mk1 golf 1.1c, now with added ALT 2.0 20v on 48's!

Bloomin Keyboards! some very good work there!

 

So let me start by saying this is the first manifold i've made so go easy on the fit/welding/whatever

i started by making a pair of jigs for cutting, one was essentially for mitre'ing straight lengths for the collector, the other was for cutting both round and bent pipe into correct lengths and angles




now with the merge collector there's a bit of maths involved to work out the rotation angle in order to get a perfect fit, if the pipes were parrelel and on a 4 cylinder engine this would be 90 degrees, but as you increase the merge angle the angle of turn increases in a sinisoidal manner, i did a bit of trig and knocked up a simple spreadsheet




with this new found knowledge i cut the second angle in the collector






when i offered it up back on the car i realised there was no way a 35 degree merge angle would work lol back to the drawing board



8 degree merge angle fitted in the bay much easier!

v

welded it all together, and cut flat



then welded the V band



with that out the way i had to redesign the manifold again to account for the different merge angle, there is definitely a correct order to do these things in, and the order i did was not it haha,

the second jig -



all cut -



in the ICEngineworks kit they also supplied tack clamps, for mocking up the steel sections, they came in *so* useful




bit of fiddling and a few hours later the whole thing was tacked and looking something that you'd recognise as a car part





excuse some of the fit up on the collector, turns out that bit was quite tricky!

apart it all come for welding, got some pipe stoppers used for stopping leaks in plumbing circles, which i adapted to fit onto a gas feed, having only one regulator i used that to work out the flow on both gas outputs, which didn't really work and i wasted a lot of gas, like a lot, i've since got a second regulator lol



welded up and tacked to the flange, wasn't the greatest fit to the merge collecter but it's nothing i can't bridge



welded to the collector






unfortunately i've had to hide all my handiwork under some heat wrap as anyone who knows mk1's will know how close the steering knuckle and driveshaft are back there




next stop, wiring

 

Amazing work buddy great attempt for a first time.

 

and this is it fitted btw

 

Top notch mate
Very nice work keep the updates coming

 

entered the trackday fold too, with the daily parts hauler



which did nothing but highlight how many bushes need replacing lol

 

Wow, that exhaust manifold is the nuts! So much awesome work in this build

 

Stunning exhaust manifold.

Which camshafts do you have in mind?

 

Great work! Did you make a template?

 

Those photos and your work are amazing!!!!!

 

nice work

 

I hear there will be some available very soon for the NA 20v from a UK supplier. not sure on details yet but i know of another tuner building up a well specced NA 20v!

obviously i'm pretty limited as it's not a common engine useage, worst comes to worst i will get my own profiles ground

long way off that just yet. think for this year i'll get it running with stock internals, then pull it apart when the shell is off for paint early next year

 

That Manifold is Awesome

 

Impressive work.

 

Very impressive work. The RS4 looks great as well.

 

been busy with a few bits lately, nothing too hands on. planning the wiring loom mainly and designing these -



got a friend printing them up with his 3D printer this week, then i'll get them wrapped in kevlar to give them a bit of strength. basically will utilise all the leftover frontal area i have

 

Don't think i'd ever seen the RS4 engine fetching photo before. Haha

 

Trumpets are currently being printed, 40 hours total time to make the 4 haha

had a weekend fabbing up a couple of bits i needed, saturday i made a water inlet and outlet -









and a gearbox mount

 

nice work , that's one of the tidier mounts I've seen made up .

 

Keep up the good work mate, gonna be sweet when finished.