Bay Window with 1.9 TDI engine -> READY

[Wilfred]

Hello,

I am Wilfred. A 25 year old student from Groningen, The netherlands. I have a 73 Bay window, with a 1600 cc engine. A slow troublemaker.

I ran into a VW Golf mk3 with a 1.9 tdI engine (110 bhp). I decided it had to end up in my van. I also bought a VW t25 AAP gearbox, 5 speed. Originally this was attached to a 112 bhp 2.1 wbx engine.

That's all I have so far. Oh and a very nice, big radiator from my 4.2 litre jaguar xj6. The actual work will start in about two months I hope. For now, I am gathering knowledge and parts

Some pics, to make this post interesting. What I bought 5 years ago:





What I made of it:


When I changed the front:




And some points, over the last years, which made me want to loose the original engine and get something reliable:




Okay, first question: Do I need to change the 'prise as' ? (what's this called in english? It's the little thing sticking out of your gearbox on which you slide the clutch plates.)

Well, so far so good
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1973 BayWindow running 1.9 110 bhp TDI with flipped gearbox.

[jp]

Some great snaps there mate ... sorry I haven't said hi yet

Bit worrying when the owner of the website doesn't even notice people joining for a couple of months Been to busy on my bus.. honest.

Def the right choice in engine I've just purchased a 110bhp Mk4 Golf TDI to replace my 110bhp B5 Passat TDI which I've had for the past 5 years now on 233k 80k+ of that on waste veg oil

Now I'm subscribed to your thread I'll look forward to your updates
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1971 Devon Bay with 1800 Ford Turbo Diesel Engine (wip)
1983 VW Golf GTI Campaign
1979 Mini 1275 GT
2013 Scirocco TDI GT

[Wilfred]

Very minor update... I picked up the gearbox.



I want to use the original t3 (t25) gear selector mechanism. I am currently looking for a scrap car to get some parts from. I also still need a sump.

And the pressure is on, as I sold the type 1 engine more or less, and it has to go out the end of february. but we still want to go away in spring.... so it's gonna be a busy time :-)
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1973 BayWindow running 1.9 110 bhp TDI with flipped gearbox.

[Wilfred]

Lately I began to doubt. Shouldn't I use the audi/passat box...

Stronger, better ratios...

But I can't find any build treat about his. Can anybody tell me where they are? I know there must be some of them.
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1973 BayWindow running 1.9 110 bhp TDI with flipped gearbox.

[Wilfred]

Nevermind. Made contact with Tim Shettle, from ultimate engineering. Sounds promising
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1973 BayWindow running 1.9 110 bhp TDI with flipped gearbox.

[jp]

Cool... he is just down the road from where I work, I really should pay him a visit. What exciting bits are you getting from him?
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1971 Devon Bay with 1800 Ford Turbo Diesel Engine (wip)
1983 VW Golf GTI Campaign
1979 Mini 1275 GT
2013 Scirocco TDI GT

[easy-does-it]

If he's been in contact with Tim, im guessing he's after these



to do this..




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'76 bay going superfly TDI

[jp]

Wow it really leans the engine over doesn't it? Do you have to add a pickup on the sump ?
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1971 Devon Bay with 1800 Ford Turbo Diesel Engine (wip)
1983 VW Golf GTI Campaign
1979 Mini 1275 GT
2013 Scirocco TDI GT

[Wilfred]

Yes, I want the adaptor plate between the engine and driveshafts, to use the passat/a4 gearbox.

I've been thinking about my t25 AAP box, and there more I think about it, the less I think it's up to the job. a 110 bhp tdi has just too much torque for this box.

So I am planning on selling the AAP box and vw golf mk 3, that I already have, and buy a complete Passat or audi a4.

I am really glad I didn't start the conversion right away and now have time to think things through!

btw, there is no real use to put it at a 50 degree angle, maybe only clearance. I am thinking of mounting it at 5 degrees, so I dont need any t25 stuff like sump and oil pickup.
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1973 BayWindow running 1.9 110 bhp TDI with flipped gearbox.

[jp]

How much is the adapter?

I'm about to take my Passat 110 tdi to the scrapper and although the engine runs fine and the box is sweet it has 235k on it of which 85k has been on Veg oil so not sure how much longer it will keep going! Not sure what I'll get from the breakers for it probably £150 to £200. Great engine though.. have now got me a MKIV Golf with the same engine with a mere 165k on the clock
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1971 Devon Bay with 1800 Ford Turbo Diesel Engine (wip)
1983 VW Golf GTI Campaign
1979 Mini 1275 GT
2013 Scirocco TDI GT

[Wilfred]

plate between engine/box = 150 GBP
axle adapters also 150 GBP.

It not really cheap, but at the moment I have the AAP gearbox, which I hope to sell for good value.

Passat or A4 scrappers are relatively cheap over here.

I could use the golf mk3 engine, as it is basically the same as the passat or A4, only the passat/a4 has a dual weight flywheel.

SO I am hoping to sell the golf as a whole, also the AAP box and get me 1 car from which I will use both engine and box.

So if anybody needs an AAP box, or golf 3 variant with 110bhp...let me know!
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1973 BayWindow running 1.9 110 bhp TDI with flipped gearbox.

[Wilfred]

From what Boxters can I use the gear linkage stuff? Particular modelyears? Engine types?

Would it be possible to use the whole porsche setup? So stuff to mount to the box, cables and shifter stick? Or would the cables be too short (can be made longer possibly)
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1973 BayWindow running 1.9 110 bhp TDI with flipped gearbox.