gooney - being reborn

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Gooney - being reborn

Post by mrbeige on Wed Oct 08, 2008 3:35 pm

Well, thought I start a fresh thread for the new motor! Meet Gooney, son of Badcrumble! Laughing

Picked this 166k 1.8 valver up from Gav and Nikki, for the princely sum of 300 squid. To say I'm pleased is an understatement! Engine sounds sweet as a nut and the interior is mint. First job is to get it MOT'd then we'll see what changes take place....

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Updated 06-04-2010

Modifications::
============


Chassis::
Koni T/A's and Koni 40/50mm Springs
280mm VR Callipers and G60 disks sporting EBC Red Stuff pads
Mk4 Golf Rear callipers
Goodridge braided lines all round
New brake lines to the rear
New brake bias valve
New bottom ball joints, wishbones and tie rod ends

Engine::
Nil so far!! Laughing

Interior::
Momo gear knob

Exterior::
Removed 16v badges
Removed Side strips
Lupo wipers
Smoked side repeaters

Job list::
Fix central locking (probably faulty pump) - fixed
Re-bushed front and rear
Replace bonnet
Some 16" wheels

OpenECU Converison - Stage 1::Acquired::Required
G400 ECU, Innovate LC-1 wideband, 1.8T fuel rail, 1.8T fuel rail extensions, 1.8T injectors, 1.8T IAT sensor, 1.8T FPR
G400 Loom, Air filter, fuel line adapters and some fuel line, VR6 air box, TPS/Passat auto throttle body, Distributor to cam position conversion using cam position sensor 'ring' from AGU engine, Lupo crank sensor.

Ghetto Turbo Conversion - Stage 2::Acquired::Required
Fit a turbot to the engine that is in the car with the aid of a spacer plate to lower compression and run relatively low boost, to prove out G400 on a turbo'd motor, in preparation for the next stages..
Standard KR 1.8 Engine, Cossie T3 Turbo, LT intercooler
T3 Turbo refurb kit, Spacer/stacked gaskets, Fabricated Log type exhaust manifold and downpipe, Various boost piping.

Ghetto Turbo Conversion - Stage 3::
Not exactly sure yet


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Re: Gooney - being reborn

Post by mic_VR on Thu Oct 09, 2008 7:23 am

Can't wait to get cracking on this dude, it's been whayyy too long!

Cool
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Re: Gooney - being reborn

Post by mrbeige on Thu Oct 09, 2008 7:49 am

mic_VR wrote:Can't wait to get cracking on this dude, it's been whayyy too long!

Cool
Oh you are soooo not wrong Smile

I've got quite a few interesting changes to the engine/block specification. Hopefully will be nailing down exactly what I want to do courtesy of this forum Very Happy

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Re: Gooney - being reborn

Post by junkie on Thu Oct 09, 2008 4:25 pm

Please please see it through this time dude, i was gutted when you broke it all last time.
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Re: Gooney - being reborn

Post by mrbeige on Fri Oct 10, 2008 1:29 am

junkie wrote:Please please see it through this time dude, i was gutted when you broke it all last time.
Without a doubt mate! First job is to get him on the road and there a is a plan for the first weekend in December to do that. I've got Gav an Nik coming down that weekend to help out. I'd like to have had all the MS parts I needed by then, but it's not looking hopeful. Just being able to drive it will be a good start Smile

I've decided to source a VR air box and filter and use that in place of the standard metering head, then use a Passat auto throttle body as it has a TPS sensor, that along with some fuel rail extensions, that I'll get at the end of the month, so I can use the 1.8T fuel rail I've got, I should be good to go. The only thing I will need is some sort of pipework to go between the throttle body and the VR airbox. Some searchign round the scrapyards is necessary for that.

My intention is to use the existing relay locations for ECU and fuel pump, but it might not be possible to do this, so something like a saab relay panel (I've seen them used before) to house the relays may be also required. We shall see.

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Re: Gooney - being reborn

Post by m15 vw on Sun Oct 12, 2008 1:45 am

mrbeige wrote:
junkie wrote:Please please see it through this time dude, i was gutted when you broke it all last time.
Without a doubt mate! First job is to get him on the road and there a is a plan for the first weekend in December to do that. I've got Gav an Nik coming down that weekend to help out. I'd like to have had all the MS parts I needed by then, but it's not looking hopeful. Just being able to drive it will be a good start Smile

I've decided to source a VR air box and filter and use that in place of the standard metering head, then use a Passat auto throttle body as it has a TPS sensor, that along with some fuel rail extensions, that I'll get at the end of the month, so I can use the 1.8T fuel rail I've got, I should be good to go. The only thing I will need is some sort of pipework to go between the throttle body and the VR airbox. Some searchign round the scrapyards is necessary for that.

My intention is to use the existing relay locations for ECU and fuel pump, but it might not be possible to do this, so something like a saab relay panel (I've seen them used before) to house the relays may be also required. We shall see.

Yes Mr Beige......Gooney WILL be mot'd that weekend along with some other optional extras whether you like it or not Wink Smile


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Re: Gooney - being reborn

Post by dirtytorque on Sun Oct 19, 2008 11:22 am

any joy with the MOT so that the fun can begin?
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Re: Gooney - being reborn

Post by mrbeige on Sun Oct 19, 2008 11:28 am

dirtytorque wrote:any joy with the MOT so that the fun can begin?
Ah, the MOT is at the beginning of December santa

Moon-roof this weekend coming though, with the assistance of Tom, so I can then get my turbo, which is currently residing on a desk in Kings Lynn Sad

Think I might have a go at making an exhaust manifold. Need to get a MIG first though... *goes off to browse eBay*

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Re: Gooney - being reborn

Post by junkie on Sun Oct 19, 2008 12:23 pm

DIY'ing all the way, what turbo you using?
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Re: Gooney - being reborn

Post by mrbeige on Sun Oct 19, 2008 12:42 pm

I've got a T3 from a Cossie. Should be good enough to start with.

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Re: Gooney - being reborn

Post by junkie on Sun Oct 19, 2008 12:59 pm

Cant you get the T34 from a cossie
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Re: Gooney - being reborn

Post by mrbeige on Sun Oct 19, 2008 1:10 pm

junkie wrote:Cant you get the T34 from a cossie
I could, but my T3 cost me £15 and a working sunroof mech Wink

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Re: Gooney - being reborn

Post by junkie on Sun Oct 19, 2008 1:15 pm

Bargain lol, i never seem to find these deals.
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Re: Gooney - being reborn

Post by mrbeige on Mon Oct 27, 2008 5:04 am

Well, been thinking and this is now the plan....

Megasquirt stage 1
= N/A, dizzy, fuel + spark

Megasquirt stage 2 = Ghetto turbo – stacked gaskets on standard 166k KR, T3 cossie turbot, log type exhaust manifold, standard inlet, dizzy, fuel + spark

Megasquirt stage 3 = As stage 2 but dizzyless, COP, modded 1.8T inlet

Megasquirt stage 4 = As stage 3 but custom built, stroked 2E block, with 83mm pistons, custom rods (156mm), 2x GT25 hybrid (yet to be decided) turbo, lightened bottom end, ported head, lightened valvegear (titanium lifters, high rate springs), Lupo crank trigger, 02A/CTN hybrid gearset + Peloquin diff.

Updated the first post with what bits I've go and what I still need for each. Need to get MS up and running first, which will prolly be after Christmas Smile

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Re: Gooney - being reborn

Post by dirtytorque on Mon Oct 27, 2008 6:37 am

Good idea with stage 1.
Just get a simple MS build going and then takeoff from there.
Good work

Got an MOT yet?
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Re: Gooney - being reborn

Post by mrbeige on Mon Oct 27, 2008 7:19 am

dirtytorque wrote:Good idea with stage 1.
Just get a simple MS build going and then takeoff from there.
Good work

Got an MOT yet?
MOT is the 6th December Cool

Thought it would be a good idea to prove out the MS as a simple config. It will give me some good experience too. I was even thinking of just running fuel to start with, but I think as a wiring exercise it would just increase the total amount of work. I do have a 32-1 toothed trigger wheel, that I was going to mount on the auxiliary pulley and then run EDIS, but I like the idea of the following, along with a COP set-up, to go for the more OE look and feel...

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Re: Gooney - being reborn

Post by saysomestuff on Mon Oct 27, 2008 8:59 am

If we work on the assumption that mine will be in and at least at troubleshooting stage by xmas, then you could hold off your final decision until we see how blown up mine becomes?

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Re: Gooney - being reborn

Post by mrbeige on Tue Oct 28, 2008 12:54 pm

Right, thought I better show what I've actually achieved so far...not a lot, but hey, it's a long and windy road...

August 29th 2007 - stripping down the 9a.....

Seem to have quite a few nuts and bolts Laughing
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When I took the oil pump off, it rattled and this fell out.... Shocked (10mm spanner there for a bit of scale)
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Anyway, managed to get this bugger out.... Was struggling to keep the pulley still whilst trying to get the central bolt out, so cunningly wrapped the cam belt around that and the crank pulley, turned it until it locked then managed to undo the bolt! using a bar with a 24mm cranked ring spanner on the end of it! How bloody tight was that!
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September 5th 2007 - more progress

Engine number two.....stripped block down, just need to get the pulleys off, but leaving them to soak in WD40 over night..
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Bores look in good nick too Very Happy Pretty sure you can still see the honing marks
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September 6th 2007 - Pistons...

The 2e piston....
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The 9a piston....
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So we have to change the crank pulley, intermediate shaft, oil pump, dizzy block-off plate. Here is a piccie of the two intermediate shafts. They are pretty much identical apart from where the pulley mounts....
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2E Intermediate shaft bearing shell looking healthy Very Happy
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The crank pulley has to be changed along with the intermediate shaft to allow the 16v head and cam pulley to work. Here is the 2e one...
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And here is the 9a one, note the 9a one is wider...
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Two oil pumps are different. 9a one is at the front...
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September 16th 2007

Eventually, after 6 separate attempts, I managed to finally get the crank pulley bolt out. I'm sure someone had welded it in and the put some threadlock from hell in there! So with that out, I could take the pistons and rods off the crank, then remove the crank.

Pistons looked a but shabby, but after a quick clean with some degresser and a washing up sponge (you know, the yellow ones with a scrubbing side, from Tescos! Laughing )......Think I need to get a stiff bristled(sp?) brush, to get into the grooves where the rings sit though.

Before
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After
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The is an odd mark on one of the bores, but I'm wondering if it a fix to the casting?
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Had a go at cleaning the block up too, looks mightily better already
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Just need to give the bottom edge of it another go with the 'Tetroclean' and a wire brush, then sort out some paint! Decided to go for the OEM look on the install, so the block with be painted silver (although still toying with doing it black).


October 6th 2007 - Block Preparation

Finally got the engine on the stand. Woohoo! cheers
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Most of the masking done!
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The plan is to use the crank seal plates to mask off where the paint should go up to. I'm assuming that it wouldn't give a good seal if I were to paint under where the seals go??
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Am I going a bit OTT with the masking??
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October 18th 2007 - Block painted


Right, here are the photos.....
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As it stands now...

And that was about as far as I got. I've cleaned up the pistons and got the crap out of the ring lands. Junked all the bearings and rings, no real point in re-using them. Need to get the pistons valve clearanced now. Calling dirtytorque, I wonder if the company who did yours still have the measurements taken so they could do mine Smile

Can I re-use the oil pump, given that bit of metal fell out of it??

Anyway, enough of that engine for the minute, I've just seen some fuel rail extensions so I can use the 20v fuel rail with the standard valver manifold. Just a VR airbox, which will be courtesy of Tom, and some fuel line adapters, fuel line and jubilee clips, and I'll be good to go on the MS conversion Stage 1!!


Last edited by mrbeige on Thu Oct 30, 2008 8:55 am; edited 1 time in total

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Re: Gooney - being reborn

Post by junkie on Tue Oct 28, 2008 1:26 pm

I would for safety buy a new oil pump, it is the heart basically so no point skimping there.

So thats where the 10mm spanners disappear to, next time i lose it i will take my sump off lol! you figured where the 13mm's end up yet?
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Re: Gooney - being reborn

Post by dirtytorque on Tue Oct 28, 2008 1:40 pm

I'm going to the engineers tomorrow for some other stuff so i'll ask.
H.T Howard Motor machining in Slough.
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Smile
Keep on keeping on.
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Re: Gooney - being reborn

Post by mic_VR on Tue Oct 28, 2008 1:45 pm

Looking good sir, can't wait to see it being built up.
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Re: Gooney - being reborn

Post by mrbeige on Tue Oct 28, 2008 1:58 pm

dirtytorque wrote:I'm going to the engineers tomorrow for some other stuff so i'll ask.
Yeah, that'd be good mate, cheers Smile
mic_vr wrote:Looking good sir, can't wait to see it being built up.
I hope you don't mind waiting Laughing

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Re: Gooney - being reborn

Post by mic_VR on Tue Oct 28, 2008 2:27 pm

But the sooner the engine stand is free, the sooner we can start on mine! Laughing
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Re: Gooney - being reborn

Post by dirtytorque on Fri Nov 28, 2008 4:10 am

mrbeige wrote:Anyway, enough of that engine for the minute, I've just seen some fuel rail extensions so I can use the 20v fuel rail with the standard valver manifold


Where can I get me some? Smile

Humbly yours...

Very Happy

I'm nice as pie when I want something.
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Re: Gooney - being reborn

Post by mrbeige on Fri Nov 28, 2008 4:29 am

I actually got them from crookesey off CF. He was running them in his 16vT before he changed it over to the modded 20v inlet. IIRC the car used to be Peter Munns's and was originally running a TT kit.

I'll post up some pictures later, as they arrived yesterday Smile

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