Marmalade 2.1

Stephanhipwell · Post by **Stephanhipwell** » Fri Sep 12, 2008 10:45 am

right i finally got round to doing a build thread.

i started fitting my 2.1 to my bug a couple of months ago hoping to get it done for a summer road trip, luck was not on my side and i had to much to do before i left

but i have allot of time to work on it now. the idea is to get it looking tidy and a clean reliable daily with a nice bit of power

After the hol, i spent the last few days unpacking and cleaning my garage. today i started work on it again, i did not do much but have to go to work so i just disconnected everything ready for engine out in the morn.

Tested my temp gauge, i had a sender that came with the gauge and one that was already fitted to the cooling system. i wired them up out of the car and diped them in boiling water to see if i got a good 100deg reading. the vw one that i was hoping to use as it was already installed and was less work gave me a ten degree increase on my gauge Sad and the other was spot on. so goes to show it's worth testing gauges if possible, also i am not saying that the VW sender was wrong just that it was not made for that gauge.

It is quite nice to be back and have all winter to play with the car. can wait to get started on my LONG to do list now

Passatman · Post by **Passatman** » Sat Sep 13, 2008 10:32 am

Please post some photos.

Stephanhipwell · Post by **Stephanhipwell** » Sat Sep 27, 2008 10:10 am

here it is before i started with the conversion

and a couple of piks of the conversion, i'll post some more later on

Passatman · Post by **Passatman** » Sat Sep 27, 2008 2:43 pm

It looks great, you will enjoy the car, it will provide a lot of torque. What gearbox are you using.

Stephanhipwell · Post by **Stephanhipwell** » Sat Sep 27, 2008 6:29 pm

for now i am using the 1200 that was in the bug, i will be keeping an eye out for a 1302/3s one though.

Stephanhipwell · Post by **Stephanhipwell** » Mon Oct 06, 2008 2:24 pm

not much to do with the engine but while i wait for funds i have been cortin out the engine bay and boot for new elecs etc

this photo is a bit pants but i painted it in metallic gun metal grey and added some glitter in so it looks like a insane metalflake job

bare metaled the boot also and painted it new, at the moment it's my favorite part of the car, I'm debating whether to splash out on powder coating the petrol tank as it needs painting, i want something durable and it would look great.

took some pics, the black is actually satin but i took the pic while it was wet, it looks much better now.

Stephanhipwell · Post by **Stephanhipwell** » Tue Oct 14, 2008 7:57 am

sorted wires out...ish

and worked on my reducer linkage

finished welding vents into my decklid

Stephanhipwell · Post by **Stephanhipwell** » Tue Oct 14, 2008 7:59 am

i'm not an expert but my pistons look like what i thought were low comp pistons, can anyone tell by this pic?

WBX Man · Post by **WBX Man** » Tue Oct 14, 2008 11:48 am

Stephanhipwell wrote:i'm not an expert but my pistons look like what i thought were low comp pistons, can anyone tell by this pic?

No, if this is a 2.1 engine you got the DJ pistons (high CR, 10.5:1)

Stephanhipwell · Post by **Stephanhipwell** » Tue Oct 14, 2008 2:23 pm

cool, i just found a pic of one with the low CR and the concave bit is much bigger. thanks.

also i have been looking for somewhere that does the late thermostat housing but no luck, any ideas? also the sealants for the heads/studs?

AMBROSIA · Post by **AMBROSIA** » Wed Oct 15, 2008 4:00 am

The sealant comes with a head gasket kit.
You really need to pop the liners out and replace the o rings also.
For your thermostat try les at superbeetles 07973 447944.

Stephanhipwell · Post by **Stephanhipwell** » Wed Oct 15, 2008 12:00 pm

yeah i was told that but i got a kit from GSF and it did not come with one, will check with vw parts and see if theirs does.

ta

AMBROSIA · Post by **AMBROSIA** » Wed Oct 15, 2008 1:01 pm

Have a word with jim @ the engine shop.
His kit has everything you need.
http://www.theengineshop.info/acatalog/
You can get away with only replacing the top green oring provided the barrels have remained in situ.
Looking at the crap on the old head gasket I would replace all them myself.

Stephanhipwell · Post by **Stephanhipwell** » Wed Oct 15, 2008 1:03 pm

cool will do, na i'm going whole hog i rekun as i'm changing con rod bolts for safe measure

AMBROSIA · Post by **AMBROSIA** » Thu Oct 16, 2008 1:11 am

I spoke to Jim about conrod bolts and he said he reuses them for all his rebuilds without any problems. That's ok for a stock engine, I guess

I was tempted to get a set of 2.2 pistons and liners off him until I saw the price

Have a chat with him, he knows his stuff.