tribetype40

I got the 'CCU' box wired up to the engine last night and the difference is instantly noticeable. with it turned off the engine revs as normal and very linearly however with the cam control turned on (with low settings so I could toggle the advance on without drivng the car) it would rev normally up to the point the cam gets triggered then the neadle whips around as the engine revs alot more freely! cool. So I think this bodes well for the end result. I didn't get around to wiring up the varable inlet tonight as its gettting dark too quick ( and, it was a little cold :camp: ) So I will get that done tomorrow. Oh, and I booked it in to Stealth for next Friday so we'll finally get to see if all this work and effort actually pays off!!! gulp. I'd rather not end this thread with one of these :epicfail: lol

not much to report today, I got the 'CCU' in the car and wired it up. Here a picture of when I had it all in bits to set it up. This first test fit has shown that I could do with changing a few components to improve a couple bits but thats 'development' i guess. I did a static test i.e. with just the multimeter connected to the output wires and to all toggle on at the correct time so the next thing to do is get the varable inlet wired in and then its time for a test drive!! I know I've said it before but this time I really think I could be booking it in for a rolling road tune this week and I'll finally see if it produces a drive similar to the mk4. Actually that had made me think, does anyone have any graphs of a standard 2.8 AUE engine MK4 golf for a comparison..?

Hi, I've started a build thread which is covering the whole car and not just the engine so I have concentrated more on that thread. theres a recent update on the running of the engine but I still haven't had the time to get enough finished to actually get it mapped yet... its getting there, but slower than I would like! this is the new thread: viewtopic.php?f=11&t=83985

I have now coined the phrase 'CCU' for my 'Cam Control Unit' ! lol I got to maplins today and sat in there with all my circuit boards then emptied the shelves to find a box that they would all fit into. turned out to be quite a big box but I did a good bit of work consoldating some of the parts of the boards into smaller parts etc, as such I have less wires to connect up now. If all this turns out to work ok and I pursue building a plug and play kit I reckon the circuits and components could be reduced be a much much smaller unit, it you can get double sided surface mount boards made at a sensible price this thing could be tiny. As for wiring it up, it only needs 5 wires connecting! Heres a few pics... The two leds will be tell tale lights to show me whats working and when - there would be no need for these in the finished module.

Heres a little bit more of the interior..... The seats are Recaro speedline seats with electric height adjust and twin lumber supports. They were the first part of the interior I re-trimmed and the paneling was inspired by the new scirroco. I also added extra panels to the bolsters which have helped to visually narrow the seat and I think make them a little more modern in style. The door cards were a lot of work. I changed the the paneling to tie in with the seats and also changed it so that the panels ran horizontally, the panels around the arm rest were also changed so that the padded section didn't run over it. I've never liked the way the leather rucks up on the origonal leather door cards. Also all the edges of the plastic parts as well as the leather that will touch the paint have had anti squeek tape ran around the edges. This should help loose any squeeks or rattle when its finally assembed..... finally! Fla, will try and get a few pics of the edging on the carpet later....

lol, the best bit is not 100% yet so I will hold back untill I'm happy but I'm hoping it should be quite different! Vick, cheers. I have to say though, I saw your car at Edition and that sure is one lucky vin number. I dont know of anyother car thats had soo much care and effort put into it over its life! and always tastfully done!

best is yet to come.... ;-)

Didn't do much tonight but I have finally started to assemble part of the car for the final time (I hope!) heres a few pics of the dash. A few closeups of putting the flipseal on the front again, then the interior of the car showing the modified heater ducts, then with the dash fianlly fitted. Oh yeah, these also show the carpets I made a little while ago, its BMW mini carpet in charcoal. Bought it on the roll, most of it is made from flat parts but there were a few bit I needed to pattern up and shape. Where I had to have a break, the edges were bound with webbing and the stitching hidden. Need to hire a carpet doctor to bring them up again as I've been getting in and out of it for the past year making and fitting the interior!

cheers, guys. it really good to get feedback from people who understand what i'm trying to do, I was laughing with Jay that when we do something and try to explain it to our fairer halves we kinda get a puzzeled smile and a 'thats nice dear' !! lol or the question, 'why dont you just by a new car!?

Thanks Kip, Believe me I'm no Electrical wizz!! was never a strong point at school. This is just a case of finding out whats needed and finding something that can produce the sinals etc... its taken the longest time to find/workout but its finally looking like I'm nearly there.....

Here we go.... Just did a short video of testing the cam control board I made. its switched manually at the moment so only switched while are idle. When actaully being used in the car the cam advance isn't activated at idle as the result of advancing the cam make for a pretty rough idle as you can hear in the video. Later in the video I rev the engine with the cam advanced, you can hear that the running smooths out. I also had the timing light on, its clear to witness but doesn't comeout verywell in the video but you can see the cam advance. [youtube:3g1ozb4d] [/youtube:3g1ozb4d]

Only a quick post this but will hopefully get more info and video up tomorrow... but, I manually connected up my control board to the Cam advance solenoid and tested it on the running engine and it works! :clap: I still have to connect it to a couple of other boards with will switch it on under the correct conditions but this is just a case of connecting them up as I already have them built. I then have to find a box suitable to house the boards in so a trip to maplins tomorow is in order.

Only a quick post this but will hopefully get more info and video up tomorrow... but, I manually connected up my control board to the Cam advance solenoid and tested it on the running engine and it works! :clap: I still have to connect it to a couple of other boards with will switch it on under the correct conditions but this is just a case of connecting them up as I already have them built. I then have to find a box suitable to house the boards in so a trip to maplins tomorow is in order.

Loving the stance on those wheels and with the new arches!

Thanks for the comments fellas. It is all slowly coming together now! Here the pics of making the new binnicle, modeling foam was attache to the leading edge and then a small jig made up to form a constant shape to the front edge. I then added card to the dial cluster and stretched a pair of tights over the binnicle and pushed the dials in. Resin was then painted over the tights and left to cure a thin skin, it holds its shape now ready for a few layers of glass fiber. This would ensure a perfect fit later.

Because of the new style centre tunnel I had to get creative with the handbrake - cue disc cutter and welder..... off.. on... The center tunnel in these photos was later thrown away as I wasn't happy with it. A new one was made to sit a little higher and I think could be seen in the earlier pics of the dash above.

The original dash, was stripped right down and most of it cut up to leave only parts you can see. The original Corrado dash was cut back and the new panels offered up. I kept cutting the corrado dash back until the new panels were in the correct place while trying to maintain all the heater ducting for the screen and face vents. I also kept the end faces of the Corrado dash and the area around the streering coloum. This ment I knew the width would be as standard and there would be no probems going around the steering coloum and the door cards. I also made a few changes from the origonal dash. I was never happy with the binnicle over the dials on the first dash so I made a new one with a more 'aggressive' style. the centre stack was also changed to be made from GF and have a more complex shape to hold the sat nav at a more horizontal angle ( i had problems with it reading the disc before) I increased the height of the center tunnel this time around so the bottom of the center had to be re-shaped New binnicle can be seen in this pic, it was later given thickness but i think those photos are on my phone, will try and get those up later. here I made the center stack infill panel and sorted the vents Here's a pic of one of the many times it was painted in pimerfiller to get the perfect finish ready for trimming - but that was someway off at this stage!

BIN!

looking good, nice clean engine! The first picture of 'what are these' are MK4 style engine mount brackets first one is the Rh (drivers side) mount that bolts to the block the other one I think is gearbox side one. Dont know what the black thing is in the other photo but the big ring one looks like it the one which holds the aux air pump and hangs of the front of the engine ( right in the middle behind the rad) on the R32.

heres some pics of when I fitted the mk4 airbox, I'd fitted one before so knew what had to be done but this time I made a better job of everything and also used part of the old fan box so I could retain the fixing by the inlet for the fan. this also ment it would position it correctly without any guess work. pictures show removal of the flange from the old box and fitting to the new mk4 box. Once in place I plastic welded the old to the new... In the last picture you can see I had removed and blocked off the pipes and outlet that goes through the bulkhead for the aircon.... during our hot spell I took the heater box out and refitted it all ready for aircon..... well probably ready for winter now!

:lol:

Cheers, B anc C pillare will need a stich line as it wont stretch enough to cover in one piece. The stitch line is what I've tried to show in that last pic. these show the patterns I made as a template first and a little bit of the process....

Eh, you can talk buddy! lol R32's looking impressive, certainly dissapeared quickly enough! I was hoping to have a good day today and get the engine running all set up and check the activation of the cam advance... but, I seem to have had one of those days were, whatever you touch you ar5e up. I've always had a little crack in the sump that just weaped oil, so thought I'd pop it off and run a sliug of weld over it - long story short and a big hole late.... i need a new sump!lol as such I may have to delay I plan for getting it mapped next week :cuckoo: So I cut my losses with the mechanical stuff and turned my attention to the interior. I have most of it trimmed now but today I did the headlining. The old headlining looked fine but on closer inspection the material had started to come away from the substraight so 'the o'l fing'll 'ave to be redone' It neded a little help where it would crease under its own weight on the thinner parts so I braceg it with a thin layer of glass fiber on either side, Then I test fitted the cover, and marked and cut the difficult areas of the sunvisor recesses, When I was happy with that it was time to start sticking stuff, first up new foam (2mm) The final fit of the alcantara... I've also finished the 'A' 'B' and 'C' pillars.... Tomorrow its the sunroof out to trim that.

MK4 engines have adjustable cams yes but its slightly different that the honda system. I think Vtec varies the timing and lift of the valve while the vw system is only timing. Early 24V's have a variable inlet cam only while the later engines and r32/audi 3.2 have variable inlet and exhaust cams

Here a few pics of the development of the front engine mount. fits around everything so you dont have to mess about with remote coolers etc...