VASK Forum (VW Audi SportKlub of NZ)

VOLKSWAGEN => Mk2 Golf - Jetta - Corrado => Topic started by: robh on February 22, 2009, 07:57:46 pm

Title: Golf Cage Install
Post by: robh on February 22, 2009, 07:57:46 pm
What have I done  :'(
Title: Re: Golf Cage Install
Post by: qta4 on February 22, 2009, 07:59:19 pm
Just make sure that the window winders dont conflict with the side bars..........Like Niks do >:D
Title: Re: Golf Cage Install
Post by: rambo_005 on February 22, 2009, 07:59:29 pm
Jeez that's a wee bit different to how I last saw it ;D

It is more intact than mine - can't wait to get some more bits attached.

What handbrake cover is that Rob?
Title: Re: Golf Cage Install
Post by: robh on February 22, 2009, 08:03:25 pm
Just make sure that the window winders dont conflict with the side bars..........Like Niks do >:D

Cage man says electric windows good, so they are staying.
Title: Re: Golf Cage Install
Post by: robh on February 22, 2009, 08:04:17 pm
Jeez that's a wee bit different to how I last saw it ;D

It is more intact than mine - can't wait to get some more bits attached.

What handbrake cover is that Rob?

You got eagle eyes there Cam, it's a black leather Golf Rallye one.

Has been removed since that pic and will be up for sale soon....
Title: Re: Golf Cage Install
Post by: rambo_005 on February 22, 2009, 08:20:39 pm
You got eagle eyes there Cam, it's a black leather Golf Rallye one.

Has been removed since that pic and will be up for sale soon....

I'm keen!
Title: Re: Golf Cage Install
Post by: typ53 on February 22, 2009, 08:55:54 pm
What have I done  :'(

Nice, tidy handy-work!  :P  Must get you round sometime to help with the Roughy...

Title: Re: Golf Cage Install
Post by: 80 Vert on February 22, 2009, 09:06:11 pm
Who did you end up going with for the cage?
Title: Re: Golf Cage Install
Post by: GTI's on February 22, 2009, 09:08:00 pm
What have I done  :'(

The right thing!
Imagine how insane that thing will be without all that junk!
Now take my lights off it!
Title: Re: Golf Cage Install
Post by: robh on February 22, 2009, 10:09:07 pm
Nice, tidy handy-work!  :P  Must get you round sometime to help with the Roughy...



Believe it or not I was actually careful removing stuff!
Title: Re: Golf Cage Install
Post by: robh on February 22, 2009, 10:09:39 pm
Who did you end up going with for the cage?

Back to Plan A, Sonic Race at the Mt.
Title: Re: Golf Cage Install
Post by: VR6 on February 23, 2009, 08:18:32 am
Believe it or not I was actually careful removing stuff!

 Ah I can truthfully say that I wasn,t careful when I stripped the 16 valve on the weekend, Knowing full well that the carpet and headliner etc were not going back in. Still got to make up my mind about the dash cover. Looking good Rob. You will need to clean the area around the base of the A pillar. I found the best way to remove the tar board was to get a blow torch and heat it up to it bubbled and the it just scrapped off easy as. Only took a few hours of chipping it before I tried another method. Are you hoping to have everything finished for the track day in May?
Title: Re: Golf Cage Install
Post by: robh on February 23, 2009, 08:22:27 am
Yeah, I'm not so sure about the dash and heater, will see what the cage man says is possible.  Probably if heater goes so will dashboard.

Prefer to keep both really at this stage, can't afford to rewire gauges, etc and prefer to stick it all back in.

Blow torch, hmm, sounds like fun, bet it smells nice.

Not in any rush to have it done.  May seems a long way away, but you know how these things go!
Title: Re: Golf Cage Install
Post by: AngleBox on February 23, 2009, 06:55:35 pm
Keep the heater for defrosting. Works much better than a rag.
Title: Re: Golf Cage Install
Post by: qta4 on February 23, 2009, 06:57:48 pm
I agree,and also for when its cold.does not weigh much either.
Title: Re: Golf Cage Install
Post by: robh on February 23, 2009, 07:53:18 pm
I agree,and also for when its cold.does not weigh much either.

I've got a VR6 to keep me warm :)

Title: Re: Golf Cage Install
Post by: qta4 on February 23, 2009, 08:02:47 pm
So you are after maximum power to weight ratio then Rob, have you thought about your 4 wheel drive bits as well?
Title: Re: Golf Cage Install
Post by: GTI's on February 23, 2009, 11:13:28 pm
I've been driving my mk1 with no heater core and the heat that gets in is massive.
So i was thinking i'd make a bilge fan hot and cold with a little dash vent flap.
blow hot on window & feet.
or shut it off.
Title: Re: Golf Cage Install
Post by: Filx on February 24, 2009, 07:30:47 am
Thats a good idea - a light weight marine blower system of some sort could be good. Being able to demist the screen is pretty essential IMHO.
Title: Re: Golf Cage Install
Post by: robh on February 24, 2009, 07:48:31 am
So you are after maximum power to weight ratio then Rob, have you thought about your 4 wheel drive bits as well?

Not really, just going to listen to advice from "cage man" on what's practical and what's not.
Title: Re: Golf Cage Install
Post by: bigbumper on February 24, 2009, 05:38:23 pm
We buggered around with 12v hairdryers and all sorts of other nonsense with XS RPM.  In the end you can't beat triple layer overalls for warmth, and smeared shampoo all over the internal glass face for demisting

Thats a good idea - a light weight marine blower system of some sort could be good. Being able to demist the screen is pretty essential IMHO.

The guy who recently replaced the windscreen in a mates car said he can make windscreens with heater elements in them (like rear screens) for a pretty reasonable cost, provided he's making them in a limited production run (6 or more, as opposed to one off)
Title: Re: Golf Cage Install
Post by: Bullseye on February 24, 2009, 08:34:48 pm
Bilge blower works for the track whore just put the intake in the footwell and she is real warm ;D
Title: Re: Golf Cage Install
Post by: robh on March 06, 2009, 09:03:01 pm
Dropped car off last weekend to Bic at www.sonicrace.co.nz

Picked up a couple of Sabelt Titan's in black and alloy brackets from Dennis at www.autoquip.co.nz

Couple of teasers pics from Bic attached.

Title: Re: Golf Cage Install
Post by: robh on March 06, 2009, 09:04:07 pm
.
Title: Re: Golf Cage Install
Post by: robh on March 12, 2009, 05:31:32 pm
Dropped seats off last night.

Main 6 point cage is done including diagonal brace from main hoop to rear tower and bracing front tubes to bulkhead.

Stuff to do:

1. Door bars, won't be full X as my dodgy old hip will struggle getting in as it is
2. Rear bar between main hoop for harnesses
3. Harness anchor points
4. Seat mounts

Hopefully have some more pics tomorrow...
Title: Re: Golf Cage Install
Post by: robh on March 14, 2009, 07:19:45 pm
Door Bar
Title: Re: Golf Cage Install
Post by: robh on March 14, 2009, 07:20:38 pm
Seat Mount
Title: Re: Golf Cage Install
Post by: qta4 on March 14, 2009, 07:31:19 pm
I really respect anyone who can weld like that, really good.

Title: Re: Golf Cage Install
Post by: NasTnaS on March 14, 2009, 07:40:24 pm
I really respect anyone who can weld like that, really good.



at work we've got some really good welders... there is 1 character who can weld in any orientation... his work is exceptional....
Title: Re: Golf Cage Install
Post by: robh on March 16, 2009, 09:46:03 pm
More...
Title: Re: Golf Cage Install
Post by: robh on March 16, 2009, 09:47:06 pm
More...
Title: Re: Golf Cage Install
Post by: qta4 on March 17, 2009, 08:19:08 am
Are you running a diagonal bar across roof Rob?
Title: Re: Golf Cage Install
Post by: robh on March 17, 2009, 08:45:22 am
Don't think so, not sure to be honest, his brief was to build a simple 6 point cage that could be added to later if desired.  I've just left him to crack on as he knows his knitting.
Title: Re: Golf Cage Install
Post by: qta4 on March 17, 2009, 08:49:33 am
I had one fitted, mostly because i condidered the roof the weakest area, it causes a litle hastle tho, with cage insulation.

But my sun roof is still installed, and i can still operate that.
Title: Re: Golf Cage Install
Post by: GTI's on March 17, 2009, 08:51:03 am
Looks awesome Robbo!  :o
he's done lots of work in the seat area to get it like that!
Title: Re: Golf Cage Install
Post by: robh on March 17, 2009, 09:12:33 am
I had one fitted, mostly because i condidered the roof the weakest area, it causes a litle hastle tho, with cage insulation.

But my sun roof is still installed, and i can still operate that.

Despite having pretty large footings the vertical tubes could be "wobbled" until he added some braces from the front tubes to the bulkhead and also the rear diagonal from the main hoop to the rear tower.

You could go nuts adding bars all over if you had deep pockets aye!
Title: Re: Golf Cage Install
Post by: NasTnaS on March 17, 2009, 10:05:11 am
when you buy a roll cage do you get any paper work with it?

thats a question for anyone that has a roll cage...
Title: Re: Golf Cage Install
Post by: choppy16v on March 18, 2009, 04:36:03 pm
i dont have one yet, but i think you send off photos of all the welds before paint with letter from engineer to mnz. they send back log book
Title: Re: Golf Cage Install
Post by: robh on March 31, 2009, 10:59:41 am
Collected car this weekend.

Cage looks good, car looks pretty sad with windows out and wiring all over the shop!

Next I'm focussing on removing all wiring looms and doing them properly, removing all redundant sections and re routing wiring out of harms way (i.e. exhaust manifold).  Surprising how much stuff isn't needed already :)

Toying with the idea of ditching standard power steering pump and fitting an electric unit so I can clear more space and weight from front of car, not sure if this will fly.  Had a good look at what the cage man did on a V8 Muscle Car and it's a really neat way to redistribute weight and free up space.

Title: Re: Golf Cage Install
Post by: qta4 on March 31, 2009, 11:02:13 am
Electric power steering, now that is a good idea,.

Are they available in NZ?
Title: Re: Golf Cage Install
Post by: 80 Vert on March 31, 2009, 11:34:23 am
9N Polo's have them as std, pump & fluid tank as one can be mounted anywhere.
Have brand new one here if you want to have a look at one.
Title: Re: Golf Cage Install
Post by: qta4 on March 31, 2009, 11:41:47 am
Could one be fitted to a mk1 golf John,maybe the whole 9N column
Title: Re: Golf Cage Install
Post by: robh on March 31, 2009, 11:48:38 am
Noel, check this link out:

http://www.bba-reman.com/content.aspx?content=remanufactured_electric_power_steering_and_electric_hydraulic_power_steering

You could use one from Peugeot, Citroen or new Polo.  Remote mount the pump, but I guess your issue is sourcing a suitable power rack?

Some others have the pump intergrated into the steering column, is that more what your thinking?
Title: Re: Golf Cage Install
Post by: robh on March 31, 2009, 11:49:57 am
9N Polo's have them as std, pump & fluid tank as one can be mounted anywhere.
Have brand new one here if you want to have a look at one.

Have you looked at the wiring for one of these?

Do you think it would be simple to run or is it going to need "special" VW black box to control?

Title: Re: Golf Cage Install
Post by: 80 Vert on March 31, 2009, 12:55:13 pm
Have not looked closely at it, from memory pump unit has + and - so should be straight forward.
There will ofcourse be a diagnostic wire also but don't see why it woudn't run without it, would be good to have a look and maybe try it.
Title: Re: Golf Cage Install
Post by: SteveC on March 31, 2009, 02:41:32 pm
Electric power steering, now that is a good idea,.

Are they available in NZ?

pretty sure the Mk5 Golf has electric PAS
Title: Re: Golf Cage Install
Post by: BB on March 31, 2009, 03:04:41 pm
I think some Vectras have a electric power steer system as well that uses a electric motor to add power to the standard rack..... or am i wrong....have been before.
 I have always toyed with adding honda PS to my mk1 from a civic. pump and rack. Couldn't be that hard could it?
Title: Re: Golf Cage Install
Post by: RS ZWEI on March 31, 2009, 05:46:53 pm
Electric power steering, now that is a good idea,.

Are they available in NZ?

Late model Civics have electric power steering, its meant to numb the steering feel though (what I have read).
Alternatively you could go to the gym ;) If you lived closer you could come alone with me? How does 6am sound?
Title: Re: Golf Cage Install
Post by: SteveC on March 31, 2009, 06:30:59 pm

steering feel on the Mk5 is way better than a wooden Mk4
Title: Re: Golf Cage Install
Post by: qta4 on March 31, 2009, 06:42:19 pm
Late model Civics have electric power steering, its meant to numb the steering feel though (what I have read).
Alternatively you could go to the gym ;) If you lived closer you could come alone with me? How does 6am sound?


The only reason for fitting P/S is to enable an increase of caster Nik.
Title: Re: Golf Cage Install
Post by: BB on March 31, 2009, 08:24:36 pm
Power steering is so you can hold your line without the steering kicking you around to much as you cant hold the wheel true enough without it really. I think on a targa it would be so tiring to not have power steer.
 Im a delicate wee thing, still snoring with the cats at 6am. 
Title: Re: Golf Cage Install
Post by: qta4 on March 31, 2009, 08:28:31 pm
Jem,,,,,,,,,,,,,,,,,,,,,,,,,,,,,FGS.
Title: Re: Golf Cage Install
Post by: RS ZWEI on March 31, 2009, 08:41:41 pm
Power steering is so you can hold your line without the steering kicking you around to much as you cant hold the wheel true enough without it really. I think on a targa it would be so tiring to not have power steer.
 Im a delicate wee thing, still snoring with the cats at 6am. 

WTF, get some weights Jem, man up. Ypu were representing Greenpeace on Breakfast last week were you? ;)
Title: Re: Golf Cage Install
Post by: BB on March 31, 2009, 09:07:44 pm
Me? No? No greenpeace.
 My arms are like twigs.
 Wob wants P/S too :-X
Title: Re: Golf Cage Install
Post by: qta4 on March 31, 2009, 09:14:13 pm
Me? No? No greenpeace.

My arms are like twigs.
 

.
I agree    ;D
Title: Re: Golf Cage Install
Post by: bigbumper on March 31, 2009, 09:37:39 pm
I think on a targa it would be so tiring to not have power steer.

Hell yeah it's tiring enough manhandling the old 130TC half a dozen laps around Taupo on a summers day!

And with FWD, an LSD and no P/S, I almost had to turn the intercom down in XS RPM - Stacey would be huffing and puffing into the mic halfway through the long Targa stages!  Hard work alright
Title: Re: Golf Cage Install
Post by: RS ZWEI on April 01, 2009, 08:14:44 am
Hell yeah it's tiring enough manhandling the old 130TC half a dozen laps around Taupo on a summers day!

And with FWD, an LSD and no P/S, I almost had to turn the intercom down in XS RPM - Stacey would be huffing and puffing into the mic halfway through the long Targa stages!  Hard work alright

How did people survive in the 70's/80's when these cars were new?

Title: Re: Golf Cage Install
Post by: BB on April 01, 2009, 08:52:20 am
They had hopeless tyres and only 1.6 engines. And they complained, hence PS became standard on almost all cars no matter how small.
 In a targa, if you dip a wheel into a corner and hit a pot hole the steering can be dangerously ripped out of your hands, PS is a good thing.
 Particularly if you want to race when you get older or have arms like twigs
Title: Re: Golf Cage Install
Post by: bigbumper on April 01, 2009, 04:27:39 pm
How did people survive in the 70's/80's when these cars were new?

Mine has wider, larger diameter tyres and a smaller Momo steering wheel, which makes the steering a fair bit heavier.  Plus the lowered suspension won't help there either
Title: Re: Golf Cage Install
Post by: BB on April 01, 2009, 05:29:53 pm
What about arms like twigs? Have you got those?
Title: Re: Golf Cage Install
Post by: ritmo on April 01, 2009, 06:31:45 pm
Nah bigbumper has huge guns. Some say Hulk Hogan rung him for advice. :D

I've looked into electric assist steering. It is attached to steering col. to help turn it, you use normal rack with a sensor such as abs to measure hub speed and then send signal with regards to how much assistance it gives. Obviously parking speed more, caning it less.
Title: Re: Golf Cage Install
Post by: vwrally on April 01, 2009, 09:55:22 pm
From what I know of these things the Opel system is reasonably easy to retrofit  to other vehicles. I think Ashton Wood and Bran Stokes are both running this set up on their BDA Escorts . (They are also using high ratio steering racks). I am sure that Colin McRae ran the same thing on his BDA as well


IMO if you need PS on a Mk1 golf then  I would suspect there was something wrong either with wheel alignment,suspension or steering rack.

One thing to check is that if you are running to much negative camber the driveshafts may need to be shortened by about 5mm.

At the extreme the driveshafts start tryng to push through the end of the CVs causing some binding

 
Title: Re: Golf Cage Install
Post by: 80 Vert on April 01, 2009, 10:04:02 pm
Had a look at the 9N Polo pump today, rack is a normal PAS rack with electric pump/res set up.
Multiple plugs on the pump so probably has "black box" built in but with a wiring diagram its easy enough to find out what each does and where it gets its signal/inputs from.
Title: Re: Golf Cage Install
Post by: VR6 on April 02, 2009, 08:02:50 am
Oh yeah the late Polo steering pumps are run by a computer alright. Quite normal to have to clear stored faults in them to be able to get them to go again after they have had a really flat battery
Title: Re: Golf Cage Install
Post by: BB on April 02, 2009, 04:46:39 pm
There is short and long driveshafts on mk1s I belive and its well bad to have the to long one in so Ive heard. :)
 Reach under your car and make sure you can clunk your shafts back and forwards a bit to make sure you have freeplay there.
Title: Re: Golf Cage Install
Post by: vwrally on April 02, 2009, 09:40:13 pm
There is short and long driveshafts on mk1s I belive and its well bad to have the to long one in so Ive heard. :)
 Reach under your car and make sure you can clunk your shafts back and forwards a bit to make sure you have freeplay there.
The problem comes if you run to much camber, it shortens the distance between the cvs and causes issues

We are running more camber than the standard set up will allow, we have sloteed the bottom holes on the struts
Title: Re: Golf Cage Install
Post by: robh on April 07, 2009, 06:18:55 pm
Well haven't progressed far.

Spent many hours last week in the evenings with looms on the dining table.

With all the trim out it so much easier to fix this stuff up.

Most of the sub looms are ok and don't need any work, I just picked my way through them looking for anything that has long since departed.

One is really messy and is a combination of original VW loom and my first attempt to fix up a pro's poor attempt at installing a Link Plus.  Think I'm going to start from scratch on this whole piece and do it properly.  The main thing that will make it easier is everything that's connected works, so I'm not having to work stuff out as I go.

Title: Re: Golf Cage Install
Post by: qta4 on April 07, 2009, 06:51:05 pm
I remember having my AEB's wiring loom on the kitchen table with an ohmeter checking continuity, drawing my own circuit diagram, before i managed to get the correct diagram from technical books in Auckland.
The biggest issue is understanding what we need and what can be discarded.
The engine bay wiring loom of the AEB Passat only required ,12v fixed, 12v starter,12v ignition,temp sensor,oil pressure , and an earth to integrate with the Mk1 wiring. The oil pressure guage was an extra,as was the temp sensor for the guage.

Good fun though.
Title: Re: Golf Cage Install
Post by: GTI's on April 09, 2009, 07:47:47 am
I remember having my AEB's wiring loom on the kitchen table with an ohmeter checking continuity, drawing my own circuit diagram, before i managed to get the correct diagram from technical books in Auckland.
The biggest issue is understanding what we need and what can be discarded.
The engine bay wiring loom of the AEB Passat only required ,12v fixed, 12v starter,12v ignition,temp sensor,oil pressure , and an earth to integrate with the Mk1 wiring. The oil pressure guage was an extra,as was the temp sensor for the guage.

Good fun though.

Sounds like you need a new project Noel? All those lonely wires not connected to nothing../.
Title: Re: Golf Cage Install
Post by: Bullseye on April 14, 2009, 08:54:02 am
Here you go Rob

http://www.trademe.co.nz/Trade-Me-Motors/Car-parts-accessories/Performance/Other/auction-212599772.htm (http://www.trademe.co.nz/Trade-Me-Motors/Car-parts-accessories/Performance/Other/auction-212599772.htm)

Cheers
Title: Re: Golf Cage Install
Post by: robh on April 14, 2009, 09:10:23 am
Yeah I saw that, but I'm a tin pot and want to try and source something cheaper than that....

Funny thing is electro pumps go for bugger all on ebay uk, pretty scarce here though.
Title: Re: Golf Cage Install
Post by: qta4 on April 14, 2009, 09:41:20 am
Here you go Rob

http://www.trademe.co.nz/Trade-Me-Motors/Car-parts-accessories/Performance/Other/auction-212599772.htm (http://www.trademe.co.nz/Trade-Me-Motors/Car-parts-accessories/Performance/Other/auction-212599772.htm)

Cheers


That unit simply replaces the power steering pump,, i think Robh was after something different
Title: Re: Golf Cage Install
Post by: robh on April 14, 2009, 10:41:15 am

That unit simply replaces the power steering pump,, i think Robh was after something different


That is exactly what I'm after, but I'm too tight to pay $500 plus for it :)
Title: Re: Golf Cage Install
Post by: GTI's on April 14, 2009, 10:46:26 am
I gather it's to gain space not BHP?
Title: Re: Golf Cage Install
Post by: robh on April 14, 2009, 11:02:55 am
I gather it's to gain space not BHP?


Yip, just trying to tidy things up in the engine bay and make everything more serviceable.

Also moves a little weight rearwards which can't be a bad thing in my car!
Title: Re: Golf Cage Install
Post by: qta4 on April 16, 2009, 07:43:02 pm
Any pix?
Title: Re: Golf Cage Install
Post by: robh on April 17, 2009, 07:53:56 am
I've posted a couple up already.  Inside of car is a bit of a mess at the moment, stuff everywhere!

I'll post some up when I've got further through tidy up....
Title: Re: Golf Cage Install
Post by: robh on April 24, 2009, 03:46:03 pm
Just found out my cage is chrome-moly :)

Bic has put some pics up here:

http://www.sonicrace.co.nz/pages/projects/news.html
Title: Re: Golf Cage Install
Post by: HaNs on April 24, 2009, 04:01:06 pm
Nice, you painting the cage?
Title: Re: Golf Cage Install
Post by: robh on April 24, 2009, 04:03:35 pm
Thinking of clear coating it.
Title: Re: Golf Cage Install
Post by: qta4 on April 24, 2009, 04:30:02 pm
Looks really good Robh.
Now you will be able to try harder at track day ;D
Title: Re: Golf Cage Install
Post by: robh on May 02, 2009, 02:50:09 pm
Did a couple of hours today, stripped some more of that black tar crap from the inside, pretty soul less work, doesn't feel much like progress!
Title: Re: Golf Cage Install
Post by: robh on May 02, 2009, 02:52:39 pm
Dummied up the battery mount for Optima (thanks Andy), will drill and bolt up tomorrow:
Title: Re: Golf Cage Install
Post by: robh on May 02, 2009, 02:54:37 pm
Started trimming back dash corners to fit around cage, still need to trim back a little more...
Title: Re: Golf Cage Install
Post by: robh on August 09, 2009, 07:29:38 pm
Haven't done much for a while.  Recently been tidying up intercooler installation.  Never been happy with how close the rear pipework sat against the bulkhead, the lack of support from underneath and also the lack of access to cable shift and clutch slave cylinder.

So I removed the silicone joiner from the front of intercooler to the 90 degree alloy bend and had the bend welded directly to the intercooler.  This pulled the intercooler forward a good inch or 2 and well clear of the bulkhead.

The alloy bend from the turbo compressor outlet was such a tight fit it had to be cut well past the straight section into the actual bend, again I was never really happy with it.  So I've replaced it with a 90 degree Samco hose that fits better and still clears the bulkhead.

To support the intercooler I've used a drainpipe clamp from Master trade that has a 10mm stud fitting underneath.  I will make up a bracket that will bolt to gearbox for the stud to bolt into.  This way when the motor/gearbox moves the intercooler moves with it all as one unit.

Title: Re: Golf Cage Install
Post by: qta4 on August 09, 2009, 07:36:58 pm
One thing i have found frustrating while building and rebuilding my car is the fact that with the authority cards we have to do 3 motorsport events per year,
I am now past that , but i found it difficult at the time.
Good luck with thsi project Rob.
Title: Re: Golf Cage Install
Post by: VDubz on August 20, 2009, 07:30:16 am
Do you have a roundabout price on what the 6 point cage cost you for the golf?
Title: Re: Golf Cage Install
Post by: GTI's on August 20, 2009, 07:58:32 am
Robh's is cro-molly a mild steel one is about 1850 like the one in my mk1
Title: Re: Golf Cage Install
Post by: robh on September 13, 2009, 08:58:38 am
Ok, I've been thinking off and on about whether I should keep or ditch factory heater/fan unit.

After talking with Brendan yesterday I'm swinging towards ditching it all and installing a simple 12v electric heater fan unit ducted into the dashboard windscreen demister ducting.  Something simple like this:

http://www.trademe.co.nz/Trade-Me-Motors/Car-parts-accessories/Other-accessories/auction-241378708.htm

What do you think?
Title: Re: Golf Cage Install
Post by: BB on September 13, 2009, 09:12:56 am
I doubt that that hair dryer would do as good a job. Tho it may be enough to keep the screen clear just.
 Is your car ever going to be used as a travel car again? If so i would keep thee factory stuff if its a track short fun driver only then ditch it.
 Too be honest I liked your car as a driver, for most of us track days are too far and few to dedicate a car like yours too.
Title: Re: Golf Cage Install
Post by: 80 Vert on September 13, 2009, 09:57:55 am
I have to agree, factory fan box weighs F all so I'd keep it.
Rip out the AC evap and put the ox back in, easier and better.
Title: Re: Golf Cage Install
Post by: GTI's on September 13, 2009, 10:10:42 am
Race cars don't need heaters!
Get some nuts!
Title: Re: Golf Cage Install
Post by: AndyGti on September 13, 2009, 10:24:32 am
cars looking good dude! i hope your keeping the battery charged whilst not usuing it? pm us if you have n e issues? looking forward to seeing out on track! n e chance of getting some measurements of your dash and what youve done to fit it?? i might put the passat dash in golf?
Title: Re: Golf Cage Install
Post by: RS ZWEI on September 13, 2009, 10:26:57 am
Race cars don't need heaters!
Get some nuts!

If your talking about getting some nuts, driver your car to the track!
Matt, Dad and I do, heaters come in handy on the cold winter morning and evening, and passing all the slow coaches towing there cars home is very satisfying.

Remember Robs car is still going to be road legal, not a deadicated race car.
I say keep the heater.

Oh, and race cars do real race meetings, not track days  ;D
Title: Re: Golf Cage Install
Post by: GTI's on September 13, 2009, 10:53:53 am
Sooner or later the 70's heater core you have will spew boiling water all over you.
And will fog your windows up  ;)
Hope to see you at a track day soon   :-*
I count on the heat generated on my firewall to keep me warm and the windows dry.
Don't think i'll be driving it around NZ anytime soon.
Can't wait for Hampton downs.
Title: Re: Golf Cage Install
Post by: RS ZWEI on September 13, 2009, 11:20:20 am
Sooner or later the 70's heater core you have will spew boiling water all over you.
And will fog your windows up  ;)
Hope to see you at a track day soon   :-*
I count on the heat generated on my firewall to keep me warm and the windows dry.
Don't think i'll be driving it around NZ anytime soon.
Can't wait for Hampton downs.


Targa cars have heaters. The weight saving would be sweet FA at the end of the day.

Dad wouldnt be without his heater on the race track during wet meetings.
Suit gets damp between races, car fogs up and even with the fan and heater on full it can be a struggle to keep the screen clear.

Hampton Downs should be good.
Title: Re: Golf Cage Install
Post by: GTI's on September 13, 2009, 01:29:29 pm
I did it mainly because i rushed to the very last minute building my car.
The option is always there to install or make something up that doesn't involve water.
You could use a mk4 core and just have a small fan that blows it towards the window.
Can't wait to see your car back on a track Robbo!
And I'm serious about coming to help a night a week to help re assemble it.
Title: Re: Golf Cage Install
Post by: bigbumper on September 13, 2009, 10:08:55 pm
Rob - We tried one of those hair dryers (in fact we tried running two) - pretty freakin useless
In the end we used shampoo to keep the windscreen demisted - worked a charm and weighs nothing

Hate to contradict you Nik but XS RPM never had a heater any of the times we did Targa
No heater in the Honda either, but I do have a windscreen fan
And the cold has never been an issue for us - if it was I guess we'd just wear an extra layer of clothes  :P
Title: Re: Golf Cage Install
Post by: robh on September 13, 2009, 10:38:00 pm
Hmm, now more undecided than before.

Not going to be driving it much on the road anymore, too loud and uncomfortable.  I would drive to Hampton Downs and the drags in it but not Taupo anymore.

So I only really want to avoid the screen misting up, don't care about keeping me warm inside the car.

I'm not really trying to remove weight more trying to simplify things for maintainence and ease of access to bits and pieces.  It's all extra wiring, hoses, etc that has to be installed.

Does the shampoo thing work really well and how long does it last?
Title: Re: Golf Cage Install
Post by: vag_nutter on September 13, 2009, 10:43:10 pm
Just replace the heater core and leave it in there, its tucked away under the dash and non ac ones weighs bugger all
Title: Re: Golf Cage Install
Post by: rambo_005 on September 13, 2009, 10:44:44 pm
As per above... if you can find one from a non A/C Mk2 it will be small, light and simple.
Title: Re: Golf Cage Install
Post by: bigbumper on September 13, 2009, 10:46:23 pm
Yep the shampoo thing works perfectly, we'd apply it at the start of the rally and then again on the morning after any rainy days

If the heater in the Golf is any good then I'd consider retaining it if I were you
Title: Re: Golf Cage Install
Post by: AndyGti on September 13, 2009, 11:49:30 pm
how bout rainx anti fog??
Title: Re: Golf Cage Install
Post by: VR6 on September 14, 2009, 07:38:07 am
Hi Rob, I found I could not get the heater box back in with the dash support bar in the way so that took care about the choices we had. But I was always worried about if the plastic heater core ends could take the extra heat demands that an engine develops at racing speeds. I mean on the road there are few places that you can run an engine at full throttle for any length of time but at the track you can do it lap after lap after lap. You definitely don,t get cold in a track car. I left the windscreen demister vent in place in the dash and simply added a blower fan to the end of it with a bit of flexible hosing. The benefits for me will be when I refit the engine and can prune some more hoses from the engine bay. Less to go wrong
Title: Re: Golf Cage Install
Post by: bigbumper on September 14, 2009, 10:19:09 am
how bout rainx anti fog??

I've never been impressed by that stuff.  Their exterior treatment works well though
Title: Re: Golf Cage Install
Post by: dubstar on September 14, 2009, 10:23:29 am
You should get down to a commercial toyota wrecker and steal one of the electric heater elements that came on the hiace buses.  Then it would be a simple matter of adapting for 24volt and setting up a fan to blow through the element
Title: Re: Golf Cage Install
Post by: robh on September 14, 2009, 08:09:32 pm
Just replace the heater core and leave it in there, its tucked away under the dash and non ac ones weighs bugger all

As per my last post it's not about the weight.
Title: Re: Golf Cage Install
Post by: robh on September 14, 2009, 08:16:37 pm
Hi Rob, I found I could not get the heater box back in with the dash support bar in the way so that took care about the choices we had. But I was always worried about if the plastic heater core ends could take the extra heat demands that an engine develops at racing speeds. I mean on the road there are few places that you can run an engine at full throttle for any length of time but at the track you can do it lap after lap after lap. You definitely don,t get cold in a track car. I left the windscreen demister vent in place in the dash and simply added a blower fan to the end of it with a bit of flexible hosing. The benefits for me will be when I refit the engine and can prune some more hoses from the engine bay. Less to go wrong

Hey Al, I know what you mean.  My cage is bracketed against the front bulkhead and doesn't have a bar running accross underneath the dash, so I do have room to put it all back in.  You've seen how hot my car gets around pukey and that's with the stock motor on 7psi so it's only going to run hotter with more boost.  I've melted my rain tray and my brake booster hose in the past :) 

So does your blower fan work?  Is it a car based one?  Are you just channalling hot air from the engine bay through it?

Title: Re: Golf Cage Install
Post by: bigbumper on September 14, 2009, 10:03:29 pm

So does your blower fan work?  Is it a car based one?  Are you just channalling hot air from the engine bay through it?


Fumes = bad idea
Title: Re: Golf Cage Install
Post by: robh on September 14, 2009, 10:29:07 pm
good point
Title: Re: Golf Cage Install
Post by: VR6 on September 15, 2009, 07:52:13 am
No I have sealed the firewall off. I just recirculate air already in the car with the fan mounted up under the dash. Never had to use the fan at Taupo at the last track day but does seem to blow air onto the windscreen quite nicely. 2 speed fan from an old kombi van about 110mm diameter. Most race cars I have seen use a boat bilge fan. We trimmed the engine bay bulkhead down, so there is no wiper cavity anymore so no fresh air intake only engine fumes. (that was the main reason to seal up the fresh air intake) I have left enough room in the engine bay to be able to run a fresh air tube from behind the grille into the cockpit at a later date if the car needs it. The window down 1/2 inch seems to work well.
Title: Re: Golf Cage Install
Post by: robh on January 04, 2010, 08:39:18 pm
Been inspired by Brendon's progress and spent a couple of afternoons over Christmas in the garage.

To be honest haven't achieved much, removing all that black tar crap takes forever and is bad for the soul!
Title: Re: Golf Cage Install
Post by: robh on January 04, 2010, 08:40:11 pm
closer look at the mess
Title: Re: Golf Cage Install
Post by: robh on January 04, 2010, 08:40:57 pm
a lot more work to do on this side...
Title: Re: Golf Cage Install
Post by: robh on January 04, 2010, 08:41:42 pm
removed rear seat belt mounts
Title: Re: Golf Cage Install
Post by: tyz-fly on January 04, 2010, 08:44:13 pm
removed rear seat belt mounts

robh where is a pic of your car?
Title: Re: Golf Cage Install
Post by: robh on January 04, 2010, 08:57:31 pm
here you go, but she will look different when back on the road...
Title: Re: Golf Cage Install
Post by: tyz-fly on January 04, 2010, 09:29:02 pm
wow!! thats awesome

EDIT: different how? want to sell your rallye lights and grill?
Title: Re: Golf Cage Install
Post by: Omes on January 06, 2010, 12:01:52 pm
lovin that cage in the mk2 Rob, makes me want one too. they look awseome behind the big windows of the three door  ;D
Title: Re: Golf Cage Install
Post by: BB on January 10, 2010, 09:58:12 am
So glad you caged this beast Robh.
 This car is fast and still has massive power potential. Its still running standard pistons and its got a turbo! Spend another 10k on that motor and it will be a red devil ;D
 You love to spend money on it Rob........... :P If only we could have more MONEY!!!!!
Title: Re: Golf Cage Install
Post by: robh on January 10, 2010, 07:58:00 pm
last of the rear belt mounts removed...
Title: Re: Golf Cage Install
Post by: robh on January 10, 2010, 08:00:20 pm
finished removing the roof sound proofing glue, all the dynamat glue from rear quarters, sound proofing glue from bulkhead and dashboard area, all the black tar crap from floor and boot...
Title: Re: Golf Cage Install
Post by: BB on January 10, 2010, 08:03:45 pm
At least you know you wont have to do that job again :P
 Looks well clean.
Title: Re: Golf Cage Install
Post by: robh on January 17, 2010, 08:03:17 pm
Removed turbo and exhaust manifold this afternoon to look into exhaust leak big enough to shoot a large ball of fire out of the exhaust in the engine bay!

Easy to spot once the turbo bag was off, the flange from the turbo to the downpipe was very loose, 1 bolt missing, the remaining 4 all in various states of looseness.

I'll get all the surfaces refaced and 1 dodgy thread recoiled then off to get the turbo HPC'd or Procoated.

Title: Re: Golf Cage Install
Post by: AngleBox on January 17, 2010, 08:55:36 pm
Procoat. Tim is great.
Title: Re: Golf Cage Install
Post by: Filx on January 17, 2010, 09:12:58 pm
Great work on the glue Rob - car looks awesome.
Title: Re: Golf Cage Install
Post by: RS ZWEI on January 18, 2010, 08:03:58 am
last of the rear belt mounts removed...

Who mounted that rear bar behind the suspension?
Title: Re: Golf Cage Install
Post by: robh on January 18, 2010, 09:07:30 am
Who mounted that rear bar behind the suspension?


It's actually in front of the suspension and it was Bic at www.sonicrace.co.nz

Title: Re: Golf Cage Install
Post by: 80 Vert on January 18, 2010, 04:44:22 pm
Same problem on ours Rob, exhaust bolts to turbo came loose and also downpipe bolts.
Seems like a reasonably common thing with turbo cars, it it keeps happening we'll just wire tie them.
Title: Re: Golf Cage Install
Post by: BB on January 18, 2010, 05:25:32 pm
Why do you remove the belt mounts? For a tidy look only or is there other reasons?
Title: Re: Golf Cage Install
Post by: 80 Vert on January 18, 2010, 06:04:55 pm
Saves weight and looks better  :-*
Title: Re: Golf Cage Install
Post by: robh on January 18, 2010, 08:02:47 pm
Same problem on ours Rob, exhaust bolts to turbo came loose and also downpipe bolts.
Seems like a reasonably common thing with turbo cars, it it keeps happening we'll just wire tie them.

The guys at Top Gear Autotech reckon I should be using studs not bolts.

I'll give it a go and see what happens....
Title: Re: Golf Cage Install
Post by: robh on January 18, 2010, 08:04:14 pm
Why do you remove the belt mounts? For a tidy look only or is there other reasons?

Removed several brackets that are never going to be used again.  Minimal weight loss but it all adds up and I have to paint the inside anyway.
Title: Re: Golf Cage Install
Post by: 5-pot on January 19, 2010, 07:47:56 am
Isn't there a thread locker for exhaust applications?  rated to several hundred degrees centrigrade or something...
Title: Re: Golf Cage Install
Post by: Filx on January 19, 2010, 09:58:35 am
Air to air IC Rob - light and simple. Colin Chapman would want you to do it.  :D
Title: Re: Golf Cage Install
Post by: robh on January 19, 2010, 10:05:11 am
Air to air IC Rob - light and simple. Colin Chapman would want you to do it.  :D

Since when was a VR6 and 4wd light and simple :)
Title: Re: Golf Cage Install
Post by: Filx on January 19, 2010, 04:20:33 pm
Since you started removing seatbelt brackets and sound deadening glue  >:D
Title: Re: Golf Cage Install
Post by: robh on January 19, 2010, 04:38:43 pm
Bugger you've got me!

I'm still not removing my water barrel.
Title: Re: Golf Cage Install
Post by: GTI's on January 24, 2010, 07:48:21 pm
I will be back into it soon mate and we'll sort the inside out and help get it all back together!
 
Title: Re: Golf Cage Install
Post by: robh on January 31, 2010, 11:27:03 am
Pulled the engine/gearbox out yesterday.

The clutch is already looking worn out to me and we only swapped it not long ago :(

Jem, it was the one we put in at my office carpark, remember?  The uprated unit.

Haven't done many km's at all with it.  I'll take it into autoclutch and also take a standard worn out Sachs unit to, then see what they recommend....

Title: Re: Golf Cage Install
Post by: 80 Vert on January 31, 2010, 11:32:45 am
Bad quality Rob or been slipping?
Whats the flywheel surface look like?
Our southbend one has been great so far, feels much better now that it has a few miles on it.
Title: Re: Golf Cage Install
Post by: robh on January 31, 2010, 11:36:11 am
Not sure, I don't think it's slipped at all though.

Flywheel face looks pretty clean and straight to me.

1st gear and the final drive is very high and you do need to slip it to get off the line, but I'm not that hard on it.

I'll see what autoclutch say.

They didn't supply the clutch though.
Title: Re: Golf Cage Install
Post by: GTI's on February 01, 2010, 11:37:54 am
Would a Puk clutch help?
Title: Re: Golf Cage Install
Post by: robh on November 02, 2010, 09:34:08 pm
Time to restart the old thread.

Off to the paint shop on Saturday to get the inside and engine bay painted.

Decided it will be worth the extra cost and hassle to get the engine bay done at the same time as it's looking pretty tatty in there.

Anyway, been stripping out the last of the bits and pieces that are still in the way.

Just got brake servo, clutch cylinders, bottom of downpipe to go and then off she goes.

Plan is to get it back before Christmas so I can start working in her over the break :)
Title: Re: Golf Cage Install
Post by: BB on November 03, 2010, 09:07:19 am
So what part of the clutch looks worn? Is the plate nearly down to the rivets or something or just some blueing and dust?
 Be good to see this car out and about again Rob ;)
 
Title: Re: Golf Cage Install
Post by: Filx on November 03, 2010, 11:44:01 am
Can't wait for this to be back on the track! A VW invasion at HD late summer 2011 would be epic.
Title: Re: Golf Cage Install
Post by: robh on November 03, 2010, 03:36:58 pm
So what part of the clutch looks worn? Is the plate nearly down to the rivets or something or just some blueing and dust?
 Be good to see this car out and about again Rob ;)
 

Plate nearly down to the rivets.
Title: Re: Golf Cage Install
Post by: BB on November 03, 2010, 03:43:04 pm
That is odd if you have done lowish Kms and haven't abused it to hard.
 How many track days did you do on it?
 You say it was never slipping, and you'd know if it was in that car.
 Yet clutch slip is the only way the plate actually wears and that usually involves much stop start town driving.
 Can you remember any times you think you may have given it a real hard time?

 Autoclutch will just want to make you a carbon kevlar plate as thats what they do, but they don't like any slipping as well, ive had to revers up a steep drive with mine and I wasn't doing anything untowards and it stank! I told him and he said "don't slip it"
 I have had it let go at track days as well but once cooled down it seems to be ok again. I must have gotten much smoother at HD because the last day I did I didn't slip it at all.
 My one only slips because its an old 020 box set up, hopeless on an ABF really but its working.
Title: Re: Golf Cage Install
Post by: robh on November 15, 2010, 11:00:41 pm
Paint colour choice for inside and engine bay?

Thinking of a base colour rather than trying to match exterior colour.  Black is no good inside of a track car, white would look odd with the outside being black, so how about silver?
Title: Re: Golf Cage Install
Post by: AngleBox on November 16, 2010, 06:49:04 am
Paint colour choice for inside and engine bay?

Thinking of a base colour rather than trying to match exterior colour.  Black is no good inside of a track car, white would look odd with the outside being black, so how about silver?

What about red?
Title: Re: Golf Cage Install
Post by: M on November 16, 2010, 06:59:44 am
Dark Grey/Silver, like a Gunmetal Metallic colour. Would look really nice.
Title: Re: Golf Cage Install
Post by: GTI's on November 16, 2010, 07:33:39 am
Battle ship grey would look nice.
like the inside of the anglebox  8)
Title: Re: Golf Cage Install
Post by: AngleBox on November 16, 2010, 07:58:22 am
I think if you're going to paint the engine bay a different colour pick something you would consider for your roll cage as well. Since it's going to be a beast, I thought red would represent the mouth of this track weapon - there's a huge range of 'reds', but we all know grey is awesome  :D
Title: Re: Golf Cage Install
Post by: robh on November 16, 2010, 09:08:19 am
interesting never thought of that, could go well????
Title: Re: Golf Cage Install
Post by: the phantom on November 16, 2010, 09:47:15 am
think practical, what is going to be easiest/most visibility if you have to work on the motor in low light situations? 

white too glarey, so a lightish gloss gray probably best, not metallic to minimise distraction
Title: Re: Golf Cage Install
Post by: Filx on November 16, 2010, 10:45:29 am
Is the cage homologated yet Rob? Sounds like it's worth getting on to this side of Christmas before the pending rule changes. I don't know the detail but I'm sure others here will have more up to date info.

I'd paint the inside a subtle, non/low reflective colour. If you want to detail it a bit a different colour cage and matching engine bay could work well as Anglebox mentioned.
Title: Re: Golf Cage Install
Post by: Trofeo on November 16, 2010, 10:56:30 am
whats changing re the cages after xmas? i know they need to be welded 360 degrees around the tubes now. Sounds obvious, but you'd be surprised how many cages don't have welds around the entire tube up by the roof. This applies to old cages too and you have two options. cut holes in the roof and weld up the cages, or cut holes in the floor, drop the cage down, weld the top, jack the cage back up again and weld in new floor mounts. crazy!
Title: Re: Golf Cage Install
Post by: 80 Vert on November 16, 2010, 11:43:48 am
Or like us, drill the roof skin off  :laugh:
Title: Re: Golf Cage Install
Post by: BB on November 18, 2010, 09:59:06 am
whats changing re the cages after xmas? i know they need to be welded 360 degrees around the tubes now. Sounds obvious, but you'd be surprised how many cages don't have welds around the entire tube up by the roof. This applies to old cages too and you have two options. cut holes in the roof and weld up the cages, or cut holes in the floor, drop the cage down, weld the top, jack the cage back up again and weld in new floor mounts. crazy!


 Oh for damn sake ::)This is really going to help safety isn't it as people either don't get cages installed at all or just drive the damn things and hope they don't get caught.
 How can they back date what THEY said was ok in the first place? I can understand new cages requiring this but to make old cages do it is crazy!
 Wonder about my Fiat?
Title: Re: Golf Cage Install
Post by: RS ZWEI on November 18, 2010, 10:16:35 am
Oh for damn sake ::)This is really going to help safety isn't it as people either don't get cages installed at all or just drive the damn things and hope they don't get caught.
 How can they back date what THEY said was ok in the first place? I can understand new cages requiring this but to make old cages do it is crazy!
 Wonder about my Fiat?

I think youre thinking about it from a track days point of view Jem. These rules are coming out for real race meeting. Though the standards will include anyone whos got a rollcage. And the way Motorsport NZ have it sorted you have to compete in a number of motorsport events a year (not including track days).

Title: Re: Golf Cage Install
Post by: ritmo on November 24, 2010, 11:08:13 pm
Changing od diameter minimum from 38mm to 44mm i think 1st jan for cages.
Title: Re: Golf Cage Install
Post by: robh on November 26, 2010, 01:21:32 pm
I spoke to the technical guy at MSNZ and he said there are some minor detail changes but the main one was the OD of the main hoop.

On the colour front we thinking of going with gray inside and engine bay, so it won't clash with the very shiney black outside.
Title: Re: Golf Cage Install
Post by: choppy16v on November 26, 2010, 02:25:35 pm
i have my car booked in to be caged before xmas. i spoke to the guy about rule changes ,he said he'd been making them compliant to the new rules since the beginning of the year. 8)
full cage for under $1000 in waiuku.
Title: Re: Golf Cage Install
Post by: robh on December 10, 2010, 12:26:51 am
Car all prepped and ready for paint, should be ready to collect next week, yeah!
Title: Re: Golf Cage Install
Post by: AngleBox on December 10, 2010, 08:41:47 am
Car all prepped and ready for paint, should be ready to collect next week, yeah!

Get that paperwork in just in case they want more photos of the welds.
Title: Re: Golf Cage Install
Post by: choppy16v on December 10, 2010, 09:43:27 am
i miss this car!! it is the most developed  :o,most psycho mk2 >:D! cant wait to see it on track.
will you be at the jan2 track day at hd rob?
Title: Re: Golf Cage Install
Post by: robh on December 10, 2010, 11:18:16 am
Get that paperwork in just in case they want more photos of the welds.

Already sent the other week, good tip!
Title: Re: Golf Cage Install
Post by: robh on December 10, 2010, 11:20:54 am
i miss this car!! it is the most developed  :o,most psycho mk2 >:D! cant wait to see it on track.
will you be at the jan2 track day at hd rob?

It'll still be a while until it's going again, got lots of brackets to fab for revised cooling, lots of hose work to change, heaps of wiring to redo, basically lots of reliability type stuff!

Trouble is every time I look at something I think "that could be better" and start fiddling.
Title: Re: Golf Cage Install
Post by: robh on December 16, 2010, 04:38:23 pm
Inside and engine bay painted, collecting Saturday, yeah!
Title: Re: Golf Cage Install
Post by: robh on December 16, 2010, 04:38:50 pm
...
Title: Re: Golf Cage Install
Post by: robh on December 16, 2010, 04:39:34 pm
...
Title: Re: Golf Cage Install
Post by: choppy16v on December 16, 2010, 04:52:03 pm
far out rob that looks wicked! this car will be equally at home on track or at a car show.
Title: Re: Golf Cage Install
Post by: Filx on December 16, 2010, 04:58:29 pm
Sweet - should be ready for HD on the 2nd of Jan then!
Title: Re: Golf Cage Install
Post by: robh on December 16, 2010, 05:02:36 pm
Sweet - should be ready for HD on the 2nd of Jan then!

2012?
Title: Re: Golf Cage Install
Post by: gti vr6 on December 16, 2010, 05:19:00 pm

Looks GREAT Rob

thumbs up!!
Title: Re: Golf Cage Install
Post by: CBRT on December 16, 2010, 08:23:53 pm
Looks GREAT Rob

thumbs up!!
have to agree look pro man
Title: Re: Golf Cage Install
Post by: RS ZWEI on December 16, 2010, 08:41:48 pm
Looks very, very cool Rob.
Title: Re: Golf Cage Install
Post by: Simon MkII on December 16, 2010, 08:57:59 pm
i miss this car!! it is the most developed  :o,most psycho mk2 >:D! cant wait to see it on track.


Hell yeah, awesome machine!
Title: Re: Golf Cage Install
Post by: 80 Vert on December 16, 2010, 09:43:10 pm
Nice work, will be good to see it on the road again.
Title: Re: Golf Cage Install
Post by: robh on February 21, 2011, 04:43:06 pm
Took the worn out (hardly any km's) uprated clutch into Autoclutch.

He took one look at it and knew straight away what the problem was.  The pedal travel needed reducing as the uprated plate was narrower than the standard plate that was in it previously.  I had no idea and no instructions came with the unit.

At least it explains why it didn't last many km's and why reverse would often crunch.

He said it was a good unit and just needed to be relined and refaced, plus a new release bearing.



Title: Re: Golf Cage Install
Post by: itsagthing on February 24, 2011, 07:32:01 pm
Looks awesome this....love the colour of the under hood etc.
Title: Re: Golf Cage Install
Post by: robh on March 15, 2011, 02:44:14 pm
Gearbox bellhousing thread repaired.

Swapping out old mark 3 cable shifter and shift tower for the updated version from the mark 4.

Also have the following parts on their way:

Link G4 Xtreme
4 bar MAP Sensor
725cc Injectors
Head Gasket Spacer to 9.0:1
ARP Exhaust Studs

Will have Link Plus G1 for sale and also 6 x 440cc high impedence injectors.
Title: Re: Golf Cage Install
Post by: Filx on March 15, 2011, 02:58:23 pm
Oooooh goody! Gonna make POWAAAAH!  >:D
Title: Re: Golf Cage Install
Post by: 00quattro00 on March 15, 2011, 06:40:27 pm
Gearbox bellhousing thread repaired.

Swapping out old mark 3 cable shifter and shift tower for the updated version from the mark 4.

Also have the following parts on their way:

Link G4 Xtreme
4 bar MAP Sensor
725cc Injectors
Head Gasket Spacer to 9.0:1
ARP Exhaust Studs

Will have Link Plus G1 for sale and also 6 x 440cc high impedence injectors.

Where did you get the spacer from?
Title: Re: Golf Cage Install
Post by: VeeDub on March 15, 2011, 06:41:05 pm
What colour is your car Rob??
Title: Re: Golf Cage Install
Post by: rambo_005 on March 15, 2011, 07:43:30 pm
An old pic of the Robmobile from a 2008 track day:

(http://i137.photobucket.com/albums/q239/rambo_005/VASK%20Track%20Day%20Taupo%202008/P5230038.jpg)
Title: Re: Golf Cage Install
Post by: VeeDub on March 15, 2011, 08:06:38 pm
What's the colour name though? paint code?
Title: Re: Golf Cage Install
Post by: robh on March 15, 2011, 08:32:53 pm
Where did you get the spacer from?

Schimmel Performance, they supplied a big pile of engine parts as well, but I haven't got around to building that yet.
Title: Re: Golf Cage Install
Post by: 80 Vert on March 15, 2011, 08:39:47 pm
Why the head spacer Rob? Thought you had an engine with forged internals?
Title: Re: Golf Cage Install
Post by: robh on March 15, 2011, 08:46:29 pm
Why the head spacer Rob? Thought you had an engine with forged internals?

Don't want to map a freshly built motor from scatch, will be easier and less risky to map my old one with a spacer and then I can just run the new motor in safely before doing a full dyno map on it.
Title: Re: Golf Cage Install
Post by: 00quattro00 on March 15, 2011, 08:59:06 pm
People have made some good power on a standard vr6 with just a head spacer
Title: Re: Golf Cage Install
Post by: RS ZWEI on March 16, 2011, 11:34:58 am
People have made some good power on a standard vr6 with just a head spacer

But for how long for?
Title: Re: Golf Cage Install
Post by: robh on March 16, 2011, 12:16:06 pm
But for how long for?


I bet I'll be able to answer that when it's going again :)
Title: Re: Golf Cage Install
Post by: 00quattro00 on March 16, 2011, 06:32:14 pm
But for how long for?

Depends on how much power you want and how good the tuner is, but people make 300-400hp quite easily, have seen one making over 550hp
Title: Re: Golf Cage Install
Post by: Omes on March 18, 2011, 11:55:22 am
Head spacer increases the compression ratio. Very important for those running a bigger aftermarket turbo on the VR motors as Vert and Rob.
Title: Re: Golf Cage Install
Post by: 00quattro00 on March 18, 2011, 11:59:17 am
Head spacer increases the compression ratio. Very important for those running a bigger aftermarket turbo on the VR motors as Vert and Rob.

It decreases it and its just a cheap way of boosting an na engine
Title: Re: Golf Cage Install
Post by: Omes on March 19, 2011, 08:02:44 am
It decreases it and its just a cheap way of boosting an na engine

sorry yep I meant decreases. Typically reduces the compression down to 9:1 which is good going for turbo running VR6's
Title: Re: Golf Cage Install
Post by: BB on March 19, 2011, 09:54:26 am
The spacers will work fine, just as long as it dont get to hot.
 But having the spacer will help with the heat.
 Plus the subaru scoop on the bonnet.........that old chestnut :laugh:
 Look forward to this car going again, it scared the hell out of me 8)
Title: Re: Golf Cage Install
Post by: robh on March 19, 2011, 02:20:53 pm
More goodies sourced:

Bosch 044 Fuel Pump from NZ Performance, thanks Paul.
Integrated Engineering Surge Tank from Flix, thanks Phil.
Mark 4 O2J shifter, cables and shift tower from VWSpares, thanks Allan.
New Mac valve for boost control from Link ECU, thanks Cameron.


Title: Re: Golf Cage Install
Post by: NasTnaS on March 19, 2011, 04:13:37 pm
More goodies sourced:

Bosch 044 Fuel Pump from NZ Performance, thanks Paul.
Integrated Engineering Surge Tank from Flix, thanks Phil.
Mark 4 O2J shifter, cables and shift tower from VWSpares, thanks Allan.
New Mac valve for boost control from Link ECU, thanks Cameron.

what voltage is the mac valve?
Title: Re: Golf Cage Install
Post by: robh on March 19, 2011, 10:17:54 pm
From memory 5v
Title: Re: Golf Cage Install
Post by: robh on March 23, 2011, 09:55:04 pm
Just sourced:

Accusump (needs a tear down and clean out)
Motul 300V Oil
Motul RBF600 Brake Fluid
Title: Re: Golf Cage Install
Post by: robh on March 24, 2011, 09:07:47 am
Next item sourced:

Mercedes A Class Electric Power Steering Pump, as used by Porsche 997 Cup Cars, very expensive if you buy the "motorsport" version ;)
Title: Re: Golf Cage Install
Post by: RS ZWEI on March 24, 2011, 11:48:25 am
Next item sourced:

Mercedes A Class Electric Power Steering Pump, as used by Porsche 997 Cup Cars, very expensive if you buy the "motorsport" version ;)

For real? Its the same part?
Title: Re: Golf Cage Install
Post by: Omes on March 24, 2011, 11:50:08 am
interesting tip  ;)
Title: Re: Golf Cage Install
Post by: robh on March 24, 2011, 01:57:57 pm
For real? Its the same part?

From what I have found on the net it is, I haven't seen with my own eyes a 997 Cup car though.
Title: Re: Golf Cage Install
Post by: dubstar on March 24, 2011, 04:20:16 pm
Maybe that explains why the A-classes flip....steering to quick for a small car.

http://www.youtube.com/watch?v=Um-XlKerWvA (http://www.youtube.com/watch?v=Um-XlKerWvA)
Title: Re: Golf Cage Install
Post by: M on March 24, 2011, 11:11:27 pm
How much Rob? I was planning on using a Polo one but Porsche 997 Cup sounds way better  :D

Was it hard to find?
Title: Re: Golf Cage Install
Post by: robh on March 25, 2011, 09:56:11 am
Hard to find in NZ, but they do pop up on ebay uk from time to time.  I won't say what I paid for mine, but it was really, really cheap!

Common fault is water getting into the electronics, but if you simply want to power the pump on and off from your own relay, aftermarket ECU, etc they will still work.
Title: Re: Golf Cage Install
Post by: Filx on March 25, 2011, 12:28:15 pm
What about mounting them etc? Pretty straight forward?

I'm really excited to see this progressing Rob - can't wait to see if I can hang with you down the back straight at Puke!
Title: Re: Golf Cage Install
Post by: robh on March 25, 2011, 02:16:25 pm
Planning on mounting inside car, pump has reservior built into it.  2 wires to drive it, 1 pressure hose, 1 return hose, done?

Imagine that a 1.8T versus VR6 contest, never seen that before on VASK aye?  If yours is faster I'll just say you spent more money on it or something like that :)
Title: Re: Golf Cage Install
Post by: Filx on March 25, 2011, 03:06:36 pm
Interesting - a friend of mine has got an MR2 electric pump (from memory) but maybe this is an easier option.
Title: Re: Golf Cage Install
Post by: robh on March 25, 2011, 03:15:52 pm
MR2 is common option, but I think the Merc one is lighter/smaller/newer, plus how cool is a Porsche motorsport part :)
Title: Re: Golf Cage Install
Post by: Filx on March 25, 2011, 08:17:46 pm
Check out the blurb about the trick mounts about 3/4 down the page here http://forums.vwvortex.com/showthread.php?4902019-I-heart-lego-s/page6 (http://forums.vwvortex.com/showthread.php?4902019-I-heart-lego-s/page6). Interesting for the VR6 Mk2 peeps me thinks.
Title: Re: Golf Cage Install
Post by: robh on April 04, 2011, 02:24:37 pm
More parts sourced:

Display Link from Link ECU, going to biff out my VDO and SPA gauges
EGT thermcouple and interface box from SPA

Still need to source some 5v sensors for:

Oil Pressure 100psi
Fuel Pressure 60psi

anyone got any leads for these?


Title: Re: Golf Cage Install
Post by: Vorsprung on April 07, 2011, 07:27:55 pm
closer look at the mess

A little late for you, but maybe not for someone else attempting the same thing. I was told that if you freeze the floor with Dry Ice pellets it freezes the sheets of sound deadener and you can whack it with  a hammer and it falls of. Tried it out last night and it works pretty well.
Title: Re: Golf Cage Install
Post by: robh on May 16, 2011, 03:25:33 pm
Nearly sorted conversion to O2J shifter on an O2A box.

Had to swap shift tower which was interesting as I couldn't get 6th gear to engage.  Found a small bolt that hits a ramp on the shift tower that pushes mechanism away from 6th gear back into 4th.  Ground 6mm off the end of the bolt and it looks good now.

Also the normal mark IV O2J gear shift wouldn't fit in mark 2 tunnel.  Tracked down a housing and arm from a 3 cylinder diesel Polo that you can move all the mark IV parts into.  Even with that I had to take a couple of small notches out to clear the propshaft hangar brackets.

Still need to test fit engine and box into car and make sure cable lengths ok and shifter works when everything is in place.

Re foamed heater box flaps.

Re doing some brake lines soon....
Title: Re: Golf Cage Install
Post by: choppy16v on May 16, 2011, 04:54:22 pm
hearty!
Title: Re: Golf Cage Install
Post by: BB on May 20, 2011, 09:07:24 am
Keep pushing.
Title: Re: Golf Cage Install
Post by: typ53 on May 29, 2011, 10:25:40 am
Rob,

I know this is slightly OT but do you know if the shift tower is the section that controls the fore and aft tension on the shifter inside the car?  Mine has a fair bit of play longitudinally but is fine laterally and I'm trying to find the offending part.

I presume there's a spring somewhere in there that's broken.
Title: Re: Golf Cage Install
Post by: robh on May 29, 2011, 05:06:42 pm
Craig, are you talking O2A shifter, tower and cables?

I'm not an expert on this, but one of the bushes in the shifter end of the cable had collapsed and made if feel like a bit of slop.  Also the gubbins in the shift tower that goes into the box can get a bit of play in it.

I never pursued stripping it all down as the O2J setup is supposed to be much better.

Your welcome to look through my O2A pile of bits, they are out of the car and may give you an idea what gets worn?
Title: Re: Golf Cage Install
Post by: typ53 on June 03, 2011, 12:53:16 pm
Yep, I've still got an 02A. 

That's a great offer Rob, I'll be in touch.
Title: Re: Golf Cage Install
Post by: robh on June 13, 2011, 08:56:35 am
Progress on some little jobs:

* Slam panel now attaches with rivnuts
* Revised FPR mount
* Revised clutch line
* Rebuilt brake master cylinder
* Swapped master cylinder reservior for neater version
* Replaced hose to clutch master cylinder
* Revised brake hard line
* Revised vacuum fittings from inlet manifold
* O2J shifter on O2A box appears to work

Only little bits, but they all take time....


Title: Re: Golf Cage Install
Post by: BB on June 13, 2011, 09:52:02 am
Im glad you still add to vask Robh.
 Love to see some photos of the beast again.
 Look forward to this incarnation and a new ride around Puke!
Title: Re: Golf Cage Install
Post by: robh on June 15, 2011, 10:55:38 am
* EGT probe install in turbo
* Air Temp Sensor installed in inlet pipework
* Removed factory heatsheild and rubber from shift cables and replaced with race spec thermo sleeve, sounds simple but was pretty fiddly to sort as you can't fully strip cables down
* Fixed a mounting thread in fuel rail
* Installed Fuel Pressure Sensor into FPR

Turbo is off to Pro Coat this week to get dealt to.

Then all that's left to do is everything else!
Title: Re: Golf Cage Install
Post by: Filx on June 15, 2011, 02:24:17 pm
Keep working man! Get that thing going!!!
Title: Re: Golf Cage Install
Post by: robh on June 20, 2011, 02:57:34 pm
Spent a few hours getting nothing done.  Tried to work out how to fit intercooler, header tank and air filter intake all in the same space and they basically don't!

Will make up air filter intake as best I can and then get someone to make me a header tank that fits whatever space is left.

Always hated plastic tanks anyway :)
Title: Re: Golf Cage Install
Post by: BB on June 22, 2011, 06:46:47 pm
Any new pics Rob?
Title: Re: Golf Cage Install
Post by: robh on June 22, 2011, 10:17:55 pm
Nothing really to see yet, all the bits I've done are tiny.
Title: Re: Golf Cage Install
Post by: RS ZWEI on July 25, 2012, 09:15:59 pm
Hey Rob, have you done any work to your Golf of late?
Title: Re: Golf Cage Install
Post by: robh on October 02, 2012, 08:37:05 am
Started on fuel system.

Had to remove fuel tank to get to lines from lift pump.

Going to use new -6 lines through out.

New surge tank and Bosch 044 main pump.

New filter and mount.

Title: Re: Golf Cage Install
Post by: ranton-inc on October 02, 2012, 08:41:41 am
Started on fuel system.

Had to remove fuel tank to get to lines from lift pump.

Going to use new -6 lines through out.

New surge tank and Bosch 044 main pump.

New filter and mount.

very nice.
Title: Re: Golf Cage Install
Post by: mark2 golf on October 02, 2012, 09:47:26 pm
That filter mount is a nice piece of kit. I was thinking about this car the other day. Good to see your still chipping away at it.
Title: Re: Golf Cage Install
Post by: choppy16v on October 05, 2012, 07:38:38 am
my favorite mk2!!!
Title: Re: Golf Cage Install
Post by: BB on October 05, 2012, 12:55:36 pm
Ive been taken round Puke in it. Fastest car I've ever been in, I was good and scared. I think my girly fear was one of the reasons Rob has decided to cage the beast.
Title: Re: Golf Cage Install
Post by: robh on November 05, 2012, 09:01:06 am
Surge tank mounted, not my best work.

But only have limited skills and tools at home so will have to do.
Title: Re: Golf Cage Install
Post by: robh on November 26, 2012, 05:17:40 pm
Done most of fuel lines now, just need to get the right size hose mounts in and put fuel tank back in place.

Will probably redo the line from the fuel filter to the rail so it has more hose in it to allow for engine movement.
Title: Re: Golf Cage Install
Post by: robh on November 26, 2012, 05:19:13 pm
more pics
Title: Re: Golf Cage Install
Post by: robh on November 26, 2012, 05:20:08 pm
one from underneath...
Title: Re: Golf Cage Install
Post by: mark2 golf on November 26, 2012, 06:25:00 pm
Hey Rob.
What did you do with your tank breather pipe? 
Title: Re: Golf Cage Install
Post by: BB on November 28, 2012, 09:58:15 am
That rocks.
 Its such a good idea to do fuel systems properly. That will be the first thing I do to my Fiat if I keep it and do stuff in it is to get a fuel cell off trade me and fit it.

 Oh and I can see your anti roll bar link is missing a bolt?
Title: Re: Golf Cage Install
Post by: robh on December 30, 2012, 08:35:32 pm
Mounted accusump...
Title: Re: Golf Cage Install
Post by: robh on December 30, 2012, 08:38:25 pm
Mounted power steering pump...
Title: Re: Golf Cage Install
Post by: robh on January 03, 2013, 09:46:09 am
Have come to a stop on radiators.  Mounted up larger Passat VR6 rad, thats ok, but not enough room for larger intercooler rad.  I'm giving serious thought to boot mounting the intercooler rad and feeding air to it from naca ducts in perspex side windows.  Didn't really want to do this but the front is so light on space.
Title: Re: Golf Cage Install
Post by: mark2 golf on January 03, 2013, 11:27:56 am
I had to trim some of the slam panel on the front I take it you have done this already.
Title: Re: Golf Cage Install
Post by: BB on January 03, 2013, 01:35:00 pm
Have come to a stop on radiators.  Mounted up larger Passat VR6 rad, thats ok, but not enough room for larger intercooler rad.  I'm giving serious thought to boot mounting the intercooler rad and feeding air to it from naca ducts in perspex side windows.  Didn't really want to do this but the front is so light on space.


 If you have to end up doing this it could look quite Boss I think.

Title: Re: Golf Cage Install
Post by: robh on June 07, 2013, 10:21:42 pm
Some bits I managed to get done before work stopped for a hip replacement.

Oil line from accusump to shutoff valve.
Title: Re: Golf Cage Install
Post by: robh on June 07, 2013, 10:22:55 pm
Oil line through to bulkhead fitting, covered line with some thermal cover so passengers don't burn their leg.
Title: Re: Golf Cage Install
Post by: robh on June 07, 2013, 10:24:49 pm
Oil line from bulkhead to oil cooler.
Title: Re: Golf Cage Install
Post by: robh on June 07, 2013, 10:26:31 pm
Oil cooler from Mazda RX :) and non return valve so Accusump can't pressurise the oil pump in the wrong direction.
Title: Re: Golf Cage Install
Post by: robh on June 07, 2013, 10:29:03 pm
Mocal oil take off, this thing was a mare to fit, no room with such large lines, had to grind a ridge off Oil Filter housing and could only get to fit with fittings that had exactly the right radius :(
Title: Re: Golf Cage Install
Post by: robh on June 07, 2013, 10:29:52 pm
And now the wife wants garage back, something to do with it raining and winter, blah, blah, blah!
Title: Golf Cage Install
Post by: Poonmobile on June 08, 2013, 01:03:11 am
Finish it!!!
Title: Re: Golf Cage Install
Post by: AngleBox on June 09, 2013, 10:40:22 am
And now the wife wants garage back, something to do with it raining and winter, blah, blah, blah!

Whatever you do, don't let her have her way; it'll be all over from there (typing quickly before my wife comes back into the room)
Title: Re: Golf Cage Install
Post by: SOFTLAD on June 09, 2013, 11:10:14 am
selective hearing is a good one also
Title: Re: Golf Cage Install
Post by: Filx on November 04, 2014, 05:50:46 pm
"I miss this car" bump - what's happening on this thing Rob?
Title: Re: Golf Cage Install
Post by: RS ZWEI on November 05, 2014, 07:37:02 am
"I miss this car" bump - what's happening on this thing Rob?

Yeah Rob, this car is awesome. Updates?
Title: Re: Golf Cage Install
Post by: robh on November 08, 2014, 11:01:43 pm
Have proper man cave now, just had hoist installed and have plenty of space to work now.

Working on mounting the radiator for intercooler inside car behind front seats with air ducted in through rear side window naca ducts.

Also done a bit of work on some of radiator pipes, intercooler plumbing, intercooler mount and mounted a really nice bmc carbon air filter.

Title: Re: Golf Cage Install
Post by: SOFTLAD on November 09, 2014, 10:22:33 am
Yeah Rob, this car is awesome. Updates?

Have proper man cave now, just had hoist installed and have plenty of space to work now.
Working on mounting the radiator for intercooler inside car behind front seats with air ducted in through rear side window naca ducts.
Also done a bit of work on some of radiator pipes, intercooler plumbing, intercooler mount and mounted a really nice bmc carbon air filter.

YEAH YEAH YEAH YEAH PICTURES
please
Title: Re: Golf Cage Install
Post by: RS ZWEI on June 18, 2015, 12:57:58 pm
Hey Rob, how is the Mk2 coming along?
Title: Re: Golf Cage Install
Post by: robh on October 21, 2015, 12:04:56 pm
Very very slowly, have had stuff going on with house at home.

Car on shiney new hoist.
Title: Re: Golf Cage Install
Post by: robh on October 21, 2015, 12:07:38 pm
revised turbo plumbing and coolant lines.
Title: Re: Golf Cage Install
Post by: robh on June 24, 2020, 07:47:34 pm
Very very old thread, but finally made a restart on this project.

Have some room in workshop now the Vento has moved on.

Mates helped me remove the engine/box so we can make a start on strengthening engine.

Pull sump and have installed ARP Rods bolts, next stop is head gasket space to lower CR and install ARP Head bolts...
Title: Re: Golf Cage Install
Post by: Filx on June 25, 2020, 08:53:23 am
This is going to be worth the wait!
Title: Re: Golf Cage Install
Post by: NasTnaS on June 25, 2020, 10:28:13 am
whoop whoop! its about time Rob!
Title: Re: Golf Cage Install
Post by: RS ZWEI on June 26, 2020, 11:31:35 am
Awesome, this car is so cool.
Title: Re: Golf Cage Install
Post by: ranton-inc on July 23, 2020, 09:18:53 pm
Ill never forget riding shot gun in this car on the road to port waikato. I think to the light house or something

Rob entering a corner that quickly became a hard 90

Rob calmly saying “oh damn that was a bit quick”
Title: Re: Golf Cage Install
Post by: robh on July 26, 2020, 09:45:59 am
Ill never forget riding shot gun in this car on the road to port waikato. I think to the light house or something

Rob entering a corner that quickly became a hard 90

Rob calmly saying “oh damn that was a bit quick”


Yeah, front end is heavy with the old 12v donk in there.  Front shocks were rooted as well, found that out later!
Title: Re: Golf Cage Install
Post by: robh on September 17, 2020, 12:56:03 pm
Head gasket spacer and ARP head studs done.

Went to reassemble turbo, exhaust manifold, etc but exhaust manifold had a bit of rust forming internally.  Decided to get it procoated but they had run out of the "super duper" black stuff and it took several weeks for it to land from the US.

External wastegate wasn't sealing properly so spent some time getting that sorted, reassembled it all on the bench.

Test fitted to engine, but not happy with the way compressor housing clears engine, so going to have a bit of a fiddle to try and work out best way to create a bit more clearance.