180hp 1.8t in Bug

**volkdent** · #1 November 29th 2007, 18:58

The throttle pedal is finally done. I wound up using a stock MkII golf/jetta cable housing, but to get the length I need, used mountainbike cable housing and some cable I found that looks identical to the stock golf cable. What was cool is that the little ends that fit onto the mountainbike housing actually fit into the golf cable, so I have a flawless joint. Worked out really well. Pics to come.

Jason

Panelfantastic · #2 November 30th 2007, 00:38

Awesome!
Any idea how long before you get to fire it for the first time? Oughtta be a podcast moment! Get us some live broadcast set up!

Jeff-

**volkdent** · #3 December 3rd 2007, 01:54

Well, all is done, but the car don't run!!! I'm not sure about getting all the coolant in, I filled the entire line from and to the engine, then I filled the expansion tank, but I'm worried I don't have anything in the engine to get it primed, and what is weird is that the expansion tank filling is not filling the system.

What was more frustrating was that the ECU is not working!!! I plugged in the custom harness, which just left a few wires for me to tackle. Those were the main power and ground, (duh), and the power for the rad fans(work fine with direct connection) and the power for the fuel pump(again works fine with direct connection) so I'm thinking there is a problem with the harness somewhere, or the ECU, either way not to easy to diagnose and really annoying consider how much I've spent so far.

I have the radiator in now pretty much finally, and I used foam to seal around it so any air entering the area is forced through rad, can't get around it.

Getting the fenders on after the dissappointment about not starting, and working on the front chin spoiler to make sure any air heading under the car is forced around it or through the radiator.

Hopefully it is something simple on the wiring, otherwise I'll be taking a trip down to Fremont with it to have it gone through.

Jason

**volkdent** · #4 December 4th 2007, 01:02

EEEEEeets Aliiiiiiiive!!!! Started her up today!!! I was so happy!!! Its been at least 5 years, and to hear this thing start up was just amazing. I actually recorded the second start, the first, which was more dramatic, I was on the phone with the tech from 034 Motorsport, and only had two hands. I went for a very short little cruise down the street, it's dark and there's no headlights, and found that there was this crazy metal on metal grinding sound from the front end. Turns out it was the inner edge of the brake rotor rubbing on the lower edge of the cup for the lower ball joint. I brought it back and ground some off of the cup, the offending area is not really a stressed area. I heard it again on the second trip, so there's a little more to do.

Big thing is that I can't find reverse!!! I'll have to pull the linkage and go through by hand to find reverse. I know I could find it before, but not with the linkage attached.

Eeeets Alive!!!

I've got the radiator fans set to come on at 90 deg. The manual says 92-100 I think, for the first stage, and hotter for the second, but I've only got one stage. I can add a secondary thermostat later to fine tune. Does 90 deg sound like a good temp for the water coming out of the head, or should I let it get warmer before the fan comes on?

I also found I had really done a dummy move. Way back I had placed a black plastic plug in the end of the coolant line coming from the expansion tank so stuff wouldn't get in there. So now I'm adding water to the tank, and it's not going anywhere. I'm adding water through the main coolant lines, but nothing is happening in the expansion tank, where you are supposed to add water. Finally, I pull the hose from the tank, and NOTHING is coming out!!! I figure I have a bad tank, pull the tank, then pull the hose off the tank. Out flows the water!!! I look, and in the end of the hose is my little plug!!! Well, now that makes sense. Hooked it back up, filled her up, no troubles now. All lines get warm, output one gets hot. Radiator gets warm, fans are working just fine. I'm curious to see how she runs on the freeway without the front lip spoiler.

Now it's getting more fun!!!!

Jason

**volkdent** · #5 December 4th 2007, 01:50

Jason

**volkdent** · #6 December 4th 2007, 02:09

Jason

Phat73VW · #7 December 4th 2007, 06:07

after all the updates.... seeing it start up in that vid makes all the waiting worth while!!!

Cant wait to see it finished and in person someday!!!

SCHWEEET PROJECT MAN!!!!

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