Intercooler and pipes

This post will be updated as i make the pipes

Intercooler 700x300x65 (core 550)

Water pipes, coolant reservoir and radiator

I made a stainless steel extension for the lower pipe, and cut a bit for the upper one.

Next i made a stailess steel coolant reservoir mount with a round lower part so that it fits better than the mk2 one on the right.

This is how it looks like in the end

Golf mk1 GTI instrument cluster / speedometer / tacho

After starting the build of the speedometer for the 3rd time, i think i'm in the right path.
Instead of using the original tdi speedo or a full digital speedo with a smaller board i found an interesting solution.

Older ibiza have a digital/analogic combo that uses a electronic signal to display the speed and convert it do move the mechanical numbers. Just what i wanted to have a stock look.

For the tachometer i read that the original mk1 one should work with the ecu signal with no modifications, i hope so...

The original MK3 conector was adapted to the mk1 cluster.

The speedo will sit on the right side as the original mk1 and the new mk5 or mk6.

This is the original ibiza circuit board where you can see the hole where sits the detachable speedo and the condensors that i would like to know if i have to use or not as they sit in the path of the current that goes to the speedo circuit.

On the left the resistors and the diode connect to the battery light

1 - T28/10 green wire from speedometer conector

+ - +12v

-  - ground

The smoked light symbols were cut from the original CE2 cluster
The battery light circuit is a copy from the CE2 cluster.
The oil light uses an inverted relay so it swithes of the light when the tdi switch send ground to the relay proving that there is oil pressure.
The malfunction Indicator Lamp is directly connected to the pin 20.

New MK4 throttle pedal

Because i sold the mk3 throttle sensor i had to make a choice:

1. Buy another mk3 pedal sensor and adapt the wiring as it works perfecly with mk4 ecu

http://forums.vwvortex.com/showthread.php?5182138-AHU-DBW-pedal...can-I-use-a-mk4-DBW-pedal-instead
http://forums.tdiclub.com/showthread.php?t=440272

mk4 pin # (color) -> mk3 pin # (color)

1 - Gray/white -> 5 - Green
2 - Yellow/green -> 2 - Pink
3 - Grey/Red -> 3 - Brown
4 - White/Blue -> 1 - White
5 - Grey/Blue -> 4 - Grey
6 - Brown/Blue -> 6 - Yellow.

only switched 1 and 4 on a friend's ptoject, info to confirm

2. Adapt the mk4 pedal that i have. So i broke off the plastic pedal to remove the metal fitting and welded it to my modified mk3 pedal.

 prototype done...

Vinyl carbon fibre and a new airfilter box

Vinyl carbon fibre on the engine cover and a new airfilter box because i think i won't be able to use the one on the right engine side.

Vent windows, GTI spoiler and Suspension Strut Top Cover

The vent windows were sand blasted and painted, the glued glasses were removed to put in bolted ones that are more secure.

Fuel tank with lift pump

To remove the fuel tank i had to unbolt the rear axle, the rest is pretty easy.

Only the first PD cars didn't have a lift pump so i wanted to use one on my car.

The easyest way is to use an external pump but i wanted to use a lift pump in my tank but needed a swirl pot just like on cars with PD engine.
External swirl pot was not something i wanted to do.

The pd swirl pot is too big to fit throught the mk1 hole in the car and i didn't want to cut it so i had to find a smaller one.

I bought a mk1 cabrio pump but it was too complicated to make an internal swirl pot that would fit with the PD lift pump adapted there and fit trought the mk1 tank hole.

I bought a mk2 GTI lift pump and made those adaptors so it would fit on the metal mk1 tank, it would be more easy to make the swirl pot but still not a peace of cake.

Finally i found the perfect fit for what i wanted to do. It is a peugeot 106 / citroen saxo lift pump with swirl pot, 2/3 the size of the PD unit so a little bigger than the mk2 lift pump.

So i opened up the metal fuel tank to see the internal swirl pot and stuff

Here you can see the different sizes of the mk1, mk2/mk3, peugueot/citroen and mk4

Welded and grinded

Painted and placed under the car

Just need to connect the fue lines and i can close it