Superb read, this thread.

OHC valve spring compessor in action

the idea is to push down the valve spring far enough to install/remove the split collets (cotters).

note: i use vasaline to 'glue' the collets in place whilst releasing the tension from the compressor

Ready to fit

note: never put a cylinder head face down on the floor, grit can easily damage the mating surface

Looking spangly.

Damn fine cleaning tank you have.

Looking spangly.

Damn fine cleaning tank you have.

used shaft mounted wire wheel to take the worst off, then took it to a place i used to work and put it in a special machine which is basically like an industrial dish washer, it sprays boiling hot solvent all over

That's a pretty quick transformation from most peoples scrap to as good as new.

started cutting up the intake manifold today too

Looking real smart there Teflon, Are you going to use plenum chamber or throttle bodies?

at the moment i'm planning on using a single golf gti throttle body, although i would settle for one off any car to be honest, i'm going to make a plenum to fit on this bit i've just cut

I'll have a think but are you going to use a Tmap sensor/throttle position switch or a maf sensor, not sure what system your using, I know some of the earlier golf/vw engines had a 2 stage opening T.B. or do you want to use a single throttle flap:)

i'm not really bothered which type of throttle body it is, but the single flap ones are more compact, i'm using an alpha-n type system which doesn't have a MAP or MAF sensor, it gets it's load signal solely from the TPS, there are details of this earlier on in this thread

going to make these bits so i can make up a plenum

i'm not really bothered which type of throttle body it is, but the single flap ones are more compact, i'm using an alpha-n type system which doesn't have a MAP or MAF sensor, it gets it's load signal solely from the TPS, there are details of this earlier on in this thread

Okay point taken:O What bore on the t.body adaptor plate are you going to use, by the way cool drawings for a plenum, ally or plastic:)

60mm bore, made from aluminium alloy

I'm looking at that and wondering if the wedge shape will give you issues with differential levels of cylinder filling end to end (and possibly mixture if you're using throttle body injection).

I'm looking at that and wondering if the wedge shape will give you issues with differential levels of cylinder filling end to end (and possibly mixture if you're using throttle body injection).

that is the whole point, the tapered chamber helps to equalize flow into each cylinder.. the only reason most manifold aren't made like that is because it's too difficult and expensive to make a casting that shape

finished chopping down the manifold, milled some flats on the back for the mounting washers/nuts, then flycut the mounting face to it's absolutely flat ready for welding

the pieces that make up the plenum cut from 5mm aluminium plate

bottom left; has 12mm hole to take a pipe for the brake servo vacuum hose

bottom right; has 6.5mm hole (tapping size for M8) for accelerator cable bracket

middle left; bottom of plenum 10mm hole to take a pipe/union for fuel pressure regulator reference

middle right; throttle body plate, 60mm bore, 5mm mounting holes (tapping size for M6)...

other piece which goes on the cut down manifold is away being welded onto the manifold as my welding machine is not powerful enough to get decent penetration

sweet, so you managed to find someone with the gear to cut it? or did you do it the ard way?

Wowzers an excellent 16 page read. Keep up the good work.

sweet, so you managed to find someone with the gear to cut it? or did you do it the ard way?

did it the hard way...

How long do you reckon untill its going to be up and running?

i'm not sure at the moment, i'm going to be really busy at work for a few weeks