[TGi]

you breaking that 6n trevor?

 

[trevorbrady]

it's a Cordoba, I put a thread in the parts for sale section: http://vagdrivers.net/forums/index.php?showtopic=28309

most parts available at unbelievably reasonable prices

 

[oWesleyo]

Your going well at this trevor
good stuff

 

[TGi]

QUOTE (trevorbrady @ May 17 2009, 11:00 PM) <{POST_SNAPBACK}>it's a Cordoba, I put a thread in the parts for sale section: http://vagdrivers.net/forums/index.php?showtopic=28309

most parts available at unbelievably reasonable prices

dang was looking for a few 6n bits

 

[trevorbrady]

like what? there's a lot of stuff the same, or so I'm led to believe...

 

[draycottgirlz]

sorry to hear this won't be in Limerick Trevor....be in aircooled instead?

as always though fairplay to al the work your doing

 

[trevorbrady]

no it won't be at Limerick.

I should be there in the beetle or if I get my shit together and get the van insured and revived from its winter sleep I might have that there.

 

[STEVEN T]

First time to see this,its going to be a sweet motor,keep up the good work

 

[trevorbrady]

I pulled the entire loom from the Cordoba yesterday, from the headlamp all the way to the roof aerial and EVERYTHING in between. I'll be using the whole thing in the Derby, I'll strip out the original loom and transplant the Cordoba one so it'll have áll the modern stuff like an ECU with diagnostics port, factory 6 speaker stereo system, rev counter, etc etc etc. In fact the ECU will thik it's still in the Cordoba, all going well. It took ages to tag the loom as I took it out but it'll save ages and a lot of head scratching when it's time to fit it all to the car.

 

[cliffperse]

Class project, keep up the good work

 

[trevorbrady]

before: 1.1 Formel E

after: 1.4 AEX

it's just sitting there as of tonight, with only the rear and rhs engine mounts bolted up. Because I used the Cordoba's 5 speed gearbox the LHS engine/box mount won't fit, the top of the gearbox where the bracket bolts on are completely different so I'll have to custom make that engine mount bracket. I was hoping to use the Cordoba alternator but the bracket holding it to the engine has no engine mount like the stock Derby engine does so I had to transfer over the old bracket and alternator onto the new engine. I took the exhaust manifold off the old engine to transfer onto the new one and while it will bolt up, the ports in the 1.1 manifold are TINY, even compared to the AEX which is known for its small ports. I have two options: grind out the ports in the manifold to suit the AEX engine or make up an adapter for the stock Derby downpipe to AEX manifold. I think I'll fire up the die grinder...

The only other conflict is a harness plug on the inlet manifold fouls on the master cylinder reservoir. I might weld the bracket to the inner wing and run the remote reservoir and feed pipes from a '70s beetle...

 

[GSBellew]

You should have a look at a 5 speed polo up to 94 to see if the engine mount will work with your gearbox.

 

[MINIVINNIE]

good progress made there,keep it up and the pics to.

 

[Newtown Mk1]

Just an idea on the master cylinder wiring. I am making a pedal box to remove the linkage to the servo for my scirocco. You could do the same. Bit like this
http://i74.photobucket.com/albums/i273/Chr...k1/IMG_0519.jpg

pat.

 

[trevorbrady]

QUOTE (GSBellew @ May 24 2009, 01:06 AM) <{POST_SNAPBACK}>You should have a look at a 5 speed polo up to 94 to see if the engine mount will work with your gearbox.

pure genuis Gearoid!! I had a look under the bonnet of a nice G40 Polo at Limerick today (thanks the owner, didn't catch his name though) and you're absolutely right, the gearbox mount is exactly what I need.

@ Pat: thanks for the advice, I'm having trouble with photobucket tonight so I'll check your pic tomorrow. Incidentally, the same G40 had a passat brake fluid reservoir fitted which was shaped to keep the right hand side of the reservoir as flat as possible. It looks like it should solve my problem nicely. I'll scout around the local scrappy tomorrow and see if there's one about...

 

[trevorbrady]

I couldn't turn up a gearbox mount for a 5 speed mk2/3 polo:

So I called the main dealer as a last resort. They wanted €120 + VAT for that small piece of steel!!! There was no chance I was going to pay that for it so I got a bit DIY and made one from the two wrong ones. The gearbox end is from the Cordoba and the chassis end is from the Derby.

the engine is now sitting happily in its new home

 

[draycottgirlz]

i have probably said it here on this thread already Trev, hats off once again

 

[trevorbrady]

ah it's nothing really. I'm just too tight to fork over that kind of dough for something I can do myself

 

[trevorbrady]

WIRING!!

I removed the old loom from the Derby and pulled the Cordoba loom through. While most stuff if easily swapped or I can use the bits from the Cordoba to replace the Derby items there are parts like the column switches that just won't cross over so I have to use the old ones. Because of that I have to mate up the wires from the Derby switches to the wires to the Cordoba fusebox. The problem is there are far more wires in the Cordoba than the Derby!! While the DIN colour codes make life easy for most of the wires, others have to be traced to their source to check what they do and what colour they match up to on the Derby switches. It's slow and labour intensive...

anyway, here's the loom halfway through being adapted to the Derby:

you can see where I've mounted the new fusebox/relay board low down on the firewall, under the dash. I'll find some kind of centre console that looks the part to hide the fusebox from view.

this is the fusebox pulled out to headbang some wires...

 

[BLZEEDUB]

...nice project Trev, loving the idea of cloaking a modern wee engine in some retro clothing; I dont envy you with all that wiring... 'torquey enough' for a 1.4 them AEX's but the stem-oil seals fail and piss oil into the chambers; I done a bit of work to a 98 AEX motor'd mk3 recently and it smoked like a tired old diesel; might be an idea to do them for piece of mind...