Oh man that looks so good and bet it was an awesome feeling to drive around the block.
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Been a while Dai fam! Hope everyone had a good break and is ready for another year of fun!
So since my last post i have completed the wiring inside the cab, hooking up the apexi gauges and radio. After driving the car afew times i also found afew small leaks which were easy to repair. For some reason i made the turbo drain hose out of standard 100 series rubber braided hose and it deformed and leaked, so made a new one using teflon wire braid.
I did have an issue with the secondary jet circuit. Vacuum lines were hooked up correctly but i found that after zinc coating all the carby linkages, the secondary actuator became a little tight and didnt operate smoothly. I bench tested one from a spare carby then changed it over.
After taking the car for another drive and having massive smiles on my face. The AFRs are a little rich down low sitting around 11.5 and abit lean high end 14.5 … this being on a hot 37c degree day. Knowing that in cooler weather the reading will be closer to 15 and the chance of damaging/melting pistons will be greater.
The next coming weeks i will play around with jet sizes to achieve a reading of 12.5 - 13 to be safe.
Ill be removing my bonnet and taking it for repair. Unfortunately the vent has cracked!
While its being repaired, it will give me time to rebuild and swap over my other driveshaft and finish cleaning up the front seats which are currently installed as i was very impatient and wanted to drive the car! Ive been driving the car to work the past few days and my god i missed it!
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Very nice G100 that you have built there mate. I can see that you put down the effort to do things the right way 
Can I ask you what kind of a 3rd brake light that is that you’ve used to fit under your spoiler?
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@silencium cheers mate! Still not 100% but shes getting there. Definitely has come a long way!
The spoiler itself is the factory kissa style spoiler. I had a look online for universal spoiler brake lights and ended up finding afew sites with similar sealed units. See the picture below for the site. This one should last alot longer than trying to reseal the factory unit
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Thanks mate
Unfortunately the vent in the bonnet had a crack around it. A little annoying after having the car painted.
The panel shop that painted the car were abit negative about it so i took it somewhere else.
Ended up stripping the paint back to bare metal, the vent broke on the way out so searched the net and worked out its a rs cosworth vent. Got it to perth within a week. Epoxy the vent in and let it sit for afew weeks to settle. Panel and primed the bonnet. Yes it was a long process but well worth the wait. Committed composites did a great job!
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Next i organised to have the bonnet painted along with more touch ups i wasnt happy with.
Had all of the body trims painted black and the rear bumper body line. This completed the outside of the car!
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I spent a day to tune the carby.
When driving, i knew that the primary jet was a little too rich sitting at 11 on the afr and the secondary was a little on the lean side sitting at 14 -14.5 during the day, also remembering at night time when the air is cooler, this number will change.
So jets out! With the primary, i didn’t have one that was already smaller. I came across an oldschool carby tuner that once told me to use electrical solder to blank to jet. Works great!
Soldered, cleaned the surface, drilled to size and placed in. I modified a screw driver to fit perfectly onto these jets and also fit into the access port on the side of the bowl.
The secondary just needed to go slightly bigger, i already had a jet at the size i wanted to try out so placed that in.
On start up the idle was very rough. I couldn’t get it to run nice and giving it revs, it was like the motor was starving for fuel. This made me think the primary jet was now too small. Took the jet to the next size up and it idled much better.
In this process i also found a vacuum port had completely been missed so blanked it off and this fixed my hunting on idle.
Took the car for a drive and instantly felt a difference! The primary jet didnt move much on 11.5 but due to having problems with a smaller jet i can settle with it. The secondary was a 12.5 which is good for during the day.
Did have a hesitation on high boost which worked out to be the gapping of the plugs. Originally ran .8 gap but took them down to .5 and the hesitation had gone.
Still afew small issues to fix but thats the main part of the tuning complete.
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great works mate. I love seeing old school tech working. It really is a dying art.
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You are right! I love it when people realise that its carby turbo.
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Took the charade down to the WAJCC meet last night. A good mate of mine came down too in his GTti. Was great to finally have them out together!
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Really nice car mate!
A friend of mine had one in my mechanic school days, it was his parents’.
Nobody was impressed by his car in our class, untill we learned the power output of that small turbo 1.0 liter engine.
That was before the downsizing days like, 2008 or something.
Never knew that some were carburated!
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