'77 LS Turbo-Diesel Build thread.

[gldgti]

well, here it is. the LS build is beginning in earnest now that I will be pulling it apart very shorlty (the carb has been sold

I thought i'd start a build thread to keep track of things and make sure I post up everyhting i do so that hopefully we can all learn.

Just to begin, heres what I have planned:

the car is a '77 LS aussie made rustbucket () which isnt too rusty. panels are ok-ish, etc, but it drives straight as a die. its the only mk1 i've ever driven that will just drive so perfectly.

that said, its surprising. theres a lot of work to be done - the front strut towers are mushroomed from excessively hard shocks. theres a few minor cracks in places there shouldnt be. good old MIG will fix this.

so what am i doing?

ENGINE:

will be going with a 1.6L turbo-diesel, intercooled, garrett T3 and performance injection pump. ported and polished head.

new parts:
- entire valvetrain and all valves (hydraulic lifter)
- balanced crank
- ARP or raceware head studs*
- water pump
- injector pump
- oil cooler
- 3" mandrel exhaust (and downpipe)*
- ceramic coated pistons

run atleast 20Psi, should easily top 110hp@4500 and who knows up to 5500. should still be good for 5l/100km too

SUSPENSION:

will be running coilovers all round.

have:

- mk3 booster, master cyl, pedal switch. mk3 rear drums. GTI from vented rotors and calipers
- 20mm front sway bar - still looking for something for the rear

new parts:
- upper front mounts
- tie rod assemblies
- all boots
- entire urethane bushing kit
- urethane engine mount insterts
- coilovers (probably hottuning, haha)
- front upper strut brace, tied to lower wishbone brace, tied to chassis (like a k-bar arrangement but also tied to the upper strut brace)
- rear strut brace

- running 14x6.5 BBS and conti rubber

BODY:

will be basically the same. will be tidying up all rust and adding new carpet.

ELECTRICS:

continuation of current situation - everything is getting a relay! WOOOT! relays for all the reasonable current draw stuff - wipers, lights, etc etc etc.

thats about it really. this car will be a daily, and a weekender, and everything. no mercy will be shown, no any extra special treatment once its done. its going to be my DRIVING car.
i cant wait to add to this thread!

[GoLfMan]

im eagerly awaiting updates man, and PHOTOS
sounds awesome

[Mischa]

awsome 2 or 4dr? btw you have a pm

[Water Boy]

Is it the blue? Or the white one in your sig?

[Jarred]

This sounds good. I'll definately be keeping an eye on this thread

Look forward to more updates

[Preen59]

awsome 2 or 4dr? btw you have a pm

It's the brother to mine. It's a 4 door.


Oh, and i'll be keeping my eye (both if it gets super interesting) on this thread. (Subscribed!)

Good luck Aydan, should be a super economical weapon!

[DVR68U]

sound like this should be fun ,
cheers brenton

[mollins]

its the white mk1 4dr in his sig.

its my fault its off the road... i stole his carby

should be a fun little car. im excited.

[Preen59]

its the white mk1 4dr in his sig.

its my fault its off the road... i stole his carby

should be a fun little car. im excited.

Well thats not very nice! I'm looking forward to this build. Hoping to learn a bit about diesels.

[gldgti]

Well on the weekend i managed to get my little MIG going, and i thought id give you guys a quick run down so that anyone who is interested in getting one themselves may be a little better informed.

The model i purchased was from a sydney based ebay store, and is marketed as a "Mars 200 MIG/MAG Welding machine". its made in china and is painted a pretty blue colour

the specs are:

185A max capacity +-7.5%
15% max load duty cycle
gas or gas-less capable
0.8-1.2mm MS, 0.8-1.0mm stainless
11 position current setting switch and infinitely adjustable wire speed

i spent 1/2 hour making up a gas line with $2 fittings from bunnings, and the welding machine has provision for a bottle at the back - and E size bottle fits nicely.

so far, i've only used 0.8mm MS wire (can't see myself needing bigger wire for anything at home) and its worked PERFECTLY. i'm really surprised. no gas leaks, very nice wire speed control, steady current flow. it'll weld forever at current setting "4" (out of 10) and do a decent 5mm throat weld with no trouble...

plugs into a normal 10A outlet (no long earth prong) and hasnt set anything on fire (yet )

so anyone out there looking for a mig to do your bodywork and exhaust stuff at home - this little baby will get you out of trouble.