RED X19

[Janis]

Starter motor is a bit off place, can’t say is it because of my mistake or because it is from Punto 1.6 and X’s 1.5 flywheel.

Gearbox feels excellent, no whining noises, at least in 1st and reverse

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[Janis]

 

[Janis]

Made air filter box. There is another plate to tighten filter to the box.
Am not proud of it, but it will do the job.
6cm thick and other dimensions are to fit Honda Civic 225x165mm air filter, bought Pipercross one.
Is steel mesh side outlet and foam side inlet?

 

[Janis]

added interior air filter between heater box and chassis.
also there is floor now in the trunk, seems handy

 

[Dr.Jeff]

Where did you place the interior filter? Over the intake inside the front cowl or somewhere inside the interior space or in the heater box itself?

 

[Janis]

Where did you place the interior filter? Over the intake inside the front cowl or somewhere inside the interior space or in the heater box itself?

In the place where it is most complicated to change

I put it on top of the box, but also got rid of that hinged flap on top, because have never used it on any car, if some smell gets in the car it is already too late to close the flap

 

[Dr.Jeff]

Mine is even harder to service. It's in the same place but under that lid. But I just used a screen rather than a real filter. My goal is mostly for leaves and larger debris that clog the core.

 

[kmead]

I would place the reservoir bottle somewhere else, the fresh air intake to the intercooler is restricted enough in my mind, putting that ball there will not help matters.

 

[Janis]

I absolutely agree with You Karl, but to do that I have to modify tube tha connects intercooler and intake manifold.
I am a bit tired of working on X every evening and weekend to get it back on road, so might modify this after that.

But had enough energy today to put muffler a little higher

To do list to pass MOT:
•speedo
•modify shifter
•ducting for radiator
•front grill
•finish seat rails for Recaros
•upgrade rear bonnet
•and few other less essential things

before

after

 

[Dr.Jeff]

I am a bit tired of working on X every evening and weekend to get it back on road

I know what you mean. I need to finish several major project cars very soon due to changing circumstances in my life. And you get to the point where it just needs to get done without any further modifications.

 

[Janis]

Made new carpet, should have bought a new one from Hank at the beginning

At some point better than previos one, if mats will hide seams than it will be great if not, will try few thing to make it look great

*it is grey, because it cost only 5€/m 1.2m wide roll

 

[Dr.Jeff]

Made new carpet, should have bought a new one from Hank at the beginning

At some point better than previos one, if mats will hide seams than it will be great if not, will try few thing to make it look great

*it is grey, because it cost only 5€/m 1.2m wide roll

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Others have done it the same way and it can look good once everything is finished. I remember someone saying they used some sealant or adhesive along the seams to help "finish" them.

 

[Janis]

SCANIA quality carpet
, might try a heat gun on sample, it might help

 

[Janis]

Live from my dining table
Might move forward with speedo this evening. Updates might follow

 

[Janis]

If anyone wants to know more detailed info, can do a bigger writeup about electronic speedo and odometer.
I am actually surprised that it worked out

 

[Dr.Jeff]

That's cool that it worked, and you mounted it like the stock speedo. I'm guessing the VW trans you used has the sending unit that matches that electronic speedo?

Funny it was so easy to do because on the VW forum there are lots of guy that swap newer engine/trans drivetrains into older VW's. That typically requires swapping the ECU, wire harness, etc, with it. And they always complain about how difficult it is to get the later style dash to work. But that forum tends to be full of idiots.

 

[Janis]

Particular Golf 4 box is upgraded Golf3 strongest box. So it has electronic speedo sensor attached where could also be cable
This is sensor from Golf4, Golf 3 VR6 sensor is same but with better connector type.
Same amount of impulses per rotation.
Golf 4 cluster is feeded through ECU, that is reason why I avoided it and worked with Golf 3 cluster where sensor is wired straight to the cluster. For sure it could be simplified and used only parts of it, not whole plate and hiden behind dashboard, but it is now too complicated for me.

Odometer shows exactly 100k more than my X, if not mistaken Golf 3 odometer resets after 299 999km. I can live with that .
But is there some simple solution how to wind it?
Sensor has 4 or 8 pulses per rotation.
Speedo sprocket has ~12teeths(from memory) diff ~24t. =8 or 16 pulses per wheel rotation. Wheel rotates 555 times per km.
555x16x200000=is a lot of pulses

 

[dllubin]

If you have access to a pulse generator, you could match the output levels to those coming from the trans and then crank the frequency up to the max the speedo will recognize.

 

[Dr.Jeff]

I'm not sure that it resets to zero after 3k, but it might. Otherwise there isn't a easy way to reset a electronic one.

 

[dllubin]

I would look for some documentation on that speedo to see if there is a reset procedure. I would expect something along the lines of grounding a particular pin or pad.