MEGASQUIRT IN JAMAICA........my family car turned project

[MOTA BOY]

We're still here!

[justvwpower]

DID SOME WORK ON THE WHALE...over the weekend .......refurbished my A/C condenser ....& started work on my pedal box ....still figuring out the ignition setup .....but seeing a solution soon

my a/c condenser..looks new now ....
unlike other ppl we in JA cannot drive hot cars in hot weather ....


look ma no wheel ....



the plan is ...since i can't get a pedal box ...gonna build 1 .....getting the clutch pedal from a RHD passat /mk3 golf gti pedal box


i can use the independent clutch assy that comes from the mk4/5 golf/passat ...but i dont like the idea of my clutch master cylinder being inside the car (fixed 2 many leaky ones) ....& being made of plastic....call me old fashion ....
!!!!stay tuned ....!!!!

[justvwpower]

don't despair ppl ..the worst thing that can happen to a proiect is whn u have other ppl work to do also ...but i'll be posting pix soon of the pedal box that i'm building ....

[justvwpower]

just busy with OPP Other Peoples Projects

[16v Drakes]

Hi love your project.............I live in Guyana also have a project will visit Jamaica in 2012
http://forums.vwvortex.com/showthrea...MANIFOLD/page3

[justvwpower]

!!!MERRY XMAS & A HAPPY NEW YEAR 2 ALL MY DUBBING FAMILY !!!!
will be here next year with the project ongoing

[justvwpower]

Hi love your project.............I live in Guyana also have a project will visit Jamaica in 2012
http://forums.vwvortex.com/showthrea...MANIFOLD/page3

i was thinking bout building a turbo manifiold ..but in JA they are reluctant 2 weld cast iron ..& its expensive to weld stainless steel ....so i do plan to buils a mild steel manifold ....
a real PITA whn ur money is devalued ....

[justvwpower]

in my small effort to clean up the engine bay ...i decided to reloc8 the windshield washer bottle so here is what i did ....
this is my passat water bottle




i plan to relic8 it under the fender...... i wanted to go with a JDM water bottle (nissan) but we have a code of conduct in JA ....only vw derived parts may be used from JDM vehicles ....so it was a no no....
now the passat is a bit long so it wud foul against the bracket tha hold up the edge of the bumper ...so i decide to use the bottle off my mk2 golf 4 L vs 5L what a L between cars ...





well it fit ...so now to anchor it ...
idecide to remove the bracket that held it in the engine bay



bored out the spot welds



& than chiseld it offf !!!!!viola!!!!




now to fit it 2 the water bottle ....


i.e is how itts gonna be anchored ....



this is where its gonna be installed ....

right up under the battery shelf .....


now to figure out how 2 attach the bracket .....

[justvwpower]

well i started on the brackets to day ....

picked up a piece of aluminium 4m my scrap pile




bent it 2 fit ....


further bending done with a pliers & a vice grip ...


removed the bumper to do my work ....BTW IT THE 1ST 2 BOLTS CLOSEST TO THE BUMPER ....did ma search on vortex...... next thing google work better than the search feature on vortex





trial fit

w/o the aluminium bracket


with the bracket ....





now to gain access to the water bottle ...i'm looking @ this hole .....


cleaned ....

jus took a hammer to it ....


with the bottle installed ...

& to think i was gonna install a nissan washer bottle there .....

[justvwpower]

the final look .....

[justvwpower]

next on the agenda ...reroute the wires & x10d the hoses ....

[justvwpower]

to all those who say i'm gonna lose my washer bottle in a crash ...!!!!!! WE DON'T BUILD CARS TO GET IN ACCIDENTS !!!!!i.e y its called an accident .....

[justvwpower]

getting ready to do the pedal box ...

[justvwpower]

i re routed ALL wires/hoses for the wind screen washer in2 the bonnet ....!!!sano!!!


removed the steering bracket ...drilled out the spot weld & took a chisel to it ....


using my angle grinder....cutting out the clutch pedal assembly 4m doner pedal box


now the chisel comes in handy for those stubborn welds .....


clutch pedal removed


clutch pedal w/ bracket


hammering out dimple to make way for other bracket ....

!!!!!!stay tuned!!!!!
morking out & boring

[justvwpower]

put master cylinder in hole & align it with the pedal box & bore the 1st hole


marked out the holes 1st b4 i bored .....


from inside the car


another shot


mark hole in pedal box ....


bore hole & bolt master cylinder to pedal box ..


getting a idea of how it should look ....


need to keep it str8 & inline

the technical part is getting the pedal ratio (height) correct & keeping the position of the steering column support bolt in its correct position .......

[justvwpower]

i finally finished the pedal box & installed it .....here are the continuing pix ...


had 2 modify the flangge are to keep the shaft str8 ....


grinded the slots to go over the rein4cement bar in the pedal assy ..this will b welded l8r ...



clutch pedal section ...



trial fit to finalize evrything b4 welding ....



need this as master cylinder rein4cement ...





FINALLY WELDED 2 GETHER ....all AOK




!!!!!FITTED!!!!next to flare the lines & install them ....


donor pedal cluster now ....

[justvwpower]

[/IMG]





sorry for posting so l8 ...
this is how the clutch system looks after evrything is done .....
making a urgent effort to start the engine ...& program mi Megasquirt ....
!!!!!STAY TUNED!!!!

[justvwpower]

just putting around mi workshop ....i found some odds & ends & realized i can make a waste gate controller so here it is .... according to the info i got on the net 4m various sites
next i have to tap the head to take the adjustment bolt , cut the spring & tighten & seal evrything with thread tape

[justvwpower]

got my mk4 back brake ...5 lug ...want to make this into a big brake for the rear of the vehicle



realized that vw is putting the anchor on2 the rear end assy rather than the stub axels ...i do kno that the polo 6n (mk3 polo )rear disc brakes uses the floating rotors but the caliper anchors are ong the stub axels ...but alas none of the mk3 polos ('94) in JAMAICA has rear disc brakes ....so it back to the fabrication shop again ...been along time since i made a visit ....but gonna get back on track to start ma engine & tune ma MEGA SQUIRT 2 .....

[MOTA BOY]

Crazy!

[ellocolindo]

i love the progress you make everytime an obstacle comes up.
here in north america many people would have run for the hills early into this build because of the fabrication needed. the rear caliper swap is it because you want bigger rotors or move away fromt he cast iron prone to seizure calipers?
the mk4 calipers are a direct bolt-on for the passat ; if it came with rear disc. if not; i can get you parts you need. i could cut the part of th rear beam and mail it to you. in return you make me a pair of pulleys for hte serpentine belt all in one belt; you made one early intot he build thread...

[justvwpower]

i love the progress you make everytime an obstacle comes up.
here in north america many people would have run for the hills early into this build because of the fabrication needed. the rear caliper swap is it because you want bigger rotors or move away fromt he cast iron prone to seizure calipers?
the mk4 calipers are a direct bolt-on for the passat ; if it came with rear disc. if not; i can get you parts you need. i could cut the part of th rear beam and mail it to you. in return you make me a pair of pulleys for hte serpentine belt all in one belt; you made one early intot he build thread...

i actually like the cast iron rear calipers cuz they can be repaired unlike the aluminium ones .....but yes i want to go bigger rear rotors (10") for my passat& lessen the unsprung weight ......... tell u what ...i'll start looking around for suitable pulleys & let u know whats up .....

[justvwpower]

next stop the fuel pump issues solved ......

[uber8vs]

ur a god

[justvwpower]

sorry i have been tardy .... but life stepped in .....as kung fu tsi said ...life is what happens whn u have other plans ....or something like that ......but my mom had 3 strokes in 1 week but thank god she is coming back around ....& now to clear up the back log of work in the garage ....& back to the project ......
well i was s'pose to do the mods to the fuel pump system .... but i have to fabricate a pipe 1st so i decided to look @ the front suspension 2do my 5 lug big brake setup (ON A LOOOOW BUDGET) sorry ECS & other big brake specialists ....but i do live in JAMAICA ....where its $JA100 buy $US1 ....so back to the mods

here is the fuel pump setup so far


gonna use the walbro intank


all of what i need


putting it all together


need this to make the coupling from the pump assy 2 the the line of the injector assy


cut out the 2 nipples


the 2 nipples


preparing to be welded


welded with bronze


cleand up with the grindr

[justvwpower]

took out front knuckle assy .....sold the shox also..... a sweet pair of boge turbogas !!!!new!!!! ....made sum1 happy




prepping the control arm for the 5 lug assy


the vr6 ball joint in the control arm ....ALAS THE 2 SIDE HOLES DON'T LINE UP....darn


marking where the holes don't line up ....


wanted to put this on ....but the anchor point for the antiroll bar is on the other side ...!!!!!DARN!!!


see it there ....new stuff....

[justvwpower]

in measuring the control arm for the vr6 .... i realized that they are almost the same length ....(less than a 1/4 " difference) & that is brought about by vw making the end point of the vr6 control arm in2 a point rather blunt ....not only that ....to prevent ppl like me from using the original arms they spaced the 2 side hols of the vr6 ball joint farther apart than the regular ball joint....i usually slot the holes on the regular control arm & weld a piece of metal over the area to keep the strength as the slotting carries the hole out to the the nd (hence y the vr6 control arm ends in a longer point ).... i have decide to do it different ly .... i'm gonna slot the ball joint to fit the regular control arms .....call me lazy ...but i think its easier
but all u ppl killing urselves to find vr6 control arms ..... no need to .....

i guess if necessity is the mother of invention ...... the father is scarcity .....

i wouldnt have found this out if i had vr6 control arms
love 2 alll

[justvwpower]

the only difference is the position of the holes ..... i'm gonna rebore the holes in the ball joint
to all the mk2 ppl who wud like to get vr6 control arms just use the regular passat arms its the same length & jus mod the vr6 ball joint

[justvwpower]

well the ball joints are finally fitted here are the pix


the holes slotted ....wonders of a 2nd cut round file ....



bolted up ....

putting on the spindles next ....

[justvwpower]

yesterday i bolted up the suspension ...still w8ting for the part to finish the fuel injection system


the spindle...... needs cleaning plus the bolt that holds on the rotor is broken in it .....darn more work ...nothing goes smooth

if i had remembered i wudnt have bought new ball joints ....oh well ...i have more spare parts ...


boring out the brokn bolt




which 1 should i use ....hmm bigger is better ...


use the stock vag nut .... think its better .....


my package in storage for years....love u santa ....





!!!!YES !!!!!!! i have to mod these as well ....not so much tho ...just replacing the white bump stop rubbers with the polyurethane 1s ....with a lot of & lube to get on .....


i used the mk2 strut mounts cuz I THINK they make the car lower as compared to the vr6 rubbers .....


beautiful ....


sweeeeeeeeeeet.......


my big brake kit taking shape .....

big calipers for big brakes .....

proof ......

what a pain .....the girling 60 bracket dont fit on the 11.3 ....but fits on the 11....
now i have to wear the ordinary looking single piston ATE calipers .....
.... hmmm can i do some machining ..... ....
looking in2 it .....
!!!!!!!STAY TUNED !!!!!!

[justvwpower]

Throw an Audi engineer down a hole with a ladder and he will fashion a shovel from it and tunnel his way out

[justvwpower]

sorry to be so tardy ...but my mom has been in & out of the ospital ...but i'm not giving up on my project .....

[justvwpower]

sorry folks ...but my mom has passed away .....i'll be back very soon .....

[MOTA BOY]

Know how it feels.

R.I.P.

[justvwpower]

my mom has passed after 6 year years of illness .....in the process of burying her .....but in the meantime THE WORK MUST GO ON .....or is it the show ...
here is what i have been doing in between time


the g60's w8......



the g54's w8 ....



the ate 57 ...w8...
hands down i am going with the ate .....



w8 of the 11.3" rotor ....
in the inters of less brake fade ..i'm going with this .....


looks sweet .....


alas ...found out that the hubs are thicker than the regular 11" rotors .....
have to get some ....

no on2 the fueling .....
i wanted the fuel to run thru the filter 1st b4 going thru the main pump ...her's how i did it .....



ready to mount up .....need some more jubilee hose clamps ....