Another ITB build thread

[grelland]

Thanks guys.

This weekend I got a bit less done than I planned, and a couple of challenges showed up.

One of them being that the clearance from the injector holder to the shelf is VERY limited. No big deal, as I can easily grid off a lot of material there, but I am unsure of how much the engine twists on its new, "heavy duty" VW rubber mounts.

klaring.jpg

[supaninja]

You could use type 3 FI spacers, that would move the manifolds up almost 1/2".

[sideshow]

A type-3 spacer or a late type-1 spacer would raise the manifold a little. But the ID of the holes is just like stock ports, this might kill any port matching you may have done.

The wall thickness of those holders are oversized and can be trimmed to fit.

[Steve Arndt]

It the clearance isn't enough, it will show up as leaking manifolds or broken manifold flange ears. Both are easy to figure out, BTDT You need at least a half inch of clearance with good mounts. Lots of good mounts. I haven't used solid mounts, strictly street with urethane and rubber. You must control ALL wheel hop or you will have problems.

At least you don't have an early bug, the clearance is much worse.

[grelland]

Thanks, guys, the heads are hardly ported at all on the intake ports, so it will not take much effort to match port these type-3 spacers.

So far I have brand new so-called heavy duty rubber mounts, but I also have a Berg-style intermediate mount that I might also use.

BTW, are these spacers readily available? I have never seen them before. Maybe only used?

[supaninja]

They used to be readily available, samba classifieds is probably your best bet. Used ones are fine as long as they are not cracked, just glue some new gasket paper to them.

[sideshow]

This thread has a couple part numbers; viewtopic.php?f=23&t=98922
Type-1: 043 129 707
Type-3: VWA311-129-707C

[grelland]

Thanks, I will look into that.

Meanwhile, I dug out the angle grinder again, and trimmed off about 20mm of the lower part of the injector holder. I hope that the additional 10mm or so from a spacer will give me enough clearance:

space.jpg

Next I fitted the fan shroud and the fuel lines behind it. A little tight, but looks good from the "front" side:

engine.jpg

I need another 12 inches or so of fuel line, and it is in the mail. Meanwhile I use a temporary one, so that I can get this thing tested. You can see the red hose end just above the shroud, and it will of course be replaced with a black one.

I also started to look into the fuel pump, as it died on me the last time I drove the car in October. When I turn on the ignition, starts the relay to oscillate, and no fuel comes out. The fuse is fine... I guess I have to take out the pump and have it checked.

[grelland]

They used to be readily available, samba classifieds is probably your best bet. Used ones are fine as long as they are not cracked, just glue some new gasket paper to them.

House of Ghia had them in stock, so I will have a pair coming my way

[andy198712]

I checked my engine movement today, on a beaten old 1200 with old mounts the left side dipped no more then about 10mm it looked like more but that was all the gap I saw when I held an Allen key flush on the cylinder tin and stabbed the throttle repeatedly.

If it were me I'd give it a good sharp smack with a hammer and wood drift on the metal work to make a clearance dent lol
Depends how nice you can make it look

[grelland]

thanks for taking the time to check and I will not wack the sheet metal of this car if I can avoid it

[andy198712]

was no trouble mate!i think you'll be ok, especially with stiffer mounts then my crappy old one lol

whats overall clearance?

[grelland]

The overall clearance is about 15 mm currently, and i have a pair of 10mm spacers in the mail, so the total will be about 20-25mm.

Other than that, I have managed to fix all the little things that seems to take forever. The accelerator cable is on, but needed an extra return spring. The TPS is hooked up and calibrated. all the fuel lines are in place, with a Fuel pressure gauge inline for checking that all is well. I also hooked up the dynamo, as I used a Porsche alternator on my previous setup, I had to do all the wiring again.

I have run into a few minor issues, though, mostly related to available space... Especially around the #3 and 4 air filter, but nothing to stop me firing it up

What remains now before I can fire it up, is mostly the fuel pump. I ordered a new walbro one, so if I cant get the current CB one working, I have a plan B.

[andy198712]

i love it when a plan comes together!

nice one mate

[grelland]

Thanks.

I went out and took a couple of pictures after I cleaned up most of the mess today:

engine.jpg

lhs.jpg

rhs.jpg

As can be seen, it is extremely tight on the left hand side, so I will have to relocate the EDIS coil pack, and I also plan on mounting the FPR on the other side of the bulkhead, so then I will hopefully have enough room for the air filters.