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Old 27-06-11, 19:34   #1
jsobey
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vl wagon turbo build finally under way

have got my a into g and started working on the beast this weekend.

have started by removing lower dash covers, glove box and center dash.

next when the rain stops will be to remove the seats and carpets and sound deading.

after will remove fuse box in engine bay and relocate to drivers inside where factory auto computer is located... it looked to be enough room to fit in there.

hopefully this weekend i can remove brake booster to completely run battery wire to the boot, rca's, stereo wiring. and de-loom engine bay by running head lamp wiring under wheel gards or something like the such. ( haven't had real good look as to where to run them yet, but they will be hidden )

will get up to this point and repost with some photos hopefully

let the sunshine!

Last edited by jsobey; 15-10-11 at 08:35. Reason: update
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Old 17-10-11, 17:03   #2
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got the engine loom sort of hidden this weekend.
have nearly finished running the head light/ horn wiring
fuse box is now inside just deciding where to to put it etc.
turbo and manifold is on to dumby up exhaust piping.

this week just trying to plump up intercooler piping

have some pics from this weekend... forgot to get some before pics.. sorry.
hope they come out find

fuse box in side now


where the fuse box used to be...


bad battery tray and brake booster..



removed brake booster and and loom... have rewired it all inside.
(two blue cables are my temp starter and alternator)



right hand side loom inside now and all steering loom rewired nicely



on removeing the blower motor to access the computer and wiring alot easier i was to find...



nothing but a mini forest in the blower motor.. wondering why fan speed was bit slow hehe

more to come... hoping this week and get intercooler piping all done and battery cable run the length of the car.. keep u posted

---------- Post added 17-10-11 at 20:22 ----------

have some photos of the turbo and manifold fitted up for the exhaust







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Old 17-10-11, 21:11   #3
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looks promising man
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Old 18-10-11, 10:47   #4
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yer looks like ittl be a wicked engine bay when finished
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Old 26-10-11, 14:29   #5
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just an update on it. done some more work this weekend. have removed carpet and nearly finished left hand side wiring.

[IMG][/IMG]

have removed rear seat and roughly run HUGE battery cable from front to rear.

[IMG][/IMG]

[IMG][/IMG]

also my work mate let me borrow some vt twin from pot calis that i could use to meassure up fitting.

[IMG][/IMG]

the brackets look like they may fit bolt on?
[IMG][/IMG]

and last thing done this weekend was puttin intercooler on to meassure up i/c piping



p.s please excuse the date on my camera... the screen is broken and i cant find how to turn date settings off lol.

enjoy
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Old 30-10-11, 07:34   #6
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update time.

being doing some more work on the car yesterday. manily engine bay stuff.

have just being trying to get intercooler piping sorted out.
had to start by making hole for piping.


then could line up the first pipe off the turbo. to look like this;




with the pipes lined up i can now get them welded up to suit

here are the three pipes ill be getting welded together;


---------- Post added 30-10-11 at 10:53 ----------

so i thought i would remove the battery tray.
my thoughts were that it "shouldnt be too hard just cut here there and it will pop off" ha i was wrong... way wrong to be infact.

after a couple of cuts i got this far;


and some more cuts;


then i stumbled apon some rust;


finally got it all out




so after two cutting discs, half of a grinding disc and a hundred of pieces i finally had it out;



now whats on mind is do cut out that piece and replace it? im thinking that will be the ideal thing to do.
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Old 30-10-11, 10:11   #7
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Where r u putting the battery in the boot mate? I'm doing it
In my wagon next weekend and I cant decide where to put it
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Old 30-10-11, 17:54   #8
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lol dude, drill the spot welds & use a chisel and hammer, 10 min job....
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Old 30-10-11, 18:26   #9
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Quote:
Originally Posted by VLWAGONIT View Post
Where r u putting the battery in the boot mate? I'm doing it
In my wagon next weekend and I cant decide where to put it
i cant decide also. my mates have surgested to put them in the spear tyre well. im thinking of putting them behind the rear wheel arches and making the sides like a sub box kinda thing so i can still carry a spear wheel lol post a thread about urs mate so i can have a look too if u can

---------- Post added 30-10-11 at 21:27 ----------

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lol dude, drill the spot welds & use a chisel and hammer, 10 min job....
i couldnt see the spot welds due to all the rust and the rust some how attached it more then the spot welds haha. but thanks for pointing that out... i did have fun cutting and bashing at my old girl hehe
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Old 30-10-11, 18:35   #10
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lol, they can be a bitch.

ive got my battery in the spare wheel well in my white wagon. but the calais wagon is having it behind the wheelarch, ive made boxs that fill both sides of the wagon area with subs, and doors for the battery & amps.
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Old 30-10-11, 18:36   #11
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so i started attacking the sound deading today. have done LH and RH front bits from fire wall to under the seats. also found more rust under it all so going to be getting some anit rust and sander out this weeekend i hope

heres some shots;
RH


LH
sorry sun was peaking in.

and have taken off the stuff under the carpet... unsure if im going to use this carpet or get new one.



since i am delooming the engine bay i have changed the route of the gear box loom i have decided to place a hole in the tunnel. by off chance the loom reached and didnt have to extend it as first thought.. thanks holden hehe



thats all for now

---------- Post added 30-10-11 at 21:37 ----------

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lol, they can be a bitch.

ive got my battery in the spare wheel well in my white wagon. but the calais wagon is having it behind the wheelarch, ive made boxs that fill both sides of the wagon area with subs, and doors for the battery & amps.
yeah the calais is the way im thinking of going. would u have an pics of that? just wana see how uve done it.
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Old 30-10-11, 18:40   #12
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*edit heres a couple of pics, a bit old but my brother in the pic is now 13 haha






with that sound deadener, chuck some dry ice on it and itll break off like glass
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Old 30-10-11, 18:46   #13
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Quote:
Originally Posted by Psi_Wagon View Post
*edit heres a couple of pics, a bit old but my brother in the pic is now 13 haha






with that sound deadener, chuck some dry ice on it and itll break off like glass
ah very nice i like that... thats basicly what im thinking. im just hoping there is enough room for a battery each side with the sub also.. i think it will be tight

haha looks like uve had that wagon for some time.

yea about the dry ice... i cant be bothered going out my way to get some so had a good arm work out today haha. on the plus side im trying to save money any way poss to keep the final cost at a min
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Old 06-11-11, 11:02   #14
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not very productive weekend on the car from working all day sat and unpredictable auckland weather on sunday 6th nov.

first off i ran all front door wiring. speakers and electric windows.
LH

RH


then decided to lightly sand down passsongers foot well and to rust kill and antirust it.







so let the first coat dry and decided to move onto something else out side the car because the smell of the rust kill was terrible lol
so decide to sus out head lamp wiring. found a good place to run the wiring up. it think it will be good because it looks like thats where the plug wants to sit any way. heres some pics...




getting a few bits and pieces this week hopfully to finish off all the wiring inside. then might be able to paint inside then dash back together and new carpet in

thats it for now i think.
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Old 06-11-11, 11:47   #15
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Love it buddy keep up the good work mate, dont be disheartened by hicups along the way mate, itll be worth it
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Old 06-11-11, 13:22   #16
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Love it buddy keep up the good work mate, dont be disheartened by hicups along the way mate, itll be worth it
thanks for that. hicups are expected and thats apart of it but yeah work hard and it will pay off
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Old 10-11-11, 16:09   #17
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so i have a lil problem that i wana over come sooner rather then later.

i have found rust and holes from the rust just under the windscreen on the insides of the car. it looks like they are from the windscreen drains.
i wana no how i can modifie this so it wont happen again..
im thinking of cutting out the rust and removing all the stuff ( rubbish, twigs, leaf's etc) and welding in a new patch of what ever and welding a guase on the out side to prevent things going down there besides water.

here are some pics of what i mean from the inside... will get back with some of the inlet to this problem.

this is just besides the heater fan above where the rb computer sits.


this is just a closer up of the rust its about 10cm in length.



any help before i assemble the dash back together.
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Old 10-11-11, 17:56   #18
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I had the same happen to mine mate, Welded it then made sure all surfaces were painted to try stop the rust from coming back.
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Old 10-11-11, 18:48   #19
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you made a mess of that battery tray mate!
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Old 11-11-11, 16:45   #20
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I had the same happen to mine mate, Welded it then made sure all surfaces were painted to try stop the rust from coming back.
oh tru i might try the same.

---------- Post added 11-11-11 at 19:45 ----------

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you made a mess of that battery tray mate!
yeah just a tad. lucky it was all rusty and needed replacement anyway
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Old 11-11-11, 17:43   #21
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Good work man it's coming along good another turbo wag around can't hurt lol
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Old 14-11-11, 18:08   #22
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Good work man it's coming along good another turbo wag around can't hurt lol
thanks for that support. im trying to get it done sooner rather then later to get out there cruzing with all you lads around nz! road trips on in the summer time

---------- Post added 14-11-11 at 21:18 ----------

didnt get much done on sat as had a drift trike event on all day.
on hangover sunday i wanted to get to the bottom of my inside water leak.
so a couple of weekends ago i found the rust under the windscreen on the sides. chipped back all the rust as far as i could. which opened up the hole larger then a bic lighter. found that it was full of rubbish ( twigs leafs etc)

on the passongers side i used a copper welding rod down the hole to "unclear" it. this didnt work. decided to cut out some more rust to make the hole a lil bigger to find out what was stuck in it. dug around a lil and found it was quite badly blocked with a combo of things. some out it looked like it was clay and leafs n stuff that my welding rod could not get thru.
i soon cleared it all out and found it was all ok.

moved on to the drivers side. found my welding rod went thru like a dream. with a sh*t load of rubbish falling out. but got it all cleared up with the help of the air gun and the rod so no cutting done on that side.

i didnt get any pics this weekend as camera is MIA at the moment lol
will try and get some sorted soon.

was trying to finish off wiring this weekend also.. how ever.. my mate got me the wrong rca cables so hopfully can get that sorted this week to be able to finish that off and back to gether

thats all for now. Jono
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Old 24-01-12, 19:12   #23
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Have dOne some more work on the beast this evening. Last week some time i got out the rust killer and anti rust coating. Went around the hole body applying 3 coats during the day. Have done the front left wiring loom all finished up. Just need to run air flow meter wiring as I'm just going to use that for a base tune and run in the new motor. Once it's run in will change wiring and use map sensor ( mayb 3 or 5 bar sensor)
The plan for this long weekend (Auckland anniversary weekend) is to get ahold of my exhaust piping. Weld the first part of that and the inside under windscreen done. Once that's sorted will paint the inside floor and water proof it. Then assemble the dash. the one biggest problem is to not have any interruptions and distractions... :O

So today was sucsessful by applying first coat of primer on to my spear brake booster as I was in the mood from painting my drift trike tomorrow's job after work is to lightly sand back and re do primer and go from there.

Wish me luck. Will try to up date tomorrow with how the booster has come along.
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Old 28-01-12, 16:57   #24
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more work done today

only had couple hours today after work. have welded a plate under the left hand inside windscreen. just waiting for it to go dark to do a test with a light to make sure its all sealed.

have welded up some holes in the engine bay as i want a very clean engine bay.

done some more wiring also sorted out the heater wiring. should be able to put dash back together tomorrow. will have to sort out the fuses and relays in or behind the glove box also

here are some pics of the holes that i welded up in the engine bay
[IMG][/IMG]



will keep uploading as i go.
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Old 30-01-12, 18:01   #25
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had another good day working on the car today.
cant say much for sunday.. went down and enjoyed the day at the 4 & rota nat drags.

so today did engine bay work after removing top half of the inlet manifold to take it to my engineer ( @advanced creations ltd) to see what we could make up out of it... we're not 100% sure on how well the air flow will be. So more research is required.. what are some of your guys thoughts?

so returned back from his place and carrired on cleaning and smoothing the bay with the welder and grinders in hand.

with the grinders i had i thought to my self there must be a faster way to do this...
here is a pic of the 6inch grinder i was slaving away with until i dug into my old mans shead and found this 10inch grinder...



so my tactic for the inner gards is where they are indented is to heat it up with a heat gun and to tap it out ( or get it as smooth as possible) the reason for this is that i dont want the engine bay to be bogged out. also thats the reason for welding up the holes instead of bog.

have also sanded the fire wall where the brake booster and clutch were due to the surface rust that was starting. have coated it in my anti rust killer stuff to set over night for possibly a coat of primer.

heres some random pics to see what u guys think... plus everyone loves photos






enjoy!
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