My Project

[shaq]

Hi,

Has anybody sourced the ''Plugs''
that fit these Polo 'COP 'to make
up a small wiring harness/loom ?
or,

Are they Main Dealer only ?

Many thanks,

Regards,

Gorilla.

You can either source loom from junkyard or buy at main dealers pins and connectors separately
and than produce your own wiring loom, also at VW they are to be sourced so called "repair wires"
and they are all yellow - it is a wire in needed diameter and on the other part is crimped a pin of
right type and size which one can later just insert in a corresponding connector.
I know that as we in family own a bunch of VWs

Here is an example how all this looks when ordered at main dealers with some prices attached:
watertight connectors vw (some of) and rep. wires

[Gorilla]

Hi Shaq,

Many thanks, I owe you a Beir when
this project is complete !!!

I will see if I can source a 'part loom'
from the Salvage Yard, if not then
I will purchase the plugs and it can all
be made into the engine Harness/Loom for
the stand alone ECU.

So long as the ECU has Ignition drivers
built in then it will be less wiring, hopefully.

Many thanks again,

Regards,

Gorilla.

[Gorilla]

Hi,

Made some more progess and have sorted
the 'COP' thanks to Shaq and the Forum.

What clutch are Guys with say 250/275 BHP
running please?

The 202 250 D at 230mm diam and 285nm looks
a possibility, or is there something better ?

http://img833.imageshack.us/i/dsc03195v.jpg/
http://img833.imageshack.us/i/dsc03194t.jpg/
http://img833.imageshack.us/i/dsc03193pm.jpg/
http://img833.imageshack.us/i/dsc03190d.jpg/
http://img833.imageshack.us/i/dsc03191m.jpg/

Regards,

Gorilla.

[Maki]

Hi
get yourself just a reinforced 16V clutch. It can handle this power levels very easy.

The problem for a clutch isn't horsepower but torque - and a N/A 16V isn't able to produce so much torque that a reinforced 16V clutch wouldn't be able to handle

There is no need to try something else.

Bye
Maki

[Gorilla]

Hallo,

Maki- many thanks for the reply.

The Sachs Uprated one looks the
simple way to go.

Many thanks,

Gorilla.

[Nagilum]

Hallo,

Maki- many thanks for the reply.

The Sachs Uprated one looks the
simple way to go.

Many thanks,

Gorilla.

The upgraded one is a good choice!
You don't feel any difference to the normal one, it's just a bit better.

Regards
- Nagi

[Gorilla]

Hi,

Is anybody running a different Gearbox in their
16v ?

I am going to use a 6 speed Gearbox from the CLK Diesel
which has nice close ratio's, and 6th is 0.87 so good for
long journeys.

The 6 Speed Gearbox is for''Electric'' speedo and the 16v Getrag
is 'Cable/Mechanical' speedo.

I have found a company in America that do a ''Conversion Box'
so that the ''Electric signal' from the 6 speed box
can be used via the Abbot Converter Box
to drive the 16v Mechanical Speedo.

http://www.abbott-tach.com/products.htm

That way you can use the Original 16v Dash and Dials etc.

However, I have tried 3 different Mercedes electric Dashes now
to see if an ''Electric'' 'Speedo' can be fitted into the 16V Dash Pod.

Merc 202 Dash, Merc 218 Dash and Merc 95 SL Dash, all
electric, but all with printed circuit etc.

Does anybody know of a Merc Speedo that is ''Electric'' and will
fit with some modification into the 16v Dash Pod/Cluster please ?

Was hoping that somebody else was running a different Gearbox
and had come across this problem.

Many thanks,

Regards,

Gorilla.

[partyboy]

Sorry Gorila, at least in the spanish mb forum there is nobody with a different gearbox in their 16v. There is one guy with the w124 24v one but it uses the 6l-3000-24v motor too. I ask him about the differences between both gear boxes and he told me that both are getrag "dog leg " but quite different, for inertia double wheel doble (twinmass) in the 24v case, and single for the 16v.

Best regards !

[Christhunter]

I Think, that the user Meisterjäger has some experiences with a 6-speed manual gearbox. I would contact him. He once said, that he's trying to convert his 2,5-16 Kompressor to a 6-Speed gearbox from a W204 or something like that.

Greets Bastian

[Gorilla]

Hi,

Update on my Project.

6 speed gearbox in and fitted,
what a pain that was, just awaiting
the front of the propshaft, being
balanced after being made shorter
for the 6 speed box.

3.46 LSD should work well with the
6 Speed Gearbox ratios, should be
around 95mph @ 3500 rpm in 6th.

1-5th gear are quite close ratio so
should make for a nice spread in keeping
the engine in the power band as well
as rev matching etc.

http://img148.imageshack.us/i/dsc03203px.jpg/
http://img198.imageshack.us/i/dsc03204e.jpg/
http://img850.imageshack.us/i/dsc03205t.jpg/
http://img823.imageshack.us/i/dsc03206e.jpg/
http://img151.imageshack.us/i/dsc03207q.jpg/
http://img59.imageshack.us/i/dsc03208t.jpg/
http://img19.imageshack.us/i/dsc03209z.jpg/

Regards,

Gorilla.

[Gorilla]

Hi,

Few more pics that did not
upload.

http://img546.imageshack.us/i/dsc03216b.jpg/
http://img339.imageshack.us/i/dsc03217rn.jpg/
http://img836.imageshack.us/i/dsc03218o.jpg/
http://img189.imageshack.us/i/dsc03219xs.jpg/

Regards,

Gorilla.

[partyboy]

Congrats for the job, great !!

[Henger]

Hi Gorilla.

Looks like a good job

Gruß Fränk

[Gorilla]

Hallo,

After untold issues more to do
with 'thirdy party's' , its hopefully
all coming to a conclusion
for stage 1.

Paint etc will be done after Christmas
and then hopefully when its all
up and running, onto stage 2.

Flaring the arches in metal to do
away with the Cosworth stick on
ones and the wider overall track was
time consuming, as was rebuilding
the engine after some nameless
numpty decided to live map the
engine, staticly and just blew it
to pieces.

To get anybody to do anything in
this Country [UK] well and on time is sure
becoming a very rare commodity.

Regards,

The Gorilla.

http://imageshack.us/photo/my-images/861/dsc03277c.jpg/
http://imageshack.us/photo/my-images/217/dsc03278q.jpg/
http://imageshack.us/photo/my-images/703/dsc03280g.jpg/
http://imageshack.us/photo/my-images/812/dsc03281d.jpg/
http://imageshack.us/photo/my-images/526/dsc03282s.jpg/
http://imageshack.us/photo/my-images/607/dsc03285y.jpg/

[ZS21]

Really nice car... Life your dream to the fullest .... Just like you do... Hope I can see this car sometime in Hockeheim at the racetrack.

Regards
Dany

[Henger]

Hi Gorilla.

Your project looks at the pictures very well.
Am looking forward to your final result and of course on your engine.

Viele Grüße

Fränk

[Maki]

Hi Gorilla as much as i ike your ideas because you are trying to think outside the box , like me i'm sorry to ay that i don't really like the bodywork- that's one point i like the OEM Style it doesn't matter if 16V or Evo.
But if it' your taste everything is good

[Gorilla]

Hi,

Have converted the Project Car
to Semi Dry Sump, as the std
sump and windage leaves a lot
to be desired with lateral 'G' force
and Type 'R' Rubber.

I originally had a DTM Oilwane but
it would have required 'fabrication'
to fit with the steering rack so I sold
it and went Semi Dry Sump.

Car is due for Final Mapping in the next week
or so and so far the semi dry set up
works well [driving around the block etc]

It also means that I can clean out the sump
pan pick up of any debris without removing
the sump.

Windage seems good, and I relocated the
Oil pressure relief valve to the Oil Filtre
housing, and uprated it to 4.5 Bar with a
a 75 Micron Mesh oil filtre.

Couple more holes added since pics taken
due to 2 dead spots on drainage.

Regards,

The Gorilla.

[Gorilla]

Hi,

Pics here as could not load on Forum
for some reason.

Tried re-scaling but no luck.

http://190rev.net/forums/showthread.php?t=41391

Regards,

The Gorilla.

[Nagilum]

Im Anhang die Bilder von Gorillas Umbau: