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Barn Find Laser Green 1.9 Gti.


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44 replies to this topic

#21
welshpug

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they are line bored in situ so only match that head.

#22
Leslie green

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they are line bored in situ so only match that head.

 

 

Thanke Mei ,well that's a bit of a pain then ! I may get out the chemical metal I guess ..



#23
welshpug

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if its just the thread then a helicoil will do the trick.



#24
Leslie green

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 Its already had a helicoil which has pulled out and its left the wall too thin and has split will have another look and see .



#25
welshpug

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you can use another cap but it will need machine work and honing.



#26
Leslie green

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Got the gasket on today ,started ok but I suspect the timing is off a bit despite me marking it as best I could , move the dissy a bit and it ran a bit better . Put on a new sad valve hose id been waiting on and managed to snap off the rad overflow while trying to fit the end to the inlet manifold ,should have took the rad off but didn't like disturbing the pipes again as they were a pain to fit !

        Doesn't like to idle just tuned up the throttle stop last week but tried to follow the haynes and set it right using the air bypass of the throttle body to lift the idle , I also metered the throttle switch stop and it's working despite having a big crack in it but need to set its position right , still leaking oil from rocker cover where screw is stripped but much less now but will try some chemical metal type stuff to give something to tap out and put a helicoil in see how it goes .

    Tried to get the back bumper of but no way the screw on the sides will budge and don't want to bust the bumper plastic so will try a nut splitter next time .

 

Temporary fix !

 

20170706_163254.jpg

 

Bit of rust on inner wing needs welding .

 

20170706_162959.jpg


Edited by Leslie green, 06 July 2017 - 07:32 PM.


#27
Leslie green

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Well chemical metal was as much use as butter in a hot engine,helicoil pulled out when hot  !  Got a man to tig weld it up yesterday ,made a little jig to hold it tight with a bit of copper pipe on the bearing surface to act as a heat soak and protect it during welding. ground it flat in the pillar drill today with an abrasive pad ,took about a mm too much off but no matter then drilled and tapped it . Seems to fit just as it did before and had the engine running ok , oil weeps out past the cover bolt heads when hot so need a fibre washer to stop that and I managed to tear my new stat gasket fitting the bearing ....had ordered plastigauge to check clearance but got impatient and it runs ok so far .

 

Idling ok now after adjusting the bypass on throttle body ,bolt was missing holding the oil filler to inlet causing an air leak too which wasn't helping. Tried to get back bumper off but nuts wouldn't turn so tried a nut splitter , got one side off but the other just chewed up  it's off now but a little of the bumper came with it as patience ran low .The centre bolt rung off with vice grips so bumper is off at last and ordered 2 bumper mount pressings as at least one side is rotten.

 

36465093445_2f81543b06_b.jpg20170809_105325 by Leslie, on Flickr

 

36419365146_71386dc605_b.jpg20170809_125305 by Leslie, on Flickr


Edited by Leslie green, 09 August 2017 - 04:49 PM.


#28
Leslie green

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Got 2 rear bumper mounts and have made a Start on the welding , not too much needed as far as I can see so started with the inner wing on passenger side,turned out ok. Have a leak down the back of the engine and checked closely today and the block has a crack ,might have been the reason it was taken offroad all those years ago or it got frost damage in storage.It's just below the bottom of the head bolt in the recess . I used air pressure to put 1 bar in the cooling system and then it drips quite a bit ...Are 1600 and 1900 blocks all the same ??  might make getting one a bit easier !

 

36484201302_2d57087f8b_b.jpg20170816_154224 by Leslie, on Flickr

 

35844383513_bdc1e3ed54_b.jpg20170818_151916 by Leslie, on Flickr

 

36515259351_1228ed79f0_b.jpg20170818_171153 by Leslie, on Flickr


Edited by Leslie green, 18 August 2017 - 06:15 PM.


#29
welshpug

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any 8v alloy xu block will do, specifically its easier to find one with the same type of tensioner, saves faffing with studs or tapping holes.

#30
Leslie green

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Thanks Mei good to know , going to give kseal a go soon as its a minor leak and it may take a while to get another block/engine.



#31
toolie72

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It'll probably work (after a fashion) long enough to locate another block
However
I had to do this a few years ago and I started having hoses popping-when I stripped block it was obvious that the sealer had set on the back side of block resulting in limited water flow (like only three sides of the rectangle) so something to watch for

#32
welshpug

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unlikely kseal will do much as its not a gasķet thats gone, well yet anyway!

the rear bolts will no longer be pulling the head down onto the liners.

#33
Leslie green

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It says it seals holes/cracks in blocks but yes as this is a linered engine I see what you mean .It's only below 1 stud at present as far as I can see in the recess though how far that extends is hard to tell, plugging the leak till I get it though mot would be nice not expecting any miracles !


Edited by Leslie green, 20 August 2017 - 08:34 PM.


#34
ciarandeery1

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Be good to see another local car out and about :)



#35
Gaz205

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Nice welding 👍

#36
Leslie green

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Yes Ciaran see you are adding more to your fleet and have got a 1.9 now  :D Looking a cheap 1.9 block (pre cat  )or a complete running  1.9 engine if you hear anything local ..  Thanks Gaz turned out better than expected made a start on the rear bumper mount but my daughters summer school club was flooded and wrecked  last night so will be closed for a while so on childcare duties  till back to school time so progress stopped (again !)


Edited by Leslie green, 23 August 2017 - 02:56 PM.


#37
ciarandeery1

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Yes Ciaran see you are adding more to your fleet and have got a 1.9 now  :D Looking a cheap 1.9 block (pre cat  )or a complete running  1.9 engine if you hear anything local ..  Thanks Gaz turned out better than expected made a start on the rear bumper mount but my daughters summer school club was flooded and wrecked  last night so will be closed for a while so on childcare duties  till back to school time so progress stopped (again !)

 

if i ever finish my black 1.9 thatll be 2  :lol: im sure that shouldnt be too hard to come across. will put the feelers out for you. 



#38
Leslie green

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These things take time  :) Back to school so got a bit more done , Got 1 bumper mount fitted these are a bit of a faff to weld in the arch and I had to adjust them a bit to fit with a big hammer ,looks like these little pieces  and a bit of sealer is all holds the 1/4 on  as I could see a small gap where the inner arch meets the 1/4 that had sealer in it .Luckily nothing else in there had any rot at all which was a bonus .Got the panels of EMPA on facebook .There is a dent in the arch end looks like it was caused by big wheels in the past but was hidden by the plastic arch and has also worn the edge of the rear valence ,bump stops had rotted away and were long gone !

 

36527838010_e63363ee6b_b.jpg20170830_150035 by Leslie, on Flickr

 

36527840310_2b784f4f15_b.jpg20170830_170615 by Leslie, on Flickr


Edited by Leslie green, 30 August 2017 - 08:21 PM.


#39
Leslie green

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Got the other side done today ,it was much more solid and harder to remove .

 

36941696255_ac80eed1e5_b.jpg20170831_133847 by Leslie, on Flickr

 

36133574583_34ce8085b4_b.jpg20170831_160617 by Leslie, on Flickr



#40
barneys66

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Nice work.

I've got a cracked block too, and Radweld (the version for blocks) has held up well so far..