I am going to be using the Digifant II system off of the 1989 Jetta Head
that I am using (Audi 80 2.0L bottom end).  The intake manifold is already
setup for the Digifant II system and I am not wanting to totally re-invent
anything.  The Diesel intake manifold would give pretty poor performance and
besides, I don't have one here! :)

It this plan of shaving down the intake runners work, I will be offering
this service to other people, so I want it as 'simple' as possible where I
could offer intake manifolds on an exchange basis.

David Marshall

Fast Forward Automotive Inc.
4356 Quesnel Hixon Road
Quesnel BC Canada  V2J 6Z3
mailto:info@fastforward.ca <mailto:info@fastforward.ca>
http://www.fastforward.ca <http://www.fastforward.ca>
Phone: (250) 992 7775           FAX: (250) 992 1160

� Vanagon Accessories and Engine Conversions
� Vanagon, Transporter and Iltis Sales and Importation
� European Lighting for most Volkswagen models

-----Original Message-----
From: Vanagon Mailing List [mailto:vanagon@gerry.vanagon.com]On Behalf
Of Pat
Sent: February 24, 2002 9:10 AM
To: vanagon@GERRY.VANAGON.COM
Subject: Re: Golf motor with Diesel Mounts intake manifold questions

bravo David, i never liked the idea of beating the sheetmetal.
some day i will start the rabbit conversion in my van and will try probably
all the intakes i have laying around.
if you do some custom fab work, you may stick a diesel intake on there and
see if this makes things easier.
remember, you can always add more material to any shaved areas with a TIG
welder.

----- Original Message -----
From: "David Marshall" <vanagon@VOLKSWAGEN.ORG>
To: <vanagon@GERRY.VANAGON.COM>
Sent: Sunday, February 24, 2002 12:59 AM
Subject: Golf motor with Diesel Mounts intake manifold questions

> Volks,
> There are quite a few of you out there who have installed an 85 - 92 Golf
/
> Jetta motor into their Vanagon using the Diesel motor mounts.  As most
> people know the intake manifold will not fit as it will hit the drive side
> wall of the van.  The common solution to this was to pound a dent into the
> side wall to make it fit.
>
> The question that I have is:  How deep of a dent did you have to make into
> the side wall?
>
> What I am thinking of doing is modifying the intake Golf manifold by
shaving
> off 12mm to 13mm off of the surface that attaches to the head to give me
> that much more clearance against the side wall.  In doing this I will have
> to build up the aluminium around the intake runners where it enters the
head
> as 13mm back from the original surface is quite thing and may not make a
> good air seal.
>
> Comments, suggestions and measurement as all welcome!
>
> David Marshall
>
> Fast Forward Automotive Inc.
> 4356 Quesnel Hixon Road
> Quesnel BC Canada  V2J 6Z3
> mailto:info@fastforward.ca <mailto:info@fastforward.ca>
> http://www.fastforward.ca <http://www.fastforward.ca>
> Phone: (250) 992 7775           FAX: (250) 992 1160
>
> . Vanagon Accessories and Engine Conversions
> . Vanagon, Transporter and Iltis Sales and Importation
> . European Lighting for most Volkswagen models
>