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Old 2nd September 2013, 12:43   #76
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Default Re: My TD to TDI VW Van (1990 model)

hello Sir,

Your thread is truly inspirational , I have been following this from Day 1 and the technical changes coupled with brilliant re engineering has resulted in a fantastic vehicle.

If you could let us know , do you have an automobile background or is this all self learning throughout ?

Regards,
Jimmy
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Old 2nd September 2013, 22:17   #77
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Quote:
Originally Posted by Jimmy_u View Post
hello Sir,
If you could let us know , do you have an automobile background or is this all self learning throughout ?

Regards,
Jimmy

Thanks, jimmy.
Yes, my automobile background started way back late 80's.

I used to be with rally team where fiats engine used to have four bike carb.(Of Corse service team ). There I learnt the limits of modification. Vehicle I owned would be my sir name by my friends. Since I am also a fabricator it helped. Golf 1.6 TD 1989 I had(sold) also helped.

Last year I modified a Gypsy. Engine replaced with G1 Isuzu engine with 5 speed gear box, front & rear diff of Mahindra. Benz steering shocks fitted to steering linkage. Since It was not mine, I dint make any documentary. Doing duties in Krishna Geri.
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Old 4th September 2013, 18:44   #78
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Default Re: My TD to TDI VW Van (1990 model)

Some more details which are helpful to you.

How I joined the wire for wire extension. This will help in no current loss , no loose connection & short circuiting.

Crimping done
My TD to TDI VW Van (1990 model)-crimped.jpg

Sleeve inserted & bit of heat shown to it
My TD to TDI VW Van (1990 model)-sleeve-heated.jpg

The finial out come.( My electrician call it burning tube ) Behind you can see the tube
My TD to TDI VW Van (1990 model)-finial.jpg

Battery clamp. Very unique & simple.
My TD to TDI VW Van (1990 model)-clamp.jpg

Clamp fixed to one side of the battery. Other side bottom is press fit to the existing OE channel.
My TD to TDI VW Van (1990 model)-clamp-fixed.jpg

Additives & grease used in this project. Grease is very expensive. Quality :-- heat resistant & water resistant . Can be use in drive shaft.
My TD to TDI VW Van (1990 model)-add.jpg


Before I show my work piece to all of you who have inspired me to reach to this point, I’d like to share my experience in this journey.

MY EXPERIENCE
My feelings about this journey is 50/50. Midway I wondered if it was worth doing, with this fast moving life.
On the bright side, when things work as you planed, the joy you get is priceless.
Here all that matters, is we create the product the way we want it. One thing is to make sure to not compare it with any other product .
I learnt a lot while working on this project.- To be patient, working chart, matching the right parts, met many unknown people, lastly TDI knowledge I got was remarkable.

MY ADVICE,
Every one should experience this kind of joy once in their lifetime. That’s it, nothing more. Make sure that you really want it & it’s at least 60% useful to your family.
Budget & time has least precedence in this.

Tomorrow I will be driving van to wheel alignment. Once done straight to catwalk photo shot.

My next posting will be, My work piece.(coming week)

Last edited by narendra.vw : 4th September 2013 at 18:48.
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Old 4th September 2013, 22:08   #79
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Default Re: My TD to TDI VW Van (1990 model)

kudos to you sir for this labour of love. The kind of attention to detail that has gone into this restoration is simply awesome. Special thanks for sharing the info for the rear hatch struts. My Marina struts fail at times to hold the hatch up and was thinking of getting them repaired but was told to get them replaced instead. Now I will try your trick and see if the channel width would press fit the struts or not. Thanks.
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Old 4th September 2013, 23:13   #80
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Quote:
Originally Posted by narendra.vw View Post
( My electrician call it burning tube ) Behind you can see the tube
This is a "Heat Sink Sleeve" Shrinks when heated. Hot air blower works better than a match-stick.

Excellent work! Please carry on..
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Old 5th September 2013, 18:25   #81
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Default Re: My TD to TDI VW Van (1990 model)

Quote:
Originally Posted by Chethan B G View Post
This is a "Heat Sink Sleeve" Shrinks when heated. Hot air blower works better than a match-stick.

Excellent work! Please carry on..
Thanks, chethan.
I came to know what I dint know. I will brain wash my electrician to use it. (Blower). For that, I have to get him one.


Update

Had been to wheel alignment .This was the first time van was in concrete jungle. Surprise, one wheel dint take any weights for balancing. Front caster, Camber & toe adjusted, Van rear wheel also needs camber & toe, but aligners dint had any spec . I have to check out in different place. As of now no pulling to right or left, no screeching noise while cornering. I think I will drive it for sometime then check tyre wear out.

Just for knowledge
1) To do Camber 2) To do caster 3) To do toe in or out
My TD to TDI VW Van (1990 model)-suspension-front.jpg
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Old 5th September 2013, 19:00   #82
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Default Re: My TD to TDI VW Van (1990 model)

Quote:
Originally Posted by narendra.vw View Post
Engine Details:--- 1.9 TDI 90 BHP Code :-ALH ( In India: Skoda Laura)
Engine had done 38,000km on the donor car.
From the pics the engine looks like its uses a distributor pump. The Laura 1.9 used PD injection system. What you have must be from the first gen Octavia
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Old 5th September 2013, 21:26   #83
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Default Re: My TD to TDI VW Van (1990 model)

Quote:
Originally Posted by Mpower View Post
From the pics the engine looks like its uses a distributor pump. The Laura 1.9 used PD injection system. What you have must be from the first gen Octavia
Thanks for Info, Mpower.
Information was given by the person who sold the engine I thought may be some carried this engine. (Had done less home work) At that point I gave importance to model. & low mileage. 2009 M clearly sticker with bar code struck on the timing belt case. Connected the wiring to instrument cluster with battery just for reference . The reading showed 38000 km + some fraction & also it showed ,ABS, Air bag display light on.

Last edited by narendra.vw : 5th September 2013 at 21:28.
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Old 20th September 2013, 11:14   #84
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Default Re: My TD to TDI VW Van (1990 model)

Hello Sir,

any updates , waiting to see the finished product :-)
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Old 20th September 2013, 20:11   #85
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Default Re: My TD to TDI VW Van (1990 model)

Quote:
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Hello Sir,

any updates , waiting to see the finished product :-)
Thanks for asking. I am waiting for Bangalore monsoon to be over soon. I am not able take any descent photos. Twice I took my van to a good location came back due to heavy rain . Hoping this weekend will work.
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Old 28th September 2013, 19:29   #86
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Default Re: My TD to TDI VW Van (1990 model)

Hi, . Bangalore monsoon finally ends. ( As of now)
Since rain has stopped & sun is shining, allowed me to complete the thread as stage 1.

Before I end stage 1, I like to thank you all who have viewed, reviewed & gave life to this thread right from Mani to FBI (For Better Information.)
In every house worming ceremony, unfinished work will be left over to be done later. Likewise Van also needs bit of work to be finished. (Front seats, front floor mats, ac gas filling)

Your IMPRESSION is my future DIRECTION.

Before you proceed any further , please go through my past

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My TD to TDI VW Van (1990 model)-ribbet-collage.jpg


Here I present PRERUNNER My MUV 2013


My TD to TDI VW Van (1990 model)-1.jpg
My TD to TDI VW Van (1990 model)-2.jpg
My TD to TDI VW Van (1990 model)-3.jpg
My TD to TDI VW Van (1990 model)-4.jpg
My TD to TDI VW Van (1990 model)-5.jpg
My TD to TDI VW Van (1990 model)-6.jpg
My TD to TDI VW Van (1990 model)-7.jpg
My TD to TDI VW Van (1990 model)-8.jpg
My TD to TDI VW Van (1990 model)-9.jpg
My TD to TDI VW Van (1990 model)-10.jpg
My TD to TDI VW Van (1990 model)-11.jpg
My TD to TDI VW Van (1990 model)-12.jpg
My TD to TDI VW Van (1990 model)-13.jpg
My TD to TDI VW Van (1990 model)-14.jpg
My TD to TDI VW Van (1990 model)-15.jpg
My TD to TDI VW Van (1990 model)-16.jpg
My TD to TDI VW Van (1990 model)-17.jpg
My TD to TDI VW Van (1990 model)-18.jpg
My TD to TDI VW Van (1990 model)-19.jpg
My TD to TDI VW Van (1990 model)-20.jpg

My fingers have become numb I will be back Sunday eve.

Last edited by narendra.vw : 28th September 2013 at 19:32.
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Old 29th September 2013, 17:39   #87
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Default Re: My TD to TDI VW Van (1990 model)

The Omega grease which you have mentioned is one of the best in business. Although it costs a bomb, the results are excellent. We have been using these in some of the critical components of the machines and have seen some excellent results. Your ride also will experience the same with these.
Do you mind sharing from where you picked these from?
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Old 30th September 2013, 18:59   #88
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Default Re: My TD to TDI VW Van (1990 model)

Quote:
Originally Posted by unk9ja View Post
The Omega grease which you have mentioned is one of the best in business. Although it costs a bomb, the results are excellent. We have been using these in some of the critical components of the machines and have seen some excellent results. Your ride also will experience the same with these.
Do you mind sharing from where you picked these from?

OK, you could notice only the lubricants I used.
Regarding itís office, I know the route but not the address. Itís just after Vijay nagar by lanes of west of cord road. I will search for old bill. If I find I will pm to you. I have my own arrangement to door delivery at my friends apt. ( In case you need, Pm.)
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Old 3rd October 2013, 21:26   #89
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Default Re: My TD to TDI VW Van (1990 model)

Continued,
Please see photos in different WINDOWS. It looks better.

My TD to TDI VW Van (1990 model)-0.jpg
My TD to TDI VW Van (1990 model)-1a.jpg
My TD to TDI VW Van (1990 model)-2a.jpg

Tired of photo shot, panther is thirsty.
My TD to TDI VW Van (1990 model)-2.jpg

Please see following 5 photos in sequence. (In different 5 windows & closing one by one.)
My TD to TDI VW Van (1990 model)-3.jpg
My TD to TDI VW Van (1990 model)-4.jpg
My TD to TDI VW Van (1990 model)-5.jpg
My TD to TDI VW Van (1990 model)-7.jpg
My TD to TDI VW Van (1990 model)-8.jpg

Ready to go back to it's nest with 800 watts power
My TD to TDI VW Van (1990 model)-11.jpg
My TD to TDI VW Van (1990 model)-12.jpg
My TD to TDI VW Van (1990 model)-13.jpg
My TD to TDI VW Van (1990 model)-14.jpg

My future dream,
Some one get me this form Germany.
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So, I can make this.
My TD to TDI VW Van (1990 model)-i-make-.jpg

Hold your breath, & I can do this.
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Just for the knowledge . 1) My unique tool collection
From left:-- Used for riveting sheet , Round pipe tube cutting ,Allen key in T shape , Spring puller, stud nut remover (Used in engine head stud ), Richet. reversible, half cut ring ( useful in removing brake fluid line nuts), C bent ring (Useful in removing starter bolts), adjustable spanner. Yes I have set of all.

My TD to TDI VW Van (1990 model)-my-unique-tool.jpg

2) Unique ramp. ( similar to bullock cart operation .)
My TD to TDI VW Van (1990 model)-ramp-1.jpg
My TD to TDI VW Van (1990 model)-ramp2.jpg

3) Engineís finial look.(Note:--No clamp on battery top.)
My TD to TDI VW Van (1990 model)-engines-finial-look.jpg

4) If you were wondering what happened to old seats. (My form house.)
My TD to TDI VW Van (1990 model)-old-seat.jpg

End of stage one.

This thread will be back with STAGE 2. Mainly details of mod performance report & Upgrading.

First upgrade will be,
CB PERFORMANCE CLUTCH PLATE. .Dia228 mm.( Before Dia215 mm. OE for TD. )
The facing used is of special woven material to withstand the extreme heat and heavy wear.
Thatís what it clams. Expecting it from US in two monthĎs time through my friend.
I wish to end stage 1, smile on your face.

Last edited by narendra.vw : 3rd October 2013 at 21:37.
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Old 16th October 2013, 12:47   #90
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Default Re: My TD to TDI VW Van (1990 model)

Hello Sir,

Thanks for this wonderful photops, can you also add the interior pics from various angles of the final setup, this should complete the need for more on this wonderful ride.

Regards,
jimmy
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