320touring gets an eco-car at last! VW GOLF 1.9 TD- The Golf 4L??

[320touring]

Originally Posted by cRiPpLe_rOoStEr

It's time to plan the weight-saving and eventually aero mods

I'd consider to get some custom-made fiberglass body panels such as rear hatch (possibly already incorporating a built-in spoiler), engine hood and front fenders (taking that retractible antenna away, so if you'd still want a radio you could get an internal windscreen-mounted one like I'm considering to do with my dad's Subaru), smaller and more streamlined rearview mirrors out of some sports motorcycle, single-blade windscreen wiper (preferably standing up while not in use, for both weight-saving and aerodynamic reasons) and stripping the interior trim as much as you feel comfortable with

I'll not be changing the body panels- too difficult to get insurance on such things.

initial thoughts are these- Aero being most important given the 80% motorway work the car sees):

Aero
Upper Grill Block- completed- approx 80% covered

Lower Grill Block- similar in technique to the upper one using pipe insulation

Smaller door Mirrors- or removal/folding of passenger one

Aero Wheel covers- possibly made out of plexiglass

Airdam- An extension to the existing front lip

Panel Gap sealing- round the engine bay, rear hatch and rear side windows

Ride height reduction- see my separate thread re this- a drop of approx 40-50mm is planned

Engine Bay
Front Belly Pan- Definitely, scope to utilise a spare one I have lying about..

Cold Air Intake- Should be simple enough to modify the current intake (which is already fairly reasonable!)

Engine Bay Insulation- looking at additional bonnet insulation options, plus panel gap sealing using insulation strip.

these mods should keep the heat in, and make for ideal veg oil running conditions

Mechanics
Gearbox oil to ATF- on the "to Do" list!

Fuelling advance- set the max fuel on the pump higher for more torque at lower rpm

Reduce idle setting- currently idles near 1000rpm, a drop to 750-800 would be a 25% saving on my coasting sections

Turbo- increase boost pressure to 12psi for a better cleaner burn

Intercooler- to help keep air cool, and density high

These will only be carried out after I've done the timing belt- dont want to risk it!


Others
Weight reduction- I'll probably aim to keep the interior pleasant- the car does mainly motorway work, so mass is not an issue- at least not as much as comfort!

[cRiPpLe_rOoStEr]

Originally Posted by 320touring

I'll not be changing the body panels- too difficult to get insurance on such things.

As long as you would keep it looking closer to OEM, wouldn't be so difficult to get insurance. Sure, if you started to mess with safety features such as door side-impact beams it would start to get harder...

Smaller door Mirrors- or removal/folding of passenger one

Folding the passenger mirror can be considered quite pointless over a removal, but I still think replacing both with more aerodynamical ones makes more sense. And you can have'em for cheap out of some wrecked sports motorcycle

Engine Bay Insulation- looking at additional bonnet insulation options, plus panel gap sealing using insulation strip.

A custom fiberglass (or carbon fiber) bonnet provides a higher insulation than the sheetmetal one
Anyway, you could check this thread: http://ecomodder.com/forum/showthrea...ver-24451.html

Weight reduction- I'll probably aim to keep the interior pleasant- the car does mainly motorway work, so mass is not an issue- at least not as much as comfort!

Replacing some of the interior trim with lighter parts wouldn't necessarily decrease the comfort

[320touring]

Originally Posted by cRiPpLe_rOoStEr

As long as you would keep it looking closer to OEM, wouldn't be so difficult to get insurance. Sure, if you started to mess with safety features such as door side-impact beams it would start to get harder...

Its honestly not worth the hassle over here!

Folding the passenger mirror can be considered quite pointless over a removal, but I still think replacing both with more aerodynamical ones makes more sense. And you can have'em for cheap out of some wrecked sports motorcycle

Agreed- sourcing smaller mirrors that will fit will be the hard bit

A custom fiberglass (or carbon fiber) bonnet provides a higher insulation than the sheetmetal one
Anyway, you could check this thread: http://ecomodder.com/forum/showthrea...ver-24451.html

I'll likely go down the route of additional insulation on the bonnet and inner wings. Although its also been pointed out that my thermostat is possibly not functioning correctly!

Replacing some of the interior trim with lighter parts wouldn't necessarily decrease the comfort

agreed- I have some good plans for weight reduction that wont impact on the comfort of the car

[320touring]

First tank is in with the grill block on. Car was running a 20/80% veg/Diesel mix

670.1 miles for 52.58L of fuel

Giving imp MPG of 57.94


thats a 0.37 mpg gain, and I'm happy, bearing in mind the traffic I've had to deal with this week.

Now running 30% veg oil..P&G too.. gonna shoot for 58.5 imp mpg!

Weekend may also see a swap of battery (current one is undersized) and a thermostat replacement- as the car is running colder than VW intended, even with grill block.

Thermostat looks like a likely suspect..


And maybe a raid around the unit to see what parts I can pilfer for modding purposes

[AndrzejM]

If you are thinking of going to the extreme with FE you should invest in some kind of instant fuel consumption gauge. It's hard with mechanical injected diesel but it's doable. You may take a look here: http://ecomodder.com/forum/showthrea...sel-16711.html

[320touring]

Originally Posted by AndrzejM

If you are thinking of going to the extreme with FE you should invest in some kind of instant fuel consumption gauge. It's hard with mechanical injected diesel but it's doable. You may take a look here: http://ecomodder.com/forum/showthrea...sel-16711.html

I dont do "geek"

Seriously though, additional instrumentation would draw unwanted attention, an possibly prove distracting on MY commute.

I'm happy with the level of feedback at a tank level- An upward trend, or continual above published MPG is enough for me.

[AndrzejM]

That's your choice, but I can tell from my experience that instant feedback from the car helps a lot to get the best FE

[320touring]

More work done Yesterday!

Took out the puny 340 cold cranking amps Battery


fitted a 500CCA one, cleaned the contacts and earthing strips- now starts much better



Insulated the fuel lines to and from the pump a bit- aiming to keep the veg oil (30% now) viscous on the colder mornings


Used the last of my pipe insulation to put in a test piece of lower grill block


Got a slight temp increase on the gauge- really need to get a thermostat and do it (probably next weekend!)

Also finally swapped over the other 195/50/15 tyres I had onto the rear- taking off the largerr and heavier 205/55's in the process

205




195

[cRiPpLe_rOoStEr]

Could even get narrower engines such as 165/60 R14, and their diameter is more intermediate between the 205/55 and the 195/50. Plus they would ride more softly, reducing any comfort loss after lowering the suspension.

[320touring]

Originally Posted by cRiPpLe_rOoStEr

Could even get narrower engines such as 165/60 R14, and their diameter is more intermediate between the 205/55 and the 195/50. Plus they would ride more softly, reducing any comfort loss after lowering the suspension.

it had 185/60/14 on the front when I got it- SCARY in the wet. these toyos are much better

I think I've sourced a lowering kit for it, for not much cash, and the first tank of 30% veg is in..

656 miles using 52.6L of fuel= 56.7mpg (imp)
15 L veg at 1/l

37.6 L Diesel at 1.459/l

thats slightly lower than the last two tanks..


BUT!

Lots of stop start on Mway due to roadworks on my commute this week, and carrying 60-65mph on longer runs (to my unit etc) rather than 55-60 I usually sit at.

plus 30% veg means I'm happy at that MPG- I reckon it'd have been better at lower speed with less tailbacks.


Sorting the thermostat should help as well.