legvw 0 Posted June 5, 2009 Author Report Share Posted June 5, 2009 Hoping to have it ready for the new year(its a more realistic time than i first thought!!). And i've given up, and got back on with it loads of times mate! Just think of what its gunna be like when its done, and that usually enough encouragement!!!Manifold will be doing this month hopefully, 3" all the way for the exhaust, all custom made by me.Update on the evenings progress. This relates back to what i was saying to john555 about the hubs.The hub on the left is vr6, and R32 on the right. You can see a 3mm difference in length.But not o/a height, in the picture above. So i made a 3mm spacer to sit between the hub and bearing.So then i assembled the front hub assemblys with ANOTHER new set of bearings! And pressed in the hub. You can see that the spacer brings the hub out to the right level so the driveshaft 'clamps' the hub/bearing.I then made the 6mm spacer plates to space the calipers, and assembled the lot! Link to post Share on other sites
rodney 17 Posted June 5, 2009 Report Share Posted June 5, 2009 where's this been hiding... Very impressive gents...Great skilss there. Keep going. Now I've found it I will be following... I love watching these build threads...you guys will have to have a mini meet when you're both finished.. Link to post Share on other sites
john555 0 Posted June 6, 2009 Report Share Posted June 6, 2009 ah i was forgetting your running a turbo that im running a charger so gona end upe spending a fortune on getting a 6 branch made up, that hub things much clearer now thanks ill make some spacers up the same this week at work.are you doing the adjustable camber and toe conversion on your back axel? just iv made the plates but im not even sure if its worth it Link to post Share on other sites
legvw 0 Posted June 6, 2009 Author Report Share Posted June 6, 2009 Getting the 6 branch might not be too much trouble, i've got to get a 3" pipe between my bulkhead and prop! I think i'm going to have to modify the bulkhead/tunnel to make it fit.As for the adjustment on the rear, i'm still a bit unsure. If it causes problems when driving then i'l do it then. I'm going to see what happens mate Link to post Share on other sites
Phat VR6 3 Posted June 6, 2009 Report Share Posted June 6, 2009 so you've pushed the R32 hub into the VR6 hub knuckle? with VR6 bearings?and the brakes are R32 discs and calipers with a 6mm spacers and then they bolt on?would the outer VR CV joints of pushed onto the R32 drive shafts so you could keep with vr hubs?good thread your covering prity much everything Link to post Share on other sites
legvw 0 Posted June 6, 2009 Author Report Share Posted June 6, 2009 so you've pushed the R32 hub into the VR6 hub knuckle? with VR6 bearings?and the brakes are R32 discs and calipers with a 6mm spacers and then they bolt on?would the outer VR CV joints of pushed onto the R32 drive shafts so you could keep with vr hubs?good thread your covering prity much everything Yes to r32 hub into vr bearing and carrier, yes to r32 brakes with 6mm spacer.No to the driveshafts, the inner spline on the cv's is larger on r32's, along with the driveshaft. If you wanted to run r32/4motion inner cv's(110mm cv) and vr outer cv's for vr hubs, you would have to have a custom shaft made with a larger spline 1 end, and the smaller vr spline the other end of the shaft. I'l try posting some pics of the difference up tomorrow. Link to post Share on other sites
legvw 0 Posted June 6, 2009 Author Report Share Posted June 6, 2009 Well back to the progress of today. I made my sri. This is the mk2 version! Hope you like!! Link to post Share on other sites
golfrabbit33 0 Posted June 16, 2009 Report Share Posted June 16, 2009 respect. Link to post Share on other sites
wayne_1@tiscali.co.uk 27 Posted June 16, 2009 Report Share Posted June 16, 2009 thats gonna be one hell of a car when finished Link to post Share on other sites
matty.vrt 120 Posted June 16, 2009 Report Share Posted June 16, 2009 Keep up the good work mate. Link to post Share on other sites
legvw 0 Posted June 19, 2009 Author Report Share Posted June 19, 2009 Actually found some time this evening to finish my inlet manifold!Modified the fuel railThen drilled an tapped all the holes for the air lines and manifold air temp senderAll assembled and ready to go on! Link to post Share on other sites
supadupagt4 0 Posted June 20, 2009 Report Share Posted June 20, 2009 sweet. keep us updated. tony. Link to post Share on other sites
golfrabbit33 0 Posted June 20, 2009 Report Share Posted June 20, 2009 real nice mate, very informative and the pics really help,this will, im sure get a few more peole going diy. Link to post Share on other sites
legvw 0 Posted June 23, 2009 Author Report Share Posted June 23, 2009 Cheers for the support, and the good words! Its the biggest project i've ever undertaken, the longest, and the most expensive! But its given me the most grief!! So if this thread helps a few people out to go diy, then why not? Having a bash your self at stuff like this is good brain fuel! Anyways, a little update from sunday.Made a start on making my exhaust manifold, using the original vw headers.First i cut the old flanges off of the original downpipe, and machined them out to fit the 2" o.d stianless u-bends i bought.I set my spare head up on a block, and started to cut, tack, cut back off, re-tack, etc pipes til i was happy!Its not finished but its a start. Got to cut the pipes down a little, and mount he turbo flange once its been machined to a T4 divided. To be continued.... Link to post Share on other sites
Phat VR6 3 Posted July 4, 2009 Report Share Posted July 4, 2009 looking good dude.. this is how i wanna make my exhaust manni but with a mig and with the turbo lower so i can use the standard inlet manni.what tig welder are you using? can you recommend anything on a budget for around the £300 mark? Link to post Share on other sites
legvw 0 Posted July 5, 2009 Author Report Share Posted July 5, 2009 I'm using 1 of these welders http://www.fronius.com/cps/rde/xchg/SID-594D6A2F-6251719B/fronius_international/hs.xsl/79_4677_ENG_HTML.htmMaybe have a look on the bay for a second-hand welder, then sort your gas out. Make sure the gas is pure argon. Link to post Share on other sites
Mk2 6POT 0 Posted July 5, 2009 Report Share Posted July 5, 2009 Just picked up on this thread and read it right through. Big respect for the work you've put in, keep us updated mate. Link to post Share on other sites
Hairyarse 0 Posted July 5, 2009 Report Share Posted July 5, 2009 Just picked up on this thread and read it right through. Big respect for the work you've put in' date=' keep us updated mate.[/quote']Just done the same, hat off to ya mate, quality work, can't wait to see this project finished Link to post Share on other sites
rodney 17 Posted July 6, 2009 Report Share Posted July 6, 2009 nice work... If I may just add a little food for thought as you're doing it yourself... not teaching you to suck eggs here..... If you can keep any individual bend below 30 degrees then the flow will improve quite a great deal. Also minimise welds as they form internally as well so unless you can get in to grind them off as you go... Though there is an argument that it helps the pulse waveforms flow. Also if you match the lengths on both then apart from stabilisg pressure it should help equalise the flow into the cylinders that always get slightly restricted flow on standard systems... Thus getting a better burn on your mixture and thus reducing heat build up on spent fuel mixture..As I said just for your gray matter keep going I always like watching these when people have more skill than I....Cheers Link to post Share on other sites
legvw 0 Posted July 13, 2009 Author Report Share Posted July 13, 2009 nice work... If I may just add a little food for thought as you're doing it yourself... not teaching you to suck eggs here..... If you can keep any individual bend below 30 degrees then the flow will improve quite a great deal. Also minimise welds as they form internally as well so unless you can get in to grind them off as you go... Though there is an argument that it helps the pulse waveforms flow. Also if you match the lengths on both then apart from stabilisg pressure it should help equalise the flow into the cylinders that always get slightly restricted flow on standard systems... Thus getting a better burn on your mixture and thus reducing heat build up on spent fuel mixture..I was trying to keep the lengths the same but i also wanted to fit the air filter i've got onto the end of my turbo, so i tryed to 'kick' the turbo to the right of the engine. Since you've said this, it has got me thinking cause were my turbo would be is were the coolant line is coming out of the head!!!! :@ So back to square 1... Link to post Share on other sites
lowvr 0 Posted July 15, 2009 Report Share Posted July 15, 2009 nice skillz there mate...keep up the good work ...i hope you dontget tempted to rush as the work so far is really good! Link to post Share on other sites
legvw 0 Posted July 17, 2009 Author Report Share Posted July 17, 2009 nice skillz there mate...keep up the good work ...i hope you dontget tempted to rush as the work so far is really good!I wish' date='i can't find the time atm to rush!! Or the money :-(But i've found a couple of hours this week in the evening to start my rear brace, (as mentioned earlier in this thread) which will support the rear cross member that supports the rear subframe, and also to act as a rear strut brace for the rear suspensionfrom this[img']http://i618.photobucket.com/albums/tt270/legvw/1025.jpgto thisShould be able to get it finished and painted tomorrow Link to post Share on other sites
john555 0 Posted July 18, 2009 Report Share Posted July 18, 2009 nice ideas looks good mate Link to post Share on other sites
legvw 0 Posted July 18, 2009 Author Report Share Posted July 18, 2009 Cheers, are you thinking of doing something similar? Should stiffen the rear end right up! Have you descided if your going to do yours yourself yet?? Link to post Share on other sites
golfrabbit33 0 Posted July 18, 2009 Report Share Posted July 18, 2009 fella, i hope this goes well for you, so much hard work. and maybe you can give the big head in the white mk1 (ak) a whoopin. Link to post Share on other sites
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