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Model specific boards => Golf mk4 => Golf mk4 gallery => Topic started by: QazGolf on 08 February 2014, 00:26

Title: Qaz's Mk4 1.8T Project 300bhp
Post by: QazGolf on 08 February 2014, 00:26
Hi everyone!

So my first car was a three door corsa 1.0 liter, it was a fun little car. After I sold it I missed it and decided I wanted something small but three door. My interests grew to a mk4 as my Mum had a v5 when I was younger, I have always admired the way they look and mainly because it had a turbo and I wanted to go fast!
So I looked high and low for one with a few mods so I could save money and not have to do them myself. I went to pick up my mk4 GTi and it was slightly hurt and needed much tlc. Instead of walking away I still wanted it and got it, the ride wasn't nice and there were a fair few things wrong with the car. I took it for an inspection as it's mot was coming up and changed a whole load of things including the wishbones, track rod ends, cv boot and joints and even timing belt. I didn't like the price of all of this at the time of just getting the car and decided I wanted to sell it once it was running better.
So it passed it's MOT and I decided I could look around and wait for a clean one and pay more for it or just stick with this as I have already put money into it!
So I think in that same month, November/ September, the road tax was due and it needed two front tires. Only got part worn tires just to drive it the way it is. After doing so the car decided it wanted to die every time the revs dropped or let go of the accelerator. This was due to throttle alignment, I think (so far lol) this was the biggest and scariest problem I had with the car and once it was fixed I felt the car did actually have potential.

However the revs still bounced around and I was told it was down to the throttle body being dirty, so I decided I wanted to try do it myself as I really want to learn more about the car and how to fix things on it so I can move onto bigger tasks... And I also changed a breather hose  :grin:

Enough back ground! I decided that it was time to get the car running smooth and then I could put more power into it. Ultimately I want to go down the k04 route so everything I do will lead up to that.

(http://i156.photobucket.com/albums/t8/Qaz96/image-1.jpeg) (http://s156.photobucket.com/user/Qaz96/media/image-1.jpeg.html)

So got the throttle body off and it looked horrible a good while later,


(http://i156.photobucket.com/albums/t8/Qaz96/image1-1.jpeg) (http://s156.photobucket.com/user/Qaz96/media/image1-1.jpeg.html)

and it was cleaner than your teeth  :grin:
now all I had to do was not break it and just put it back on.
 
(http://i156.photobucket.com/albums/t8/Qaz96/image2.jpeg) (http://s156.photobucket.com/user/Qaz96/media/image2.jpeg.html)

Job done. I started the car and the revs sat perfectly and I was a very happy bunny, I did this round the end of January and then decided to was time to get the car driving smoother. Into the garage it went where the tie rod ends, ball joints were changed but this didn't solve the problem.
Further investigation told me that my front wishbone rear bushes had gone so I decided to get poly flex bushes as an upgrade!

(http://i156.photobucket.com/albums/t8/Qaz96/image3-1.jpeg) (http://s156.photobucket.com/user/Qaz96/media/image3-1.jpeg.html)

(http://i156.photobucket.com/albums/t8/Qaz96/image4-1.jpeg) (http://s156.photobucket.com/user/Qaz96/media/image4-1.jpeg.html)

I also cheekily ordered a decat and 3 inch downpipe
(http://i156.photobucket.com/albums/t8/Qaz96/image5-1.jpeg) (http://s156.photobucket.com/user/Qaz96/media/image5-1.jpeg.html)
The bushes and downpipe were fitted yesterday.

The car runs so smooth now and has a better pick  up.

I have now decided for another couple of months not to spend any more money on the car however a local breaker is selling a k04 so I may get an early birthday present lol. I really look forward to questions and any advice as I want the car to run right, I hope to get the car done within a year span focusing on power then handling and lastly looks in that order.
I will try and update this thread occasionally if my funds allow me to do so! The thread will probably compose of pics of the setup I buy then bam it'll be on the car, unless I can do it then I will try to!
Big shout out to wazzer for all his help and also mattyfairbro240579 as he has taught me a bit about the k04 path  :evil:

Thanks for reading and stay posted!

Qaz
Title: Re: Qaz's Mk4 1.8T Project 300bhp
Post by: dom on 08 February 2014, 17:04
Looks a nice project :afro:

Hows the ride with the poly bushes? Any different to standard?
Title: Re: Qaz's Mk4 1.8T Project 300bhp
Post by: QazGolf on 09 February 2014, 22:04
Thank you Dom I really appreciate that.
Before I changed the bushes I had A LOT of under steer issues but now it feels tighter and sticks slightly better through turns.
I think they are a good upgrade and my car hasn't been sliding around as much.
Title: Re: Qaz's Mk4 1.8T Project 300bhp
Post by: QazGolf on 09 February 2014, 22:06
And overall much smoother but that's because my old bushes were fully gone. So ride is a lot more smoother and no knocking.
Title: Re: Qaz's Mk4 1.8T Project 300bhp
Post by: QazGolf on 12 February 2014, 20:34
So after a really raining week I decided to would be a good idea to get the car washed!

(http://i156.photobucket.com/albums/t8/Qaz96/image11.jpeg) (http://s156.photobucket.com/user/Qaz96/media/image11.jpeg.html)

I got home and decided to quickly polish it before work and it decided to drizzle half way through so the car didn't look amazingly clean but still looked alright

(http://i156.photobucket.com/albums/t8/Qaz96/image10.jpeg) (http://s156.photobucket.com/user/Qaz96/media/image10.jpeg.html)

After searching for a k04 I finally got my hands on one! Got the manifold along with it, however I don't plan on using the stock manifold.

(http://i156.photobucket.com/albums/t8/Qaz96/image9.jpeg) (http://s156.photobucket.com/user/Qaz96/media/image9.jpeg.html)

I can't wait to start getting other bits and pieces together after easter when I have some money haha. I am looking to get a cupra R fuel pump, s3/tt injectors, and a badger5 TIP. And a relentless v3 manifold.
Now I must not spend any more money on the car, the turbo is actually hidden away hence the only picture being in the dark as if someone finds out I spent more money on the car they won't be happy.

If anyone could advise me on other parts to try and get 300bhp that would be greatly appreciated or am I on the right path??

When no one is at home I will have a little photo shoot with the turbo haha.
That will be all for a few weeks as I have to send my Mum on holiday.
Thank you for reading  :smiley:
Title: Re: Qaz's Mk4 1.8T Project 300bhp
Post by: QazGolf on 12 February 2014, 20:35
And if noticed yes some has stolen my wheel caps lol  :sad:

Ps if anyone knows where I can send my turbo off to get hybrid-ed that would be great. I asked Dan from beach buggy turbos but he only supplies them hybrided.
I am also gonna put a forge actuator on the turbo too

Thanks
Title: Re: Qaz's Mk4 1.8T Project 300bhp
Post by: sharki786 on 12 February 2014, 20:42
And if noticed yes some has stolen my wheel caps lol  :sad:

Wow some right tramps there. Good going with the k04 keep the updates comming. :wink:
Title: Re: Qaz's Mk4 1.8T Project 300bhp
Post by: QazGolf on 12 February 2014, 20:46
Mate the sad thing is I parked it behind my road for a night whilst waiting for my residential permit to arrive and someone took it, in my own area!
Thanks man I really appreciate it, it may take some time to get all the parts but I would rather wait and get everything right so in the end nothing goes boom haha. Need to stay away from eBay and youtube keep watching relentless manifolds glow  :laugh:
Title: Re: Qaz's Mk4 1.8T Project 300bhp
Post by: sharki786 on 12 February 2014, 20:52
Hahaha i know what you mean. I have an agu an i spent 3 hrs after work yesterday doing bits and bobs to my car with a FAIL! So i went back today and got 1 out of 3 things complete.so nearly there but a long way to go yet for me aswel.
Title: Re: Qaz's Mk4 1.8T Project 300bhp
Post by: QazGolf on 12 February 2014, 20:54
Haha I hear you man, the first time I tried cleaning the throttle body I dropped one of the bolts in the engine bay moved the car forward and back, and I couldn't find it so had to wait till I got some more bolts. It happens I guess  :grin:
The only thing is my engine is AGU and I have noticed most k04 engines have the inlet on the opposite way, will I need to change my inlet manifold too?
Title: Re: Qaz's Mk4 1.8T Project 300bhp
Post by: sharki786 on 12 February 2014, 21:04
I aint done the k04 or any turbo upgrade convo yet :grin: but you can get it to fit. Someone will pop over and tell you how its done. This is a good forum if you need help.!!
Title: Re: Qaz's Mk4 1.8T Project 300bhp
Post by: mattyfairbro240579 on 12 February 2014, 22:19
Looks a nice project :afro:

Hows the ride with the poly bushes? Any different to standard?
Poly bushes are the way forward Dom, transformed the way mine handles now mate  :smiley:
Title: Re: Qaz's Mk4 1.8T Project 300bhp
Post by: mattyfairbro240579 on 12 February 2014, 22:28
Hi there Qaz  :smiley: good to see your build treads up and running !!!

You were saying your getting tt injectors, go for the saab big reds got them on mine mate and they work perfectly, theres 3 different types of saab reds tho !! so make sure you get the highest cc ones think there 360cc

Just bought another AGU engine which I've got big plans for so may have various bits for sale over the next few months mate
Title: Re: Qaz's Mk4 1.8T Project 300bhp
Post by: QazGolf on 12 February 2014, 22:55
Thanks man, means a lot coming from you haha

Ahh ok, where exactly can I get them from? Will any injectors over 360cc be good enough then?

Ooo why do I get the feeling a big turbo conversion is coming along?! I will keep my eyes peeled! Do let me know what pieces you're getting rid of I may need them  :grin:
Title: Re: Qaz's Mk4 1.8T Project 300bhp
Post by: QazGolf on 04 June 2014, 20:37
Right, it's been a while.
OK so the build isn't lightning fast but step by step things are happening. In my dreams mainly.
Anyway here's an update, so after getting the k04 I did a lot and a lot of questioning and researching on manifolds, a lot of people told me different things. Everyone I asked gave brilliant advice, in the end however I went with this:

(http://i156.photobucket.com/albums/t8/Qaz96/image16-1.jpeg) (http://s156.photobucket.com/user/Qaz96/media/image16-1.jpeg.html)

A box with fluffy stuff.

(http://i156.photobucket.com/albums/t8/Qaz96/relnt.jpeg) (http://s156.photobucket.com/user/Qaz96/media/relnt.jpeg.html)

(http://i156.photobucket.com/albums/t8/Qaz96/image19.jpeg) (http://s156.photobucket.com/user/Qaz96/media/image19.jpeg.html)

Some go fast stickers worth an additional 10bhp.

(http://i156.photobucket.com/albums/t8/Qaz96/d73a5fbd-85ce-4034-8701-e5b37ce77300.jpg) (http://s156.photobucket.com/user/Qaz96/media/d73a5fbd-85ce-4034-8701-e5b37ce77300.jpg.html)

(http://i156.photobucket.com/albums/t8/Qaz96/image21.jpeg) (http://s156.photobucket.com/user/Qaz96/media/image21.jpeg.html)

(http://i156.photobucket.com/albums/t8/Qaz96/image22.jpeg) (http://s156.photobucket.com/user/Qaz96/media/image22.jpeg.html)

Behold the Pro4 manifold, I call it a spider manifold it just looks weird to me but anyway.

So after getting the manifold it was time to save up money to get the turbo ported and a TIP for the project. However the car got parked up as road tax ran out and this week gave her a wash and polish.

(http://i156.photobucket.com/albums/t8/Qaz96/image16.jpeg) (http://s156.photobucket.com/user/Qaz96/media/image16.jpeg.html)

So the other day I was driving along, and embaressingly stalled. The car refused to turn over so after a bump start it started and drove home after thinking and messing around with it came to the conclusion the starter motor had died on it so fitted a new one today.

(http://i156.photobucket.com/albums/t8/Qaz96/image17.jpeg) (http://s156.photobucket.com/user/Qaz96/media/image17.jpeg.html)

Before I was going to throw power at the car but I think I want clutch and flywheel next, then TT subframe and then do the turbo conversion at home to save some money. Also on a look out for a cheap 3 inch exhaust and even a used TIP.

Thank you for reading
Title: Re: Qaz's Mk4 1.8T Project 300bhp
Post by: Scott-R on 07 July 2014, 23:12
Nice manifold, keep up the good work. :cool:
Title: Re: Qaz's Mk4 1.8T Project 300bhp
Post by: QazGolf on 08 June 2015, 17:02
Ok well it has been a while, not sure if this is worth following up as there are other more exciting builds happening but might as well finish what I started!

So after managing to get almost everything I needed for the k04 build it was time to get the old turbo out which was not the easiest thing in the world. Not to sure if I'm allowed to post this link but this is the guide I followed much of the way http://forums.vwvortex.com/showthread.php?3562254-Stock-Turbo-Removal-Ko4-20-Install-My-DIY

(http://i156.photobucket.com/albums/t8/Qaz96/image1.jpg) (http://s156.photobucket.com/user/Qaz96/media/image1.jpg.html)

She looked so sad here.

(http://i156.photobucket.com/albums/t8/Qaz96/image2.jpg) (http://s156.photobucket.com/user/Qaz96/media/image2.jpg.html)

(http://i156.photobucket.com/albums/t8/Qaz96/image4.jpg) (http://s156.photobucket.com/user/Qaz96/media/image4.jpg.html)

(http://i156.photobucket.com/albums/t8/Qaz96/image3.jpg) (http://s156.photobucket.com/user/Qaz96/media/image3.jpg.html)

(http://i156.photobucket.com/albums/t8/Qaz96/image5.jpg) (http://s156.photobucket.com/user/Qaz96/media/image5.jpg.html)

While I had the k04 off I had it ported to match the pro4 by JNL Racing.

(http://i156.photobucket.com/albums/t8/Qaz96/image6.jpg) (http://s156.photobucket.com/user/Qaz96/media/image6.jpg.html)

It was time to get to work, I pretty much followed the guide I think one of the difficult things for me was getting to the top two downpipe nuts as it was three inch and there wasn't much space. For the top right one I used a load of extensions and went behind the subframe and somehow got it to reach. Apparently it's all about the 'angles'.

(http://i156.photobucket.com/albums/t8/Qaz96/image7.jpg) (http://s156.photobucket.com/user/Qaz96/media/image7.jpg.html)

Once that side was all off started on the top, first bit of happiness was the manifold coming off..

(http://i156.photobucket.com/albums/t8/Qaz96/image8.jpg) (http://s156.photobucket.com/user/Qaz96/media/image8.jpg.html)

Finally got this out

(http://i156.photobucket.com/albums/t8/Qaz96/image9.jpg) (http://s156.photobucket.com/user/Qaz96/media/image9.jpg.html)

Then it was time to get a load of gaskets washers, and all the boring bits and pieces to drop the k04 in!

(http://i156.photobucket.com/albums/t8/Qaz96/image1_1.jpg) (http://s156.photobucket.com/user/Qaz96/media/image1_1.jpg.html)

I decided to go with the all famous welly cooler, had no idea it was this big and weighed a ton or how the hell it was going to sit behind my bumper but it was much needed

(http://i156.photobucket.com/albums/t8/Qaz96/image2_1.jpg) (http://s156.photobucket.com/user/Qaz96/media/image2_1.jpg.html)

K04 sitting pretty with its BBT actuator

(http://i156.photobucket.com/albums/t8/Qaz96/image3_1.jpg) (http://s156.photobucket.com/user/Qaz96/media/image3_1.jpg.html)

Top view, manifold wasn't the easiest thing on installing and getting the turbo to line up but in the end it got done, had a crap time with the oil line to the front, managed to cross thread it and then needed a new oil filter housing. Lesson learnt be patient and don't rush as it'll just do more damage.

(http://i156.photobucket.com/albums/t8/Qaz96/image5_1.jpg) (http://s156.photobucket.com/user/Qaz96/media/image5_1.jpg.html)

Getting it all piped up for it's first start up, car was very loud due to just running on downpipe and a little bit of pipe but did sound very nice and turbo-ey  :laugh:

(http://i156.photobucket.com/albums/t8/Qaz96/image6_1.jpg) (http://s156.photobucket.com/user/Qaz96/media/image6_1.jpg.html)

Just a rough mock up, need to jubilee clip everything together, but that's how its going to stay.Credit to Prawny for his intercooler guide http://www.golfgtiforum.co.uk/index.php?topic=238012.msg2193625#msg2193625

Also thanks to everyone or anyone who helped, a big thank you to Golfyste who guided me when I was a bit lost.
Car went to my mechanics just to get checked over on vag, n75 unplugged and the old maf instead of vr6 got the all clear went to drive off and it literally died in second. Im guessing its because of back pressure so the cars been booked to get a bit of pipe welded in this week and then i still need to weld the little bungs on the intercooler piping and it should be all done.
However I did notice a small oil leak on the top of the turbo, both washers are there, going to try tighten it but I have been looking at k04 chra/cartridges and thinking of taking it out and just changing it if I can't get it to stop. Anyone used one or is it best to send it off and have it rebuilt? It's coming directly from around the banjo...

Thanks for reading it has been a bit of a long time and I still haven't managed to take it for a spin, but hopefully it should be worth it once all the little bits and pieces are finished. Just need to find me some overtime for pay for it all haha!

Title: Re: Qaz's Mk4 1.8T Project 300bhp
Post by: QazGolf on 23 August 2015, 15:38
Been reading a lot of peoples builds lately and got inspired to update mine again.
OK so once the turbo was fitted there was some sort of vacuum leak which meant the car was useless, not to mention the small oil leak.
So a couple of weeks back I got time and the turbo was ripped out, I figured since it was out again for peace of mind I sent it to Dan at bbt to rebuild, up rated seals, and even changed out the oil cast wheel for a billet one.
The oil leak turned out to be the oil line, instead of buying ANOTHER k04 oil line the old k03 one was bent carefully and correctly into place, car back together everything in the right place.

(http://i156.photobucket.com/albums/t8/Qaz96/image_2.jpg) (http://s156.photobucket.com/user/Qaz96/media/image_2.jpg.html)

I cannot explain how fun and quick the car is on actuator pressure alone!  :laugh:
I feel like the k04 kicks in a little bit later than my k03 did but makes up for it.

So with the car being back on the road for a week I noticed another oil leak!! This time it was from the oil return line but at the point where it meets the sump, at first I thought it was the gasket however on closer inspection I noticed the bottom nut kept spinning.
Now had to decide whether to just get a new sump or send this one off to a machinist. I decided to just fix this one and now the car is pretty much problem free and is very quick.

Yesterday was boiling so I decided to give it a good old clean

(http://i156.photobucket.com/albums/t8/Qaz96/image.jpg) (http://s156.photobucket.com/user/Qaz96/media/image.jpg.html)

(http://i156.photobucket.com/albums/t8/Qaz96/image2.png) (http://s156.photobucket.com/user/Qaz96/media/image2.png.html)

(http://i156.photobucket.com/albums/t8/Qaz96/image_1.jpg) (http://s156.photobucket.com/user/Qaz96/media/image_1.jpg.html)

(http://i156.photobucket.com/albums/t8/Qaz96/image2_2.jpg) (http://s156.photobucket.com/user/Qaz96/media/image2_2.jpg.html)

(http://i156.photobucket.com/albums/t8/Qaz96/image3_2.jpg) (http://s156.photobucket.com/user/Qaz96/media/image3_2.jpg.html)

At the moment it still needs a few more things before it can get mapped, but I have a general direction and list that just keeps getting longer and longer.
A friend of mines mk 2 20v agu k04 is going in for mapping on Thursday at badger5 if I can get the day off work it might be an interesting day!
Title: Re: Qaz's Mk4 1.8T Project 300bhp
Post by: QazGolf on 27 August 2015, 23:15
So quick question anyone know who used to own this mk2??? Has a club gti sticker on the front window too...
Will write up its remap day at badger5 tomorrow when I have more energy. All I can say is I cannot wait to be remapped!!  :laugh:


(http://i156.photobucket.com/albums/t8/Qaz96/Mobile%20Uploads/image_1.jpg) (http://s156.photobucket.com/user/Qaz96/media/Mobile%20Uploads/image_1.jpg.html)
Title: Re: Qaz's Mk4 1.8T Project 300bhp
Post by: QazGolf on 05 September 2015, 00:09
Ok so the other week my friends mk2 20v went off for mapping so I got the day off work and a road trip was made out of it, without the mk4 :(
The day started off rainy but eventually we made it

(http://i156.photobucket.com/albums/t8/Qaz96/image1_4.jpg) (http://s156.photobucket.com/user/Qaz96/media/image1_4.jpg.html)

(http://i156.photobucket.com/albums/t8/Qaz96/image3_4.jpg) (http://s156.photobucket.com/user/Qaz96/media/image3_4.jpg.html)

Car getting prepped up ready for powaarh

(http://i156.photobucket.com/albums/t8/Qaz96/image2_4.jpg) (http://s156.photobucket.com/user/Qaz96/media/image2_4.jpg.html)

Some more setting up, and mapping was in process. It was a great day at badger5 and managed to learn a few things and see Bill's track car up and close.

(http://i156.photobucket.com/albums/t8/Qaz96/image4%201_1.jpg) (http://s156.photobucket.com/user/Qaz96/media/image4%201_1.jpg.html)

And then a really nice drive back to London on some nice roads. There was a 335D with us but after mapping well I will leave that to your imagination... It was hilarious and yes there are videos haha!

Ok so last weekend there was a charity meet at style dynamics, so I figured sweet I'll cange my turbo intake pipe to my oversized one and wash the car and I'll be down..

(http://i156.photobucket.com/albums/t8/Qaz96/image1_2.jpg) (http://s156.photobucket.com/user/Qaz96/media/image1_2.jpg.html)

This beast of a thing, yes I gave it a clean it had been lying about for some time. Then decided to label up everything with the help of snapchat yes you read that right snapchat! Just so everything goes back to where it is meant to be and no mistakes were made.

(http://i156.photobucket.com/albums/t8/Qaz96/image2_3.jpg) (http://s156.photobucket.com/user/Qaz96/media/image2_3.jpg.html)

(http://i156.photobucket.com/albums/t8/Qaz96/image3_3.jpg) (http://s156.photobucket.com/user/Qaz96/media/image3_3.jpg.html)

(http://i156.photobucket.com/albums/t8/Qaz96/image4%201.jpg) (http://s156.photobucket.com/user/Qaz96/media/image4%201.jpg.html)

(http://i156.photobucket.com/albums/t8/Qaz96/image5_2.jpg) (http://s156.photobucket.com/user/Qaz96/media/image5_2.jpg.html)

Next was to remove everything, air filter which will soon be changed anyway, and Maf sensor..

(http://i156.photobucket.com/albums/t8/Qaz96/image6_2.jpg) (http://s156.photobucket.com/user/Qaz96/media/image6_2.jpg.html)

(http://i156.photobucket.com/albums/t8/Qaz96/image7_1.jpg) (http://s156.photobucket.com/user/Qaz96/media/image7_1.jpg.html)

N75 out..

(http://i156.photobucket.com/albums/t8/Qaz96/image8_1.jpg) (http://s156.photobucket.com/user/Qaz96/media/image8_1.jpg.html)

Recirc valve out..

(http://i156.photobucket.com/albums/t8/Qaz96/image9_1.jpg) (http://s156.photobucket.com/user/Qaz96/media/image9_1.jpg.html)

A jubilee on the turbo side and out it comes, look at the size difference. And how clean the other one is haha. I really don't think the picture does it justice.

(http://i156.photobucket.com/albums/t8/Qaz96/image10_2.jpg) (http://s156.photobucket.com/user/Qaz96/media/image10_2.jpg.html)

Just a little check up on the fresh core turbo, put it in the car at 113,400ish and it's now done 200 miles with no problems, effortless and crazy boost haha. Next what you don't see is the gear box linkage being undone and me swearing and bleeping at the car because this pipe was a nightmare to get in. Honestly it was a b****! Three I think it was 13mm bolts linkage out and then there is a metal coolant pipe from the heater matrix which needed messing around, last time I tried installing this pipe onto the turbo I bent this metal coolant pipe and needed to change it so be careful. Be patient. I just pushed it down away from everything, tip went onto the turbo. Fiiiiinally, although it was a really tight fit.

(http://i156.photobucket.com/albums/t8/Qaz96/image11_1.jpg) (http://s156.photobucket.com/user/Qaz96/media/image11_1.jpg.html)

Then put the gear linkage back on might have to hold it in place, screw it all in and then go inside make sure it all goes into gear. Reattach everything back to the pipe and it was done.

(http://i156.photobucket.com/albums/t8/Qaz96/image14_1.jpg) (http://s156.photobucket.com/user/Qaz96/media/image14_1.jpg.html)

(http://i156.photobucket.com/albums/t8/Qaz96/image15.jpg) (http://s156.photobucket.com/user/Qaz96/media/image15.jpg.html)

(http://i156.photobucket.com/albums/t8/Qaz96/image12.jpg) (http://s156.photobucket.com/user/Qaz96/media/image12.jpg.html)

(http://i156.photobucket.com/albums/t8/Qaz96/image13_1.jpg) (http://s156.photobucket.com/user/Qaz96/media/image13_1.jpg.html)

As much as I would like to say its in and never coming out, it'll probably come out one day. But I am not doing it again!
Side note make sure the hockey puck goes this way into the tip as I put it the wrong way first and golfyste corrected me, cheers for that mate!

(http://i156.photobucket.com/albums/t8/Qaz96/image17.jpg) (http://s156.photobucket.com/user/Qaz96/media/image17.jpg.html)

Ok so next on the list was to straighten out the bottom valance as it angled down and forward because of the welly cooler and scraped every bump and I had enough of that. Before:

(http://i156.photobucket.com/albums/t8/Qaz96/image18.jpg) (http://s156.photobucket.com/user/Qaz96/media/image18.jpg.html)

Some zip ties and a JDM repair later:

(http://i156.photobucket.com/albums/t8/Qaz96/image19.jpg) (http://s156.photobucket.com/user/Qaz96/media/image19.jpg.html)

Not perfect but it will do for now.

Note to self don't try to move the car while it's on the jack. Had a heart attack after everything was done, as I sat in the car tried to move it and hear some unholy noise. Thought my clutch had given up or it wasn't in gear properly because of the linkage went back to the bonnet undid the maf air box, jubilee for the tip to turbo and then realised it was still in the air!!! Have breakfast before you work on cars people haha. Lesson learnt car on the floor and all was good. In the end I didn't go down to the meet as I was with family, but took the car out for a blast in the evening  :laugh:
Title: Re: Qaz's Mk4 1.8T Project 300bhp
Post by: QazGolf on 19 September 2015, 23:47
Alright so next on the list was meant to be 3 inch downpipe and exhaust meaning more power. However since launching the car one night it then made some seriously unholy noises on moving off and even idle. I genuinely thought the clutch or flywheel had died. So I decided to change that next instead, with great power comes responsibility so time to be responsible!


(http://i156.photobucket.com/albums/t8/Qaz96/image3%201.jpg) (http://s156.photobucket.com/user/Qaz96/media/image3%201.jpg.html)

Gearbox out

(http://i156.photobucket.com/albums/t8/Qaz96/image4%201_2.jpg) (http://s156.photobucket.com/user/Qaz96/media/image4%201_2.jpg.html)

Old clutch out

(http://i156.photobucket.com/albums/t8/Qaz96/image5_3.jpg) (http://s156.photobucket.com/user/Qaz96/media/image5_3.jpg.html)

And a good thing it's out too! Houston we definitely have a problem

(http://i156.photobucket.com/albums/t8/Qaz96/image2_5.jpg) (http://s156.photobucket.com/user/Qaz96/media/image2_5.jpg.html)

The upgrade, any guesses?

(http://i156.photobucket.com/albums/t8/Qaz96/image7_2.jpg) (http://s156.photobucket.com/user/Qaz96/media/image7_2.jpg.html)

Ok so the upgrade I went for I won a while back on eBay is a lightened 7kg single mass g60 flywheel and vr6 clutch

(http://i156.photobucket.com/albums/t8/Qaz96/image8_2.jpg) (http://s156.photobucket.com/user/Qaz96/media/image8_2.jpg.html)

This definitely looks like it can take a beating!

(http://i156.photobucket.com/albums/t8/Qaz96/image10_3.jpg) (http://s156.photobucket.com/user/Qaz96/media/image10_3.jpg.html)

All bolted up

(http://i156.photobucket.com/albums/t8/Qaz96/image9_2.jpg) (http://s156.photobucket.com/user/Qaz96/media/image9_2.jpg.html)

Putting the box back on took so much longer than expected because of the tip but mainly because of the black metal coolant pipe off the matrix hose. If anyone knows what the best alternative is I would really appreciate it!

(http://i156.photobucket.com/albums/t8/Qaz96/image11_2.jpg) (http://s156.photobucket.com/user/Qaz96/media/image11_2.jpg.html)

So got back in the car and the biting point is SO low, feels like my driving lessons. Sound old now. But no more unholy sounds or anything. Just have to be gentle for 1000 miles which means changing gear off boost :( Makes me wish I did this before the turbo so I could put my foot down but now have to wait. Will need to do a road trip up to somewhere and get them miles ticked off!
Title: Re: Qaz's Mk4 1.8T Project 300bhp
Post by: Scott-R on 21 September 2015, 19:15
What clutch did you go for black diamond?
Title: Re: Qaz's Mk4 1.8T Project 300bhp
Post by: QazGolf on 23 September 2015, 07:14
Just a standard Sachs VR6 mate
Title: Re: Qaz's Mk4 1.8T Project 300bhp
Post by: QazGolf on 13 November 2016, 20:39
Ok like always it's been a while but a lot has been done in that time.

First of all ordered a 3 inch exhaust and got that put on. Also ordered a relentless 3 inch downpipe which I was told would fit by them but didn't ended up having to cut it apart and make a custom downpipe. Will upload videos of it when I can figure out how to from an iPhone. Performance wise big difference, absolutely love the sound of it too.

(http://i156.photobucket.com/albums/t8/Qaz96/IMG_1635.jpg) (http://s156.photobucket.com/user/Qaz96/media/IMG_1635.jpg.html)

Then the usual MOT time came round, replaced the rear shocks as they were dead, I plan on changing the entire suspension unit in the near foreseeable future so this is just temporary. Was pretty ok to do at home.

(http://i156.photobucket.com/albums/t8/Qaz96/IMG_2312.jpg) (http://s156.photobucket.com/user/Qaz96/media/IMG_2312.jpg.html)

(http://i156.photobucket.com/albums/t8/Qaz96/IMG_2313.jpg) (http://s156.photobucket.com/user/Qaz96/media/IMG_2313.jpg.html)

Changed two front tyres, and managed to squeeze it through MOT.

A mod I have been wanting to do was do the dogbone mount bush as I did have a bit of play with engine movement, so changed that to the softer red bush for now. May change it again later was put off by the amount of people saying it vibrates a lot.

(http://i156.photobucket.com/albums/t8/Qaz96/IMG_2318.jpg) (http://s156.photobucket.com/user/Qaz96/media/IMG_2318.jpg.html)

(http://i156.photobucket.com/albums/t8/Qaz96/IMG_2319.jpg) (http://s156.photobucket.com/user/Qaz96/media/IMG_2319.jpg.html)

(http://i156.photobucket.com/albums/t8/Qaz96/IMG_2320.jpg) (http://s156.photobucket.com/user/Qaz96/media/IMG_2320.jpg.html)

(http://i156.photobucket.com/albums/t8/Qaz96/IMG_2321.jpg) (http://s156.photobucket.com/user/Qaz96/media/IMG_2321.jpg.html)

(http://i156.photobucket.com/albums/t8/Qaz96/IMG_2324.jpg) (http://s156.photobucket.com/user/Qaz96/media/IMG_2324.jpg.html)

Looking at this picture I definitely will be putting in the stiffer bush and also changing the small bush as I didn't do it at the time. Muppet.

(http://i156.photobucket.com/albums/t8/Qaz96/IMG_2325.jpg) (http://s156.photobucket.com/user/Qaz96/media/IMG_2325.jpg.html)

(http://i156.photobucket.com/albums/t8/Qaz96/IMG_2326.jpg) (http://s156.photobucket.com/user/Qaz96/media/IMG_2326.jpg.html)

(http://i156.photobucket.com/albums/t8/Qaz96/IMG_2327.jpg) (http://s156.photobucket.com/user/Qaz96/media/IMG_2327.jpg.html)

(http://i156.photobucket.com/albums/t8/Qaz96/IMG_2328.jpg) (http://s156.photobucket.com/user/Qaz96/media/IMG_2328.jpg.html)

(http://i156.photobucket.com/albums/t8/Qaz96/IMG_2329.jpg) (http://s156.photobucket.com/user/Qaz96/media/IMG_2329.jpg.html)

(http://i156.photobucket.com/albums/t8/Qaz96/IMG_2330.jpg) (http://s156.photobucket.com/user/Qaz96/media/IMG_2330.jpg.html)

(http://i156.photobucket.com/albums/t8/Qaz96/IMG_2331.jpg) (http://s156.photobucket.com/user/Qaz96/media/IMG_2331.jpg.html)

(http://i156.photobucket.com/albums/t8/Qaz96/IMG_2334.jpg) (http://s156.photobucket.com/user/Qaz96/media/IMG_2334.jpg.html)

(http://i156.photobucket.com/albums/t8/Qaz96/IMG_2338.jpg) (http://s156.photobucket.com/user/Qaz96/media/IMG_2338.jpg.html)

(http://i156.photobucket.com/albums/t8/Qaz96/IMG_2339.jpg) (http://s156.photobucket.com/user/Qaz96/media/IMG_2339.jpg.html)

(http://i156.photobucket.com/albums/t8/Qaz96/IMG_2340.jpg) (http://s156.photobucket.com/user/Qaz96/media/IMG_2340.jpg.html)

(http://i156.photobucket.com/albums/t8/Qaz96/IMG_2341.jpg) (http://s156.photobucket.com/user/Qaz96/media/IMG_2341.jpg.html)

(http://i156.photobucket.com/albums/t8/Qaz96/IMG_2342.jpg) (http://s156.photobucket.com/user/Qaz96/media/IMG_2342.jpg.html)

(http://i156.photobucket.com/albums/t8/Qaz96/IMG_2342.jpg) (http://s156.photobucket.com/user/Qaz96/media/IMG_2342.jpg.html)

(http://i156.photobucket.com/albums/t8/Qaz96/IMG_2345.jpg) (http://s156.photobucket.com/user/Qaz96/media/IMG_2345.jpg.html)

Gear changes were tighter, and it really did help put the power down.
I managed to get my hands on a vag com copy which said I had a coolant temp sensor fault code and fuel pump relay so swapped those out same day.

(http://i156.photobucket.com/albums/t8/Qaz96/IMG_2346.jpg) (http://s156.photobucket.com/user/Qaz96/media/IMG_2346.jpg.html)

(http://i156.photobucket.com/albums/t8/Qaz96/IMG_2347.jpg) (http://s156.photobucket.com/user/Qaz96/media/IMG_2347.jpg.html)

(http://i156.photobucket.com/albums/t8/Qaz96/IMG_2348.jpg) (http://s156.photobucket.com/user/Qaz96/media/IMG_2348.jpg.html)

(http://i156.photobucket.com/albums/t8/Qaz96/IMG_2350.jpg) (http://s156.photobucket.com/user/Qaz96/media/IMG_2350.jpg.html)

(http://i156.photobucket.com/albums/t8/Qaz96/IMG_2351.jpg) (http://s156.photobucket.com/user/Qaz96/media/IMG_2351.jpg.html)

(http://i156.photobucket.com/albums/t8/Qaz96/IMG_2352.jpg) (http://s156.photobucket.com/user/Qaz96/media/IMG_2352.jpg.html)

So all was good until I started getting throttle cut on full throttle my vag com is basically rubbish so I was unable to log it and see what was actually happening but I figured try upgrading the fuel pump and see what happens, went for the A35HV from badger5. It seemed straight forward but was very annoying, getting the old c clips of the fuel lines. Then the lines themself, use a blade makes it much easier.

(http://i156.photobucket.com/albums/t8/Qaz96/IMG_2406.jpg) (http://s156.photobucket.com/user/Qaz96/media/IMG_2406.jpg.html)

(http://i156.photobucket.com/albums/t8/Qaz96/IMG_2407.jpg) (http://s156.photobucket.com/user/Qaz96/media/IMG_2407.jpg.html)

(http://i156.photobucket.com/albums/t8/Qaz96/IMG_2408.jpg) (http://s156.photobucket.com/user/Qaz96/media/IMG_2408.jpg.html)

(http://i156.photobucket.com/albums/t8/Qaz96/IMG_2409.jpg) (http://s156.photobucket.com/user/Qaz96/media/IMG_2409.jpg.html)

(http://i156.photobucket.com/albums/t8/Qaz96/IMG_2410.jpg) (http://s156.photobucket.com/user/Qaz96/media/IMG_2410.jpg.html)

Back it went in the fuel tank and away went my throttle cut. Temporarily, I think it may be down to injectors, I also did scan it again and find a maf intermittent and o2 sensor fault, will be changing those soon to see if it helps. If anyone has any ideas or could help me log the issue please do give me a shout!

I then had a wheel bearing go on me and changed it, by far the most annoying job I've done on the car as I didn't have the right puller tools so took the axle stub off with the inner race on it to JNL racing where he very kindly managed to get it off. No pictures were taken as I just wanted to get it done with. A week later same side opposite bearing has begun making noise and will change that as soon as it's too loud to bare. Did this in a rush in order to get down to Santa Pod for GTi festival, didn't drag but went down with few friends which one of which did. Great day, lots of nice cars.

For a while now I've had a temperature problem concerning my thermostat hot days would rise, heaters on would drop significantly so I got a 74 degree thermostat off eBay and swapped it round. Very small space to work in. But is possible to do with alternator in place.

(http://i156.photobucket.com/albums/t8/Qaz96/IMG_2598.jpg) (http://s156.photobucket.com/user/Qaz96/media/IMG_2598.jpg.html)

Old  thermostat

(http://i156.photobucket.com/albums/t8/Qaz96/IMG_2599.jpg) (http://s156.photobucket.com/user/Qaz96/media/IMG_2599.jpg.html)

(http://i156.photobucket.com/albums/t8/Qaz96/IMG_2601.jpg) (http://s156.photobucket.com/user/Qaz96/media/IMG_2601.jpg.html)

(http://i156.photobucket.com/albums/t8/Qaz96/IMG_2602.jpg) (http://s156.photobucket.com/user/Qaz96/media/IMG_2602.jpg.html)

Nice new one.

(http://i156.photobucket.com/albums/t8/Qaz96/Mobile%20Uploads/image.jpeg) (http://s156.photobucket.com/user/Qaz96/media/Mobile%20Uploads/image.jpeg.html)

Old one completely destroyed by the looks of it?

(http://i156.photobucket.com/albums/t8/Qaz96/Mobile%20Uploads/image_1.jpeg) (http://s156.photobucket.com/user/Qaz96/media/Mobile%20Uploads/image_1.jpeg.html)

(http://i156.photobucket.com/albums/t8/Qaz96/Mobile%20Uploads/image_4.jpeg) (http://s156.photobucket.com/user/Qaz96/media/Mobile%20Uploads/image_4.jpeg.html)

(http://i156.photobucket.com/albums/t8/Qaz96/Mobile%20Uploads/image_5.jpeg) (http://s156.photobucket.com/user/Qaz96/media/Mobile%20Uploads/image_5.jpeg.html)

(http://i156.photobucket.com/albums/t8/Qaz96/Mobile%20Uploads/image_6.jpeg) (http://s156.photobucket.com/user/Qaz96/media/Mobile%20Uploads/image_6.jpeg.html)

And that went back into the car with a nice new O ring, since then went down to Audi driver and decided to take it on the Castle Combe track. One and a half laps in my boost pipe popped off which didn't entirely ruin the day but identified a weakness in the car, only blew off because that pipe was cut down all other pipes are beaded just need to properly bead that.

Lots planned for the future as an s3 with 3 inch exhaust and revo intake and r32 mk5 are my rivals, feel like the underdog as they both have 4 wheel drive system. Thinking of rods...  :whistle:

Thanks for reading guys
Title: Re: Qaz's Mk4 1.8T Project 300bhp
Post by: QazGolf on 13 November 2016, 20:43
(http://i156.photobucket.com/albums/t8/Qaz96/DSC_0567.jpg) (http://s156.photobucket.com/user/Qaz96/media/DSC_0567.jpg.html)

(http://i156.photobucket.com/albums/t8/Qaz96/DSC_0568.jpg) (http://s156.photobucket.com/user/Qaz96/media/DSC_0568.jpg.html)

(http://i156.photobucket.com/albums/t8/Qaz96/DSC_0577.jpg) (http://s156.photobucket.com/user/Qaz96/media/DSC_0577.jpg.html)

Few pics from pod day, do have more if anyone's interested.
Title: Re: Qaz's Mk4 1.8T Project 300bhp
Post by: QazGolf on 06 October 2017, 18:13
Ok been a while as always, update time. So I guess I have just been trying to perfect all the mods that I need in order to make sure it does well on mapping day, so that along with maintenance is the following.

Firstly I wanted a boost gauge, I just wanted to see how much boost I was running unmapped and whether everything was running right, in addition to this fitted a catch can and inlet 034 motorsports inlet manifold spacer.

(https://i.imgur.com/aYURzWV.png)
The injectors are 630cc injectors and the air filter is an 80mm JR filter, which will be put on when closer to mappping.

(https://i.imgur.com/u0pi57Q.png)
Title: Re: Qaz's Mk4 1.8T Project 300bhp
Post by: QazGolf on 06 October 2017, 18:15
I then went ahead and ordered a mocal oil cooler with a thermostatic sandwich plate, as much as I want my car to reach full power potential I want it to be reliable.

(https://i.imgur.com/PFD2l94.jpg)

(https://i.imgur.com/WCbyWMb.jpg)
LOVE these fittings, my car is officially a race car with these fittings lol

(https://i.imgur.com/0jI2cFF.jpg)

(https://i.imgur.com/TAL23Au.jpg)

(https://i.imgur.com/6EGkorn.jpg)

(https://i.imgur.com/CshgJk9.jpg)

Originally I mounted it there, realised stupid idea and then moved it.

(https://i.imgur.com/ECk2Y5Y.jpg) To down here.

I then realised I had dead front struts so I ordered AP coilovers with new bearings from Awesome GTi and I also ordered silver project top mounts. Which are camber and caster adjustable.

(https://i.imgur.com/PTHu8fA.jpg)

(https://i.imgur.com/rqSoonc.jpg)

How I drove with these springs I do not know.

(https://i.imgur.com/nudSNMC.jpg)

(https://i.imgur.com/IqJIK2L.jpg)

(https://i.imgur.com/9KIh434.jpg)

(https://i.imgur.com/330RclA.jpg)

(https://i.imgur.com/xFfQTdH.jpg)

Ok so if you're planning on doing coilovers at home go onto eBay and get the strut spreader tool it makes your life so much easier when doing it so you don't waste time.

(https://i.imgur.com/Qm8iagj.jpg)

Replacing battered bolts along the way.

(https://i.imgur.com/OCS3tjB.jpg)

(https://i.imgur.com/aWkmE0T.jpg)

How my top mounts are currently set up, not sure if they're perfect but I'll get someone to fix them if they aren't?

(https://i.imgur.com/Q3IFk6V.jpg)

(https://i.imgur.com/g5B8DRH.jpg)

It looks a lot more cambered from the angle that the picture was taken it is only slightly cambered however it has made a big difference in handling.

After that the car was parked up for some time so just changed the oil to keep everything fresh.

(https://i.imgur.com/BfbXsRk.jpg)
Title: Re: Qaz's Mk4 1.8T Project 300bhp
Post by: QazGolf on 06 October 2017, 18:36
My next attention was brakes, now although the idea of 17z cupra r 4 pots are very appealing I couldn't fork out the money for the calipers, new discs and new pads and additionally wheels that would clear them so I settled for the 312mm s3 setup, and while I was at it got a good offer on a s3 steering rack too.

(https://i.imgur.com/bfHhYSw.jpg)

My old brakes clearly not much life in them haha

(https://i.imgur.com/jUqUxMM.jpg)

312mm setup discs and pads have plenty of life so will be using it until they die, used type200 brake fluid.

(https://i.imgur.com/vESk90x.jpg)
New bush for the steering rack might as well upgrade it since changing it.

(https://i.imgur.com/OVnNMCY.jpg)

(https://i.imgur.com/AJ7B4MH.jpg)

(https://i.imgur.com/4pyxDd5.jpg)

Together the brakes and steering rack, with the camber, make the car stick through bends so much more. The difference really is night and day, highly recommend the quick rack and camber!
Title: Re: Qaz's Mk4 1.8T Project 300bhp
Post by: QazGolf on 06 October 2017, 18:45
I then really purchased a set of used agu engine mounts and decided to poly fill them with 70a as opposed to 85, purely because it's a daily and I didn't want to have a lot of vibration.

(https://i.imgur.com/GPp3ZIf.jpg)

(https://i.imgur.com/6grcEUZ.jpg)

(https://i.imgur.com/ay4lBut.jpg)

(https://i.imgur.com/g6HQkP5.jpg)

(https://i.imgur.com/6hV8zSN.jpg)

Tape them up as much as possible I didn't tape up the first side good enough resulting in some of it leaking out.

First mount drying, remember to pour it slow to avoid air bubbles and try to do it quickly as it hardens very quickly, made a mess on this one because it was leaking and I was panicking and trying to finish it.

(https://i.imgur.com/8K27PFK.jpg)

This one I taped up thoroughly, no leaks.

(https://i.imgur.com/0vRdyQ3.jpg)

Before and after they had dried

(https://i.imgur.com/ZAH0paL.jpg)

(https://i.imgur.com/NYEN3Yk.jpg)

Now I really want to spray them silver and put them into the car, anyone know a good silver? Or will halfords silver be up to the job? It isn't a show car by any means but I would like a nice oem looking fresh silver if that makes any sense haha

There's still a few things left on my list before it gets booked in for mapping, my current predicament is whether or not to forge the bottom end?
Also who here is running a different radiator? Looking at fitting an aftermarket radiator is it worth while or a waste of money?

Many thanks for reading will try to update more regularly, apologies for the lack of detail not feeling too great so thought I would update this. Happy to answer any questions
Title: Re: Qaz's Mk4 1.8T Project 300bhp
Post by: naiman on 10 October 2017, 07:35
good work, keep it that way.
 I got a 1.8t agu with k04-022 and I pulled the dyno 220 whp.
I'm curious how much you get off.
Title: Re: Qaz's Mk4 1.8T Project 300bhp
Post by: sharki786 on 22 December 2017, 19:53
Wow qaz. Come along way. Been some time. Iv got same ap coilovers on mine. And im rebuilding some octy vrs calipers and building a k03s hybrid stage 2. Jus the core no machining done yet. I wanted to ask you about the fuel pump. Im collecting parts atm. But wanted to know who does that fuel pump perform? I have heard bad stuff about the walbro 225 as it doesnt work properly when 3/4 tank left.
Title: Re: Qaz's Mk4 1.8T Project 300bhp
Post by: QazGolf on 06 January 2018, 20:32
Wow qaz. Come along way. Been some time. Iv got same ap coilovers on mine. And im rebuilding some octy vrs calipers and building a k03s hybrid stage 2. Jus the core no machining done yet. I wanted to ask you about the fuel pump. Im collecting parts atm. But wanted to know who does that fuel pump perform? I have heard bad stuff about the walbro 225 as it doesnt work properly when 3/4 tank left.

Bro!! Where have you been? Hope you're well. Good to see you're still fiddling, I have a good link for the hybrid you're building however it would require machining. PM me if interested!
My fuel pump is a copy of the DW pump, it works alright so far though my car isn't mapped yet. I have seen that it doesn't flow well past around 320bbhp or something but for your turbo it should be alright. I have read somewhere that it needs 2 O rings at the bottom so it sits properly though
Title: Re: Qaz's Mk4 1.8T Project 300bhp
Post by: QazGolf on 06 January 2018, 21:04
Ok happy new year guys, hope you all had a good one and got the mods you wanted over Christmas!

Little update sprayed my engine mounts because show car.

(https://i.imgur.com/5NDkCO2.jpg?1)

(https://i.imgur.com/xUD4wAr.jpg?1)

(https://i.imgur.com/BDGVM8S.jpg)

(https://i.imgur.com/kTRJeaK.jpg)

(https://i.imgur.com/ed5qzu2.jpg?1)

Gave them a clean with brake cleaner and then a couple of licks of spray from halfords and came out decent.
Title: Re: Qaz's Mk4 1.8T Project 300bhp
Post by: Wazzzer on 06 January 2018, 21:05
Will probably be picking your brains at some point mate as I'm going K04 somewhen :wink:
Title: Re: Qaz's Mk4 1.8T Project 300bhp
Post by: QazGolf on 06 January 2018, 21:09
Will probably be picking your brains at some point mate as I'm going K04 somewhen :wink:

Please feel free to bro! Though with the turbo you're going from to k04 I wouldn't say it's worth it. I would recommend the tfsi k04 064 as opposed to mine, but that's purely because of the turbo you are planning on running.
Title: Re: Qaz's Mk4 1.8T Project 300bhp
Post by: QazGolf on 06 January 2018, 21:56
Ok so, due to these turbos being small we've all heard and seen rods bend around 300 pounds of torque, however after a long debate I decided I wanted to get the most out this turbo and make sure it's done safely and reliably.

So one day I got lucky and found a set of rods cheap, had been sat in a garage and needed tidying up and for months they sat in my room and I think I finally have everything.

Got new everything since the car has come up to 120k ish so for piece of mind and longevity gonna do it once and properly. Hopefully.

(https://i.imgur.com/HGh0vVv.jpg)
New water pump.

(https://i.imgur.com/TfZuyKQ.jpg)
Got my fuel filter changed today too!

(https://i.imgur.com/Pf7bhip.jpg)
Goezte piston rings.

(https://i.imgur.com/0BSIeIF.jpg)

(https://i.imgur.com/4OSeTB8.jpg)
KS sputter big end bearings.

(https://i.imgur.com/W1ZV47F.jpg)

(https://i.imgur.com/ee7UQMF.jpg)

(https://i.imgur.com/XZFU16a.jpg)

(https://i.imgur.com/PGbqngk.jpg)

(https://i.imgur.com/3He7jbP.jpg)
The rods needed cleaning up, I know I know no one is gonna see them and it is inside of an engine but it makes me feel better. Used steel wool and WD40 on them and then wiped off with brake cleaner.

(https://i.imgur.com/3jh85wX.jpg)

(https://i.imgur.com/YOZXRez.jpg)

(https://i.imgur.com/h3ab1uX.jpg)

(https://i.imgur.com/zxvzZOV.jpg)

(https://i.imgur.com/x5uagVa.jpg)

DM forged rods, came out well. Don't have before pictures to show the difference. Onto the necessities!

(https://i.imgur.com/gne0BpN.jpg)

(https://i.imgur.com/KbJrJ4O.jpg)

(https://i.imgur.com/vyKwqCf.jpg)

(https://i.imgur.com/7KW082p.jpg)

(https://i.imgur.com/g6XSzTP.jpg)

(https://i.imgur.com/xk15Dcb.jpg)

(https://i.imgur.com/nqNEbEO.jpg)
Going back to an oem thermostat just because the 74 degree one I have on the car means overfilling because the car needs to get warmer. So to avoid over fueling gonna use the oem one during run in of the engine.

(https://i.imgur.com/3YSh470.jpg)

(https://i.imgur.com/b03Jd9P.jpg)

(https://i.imgur.com/DXS3WTU.jpg?1)
And a new oil pick up pipe.

(https://i.imgur.com/tIJ0HVQ.jpg)
(https://i.imgur.com/OhFDG75.jpg?1)
And ARP bolts to hold it all together.

I also have new spark plugs, filters and Millers CRO running in oil but that is downstairs so will take pictures tomorrow. Engine mounts will also be put into the car at time of the engine being rebuilt.
Also magnets on the oil filter, anyone done this? Assuming it doesn't make a great deal of difference but got two small ones off ebay purely for run in period.

Once again thanks for reading,

Qaz

Title: Re: Qaz's Mk4 1.8T Project 300bhp
Post by: Wazzzer on 09 January 2018, 21:39
Sounds like you're doing the same as me mate, good luck with it all!

You going for a new oil pump? I bought one for mine, wasn't too expensive either
Title: Re: Qaz's Mk4 1.8T Project 300bhp
Post by: QazGolf on 13 January 2018, 23:59
Sounds like you're doing the same as me mate, good luck with it all!

You going for a new oil pump? I bought one for mine, wasn't too expensive either


Thanks bro at this rate I need a lottery behind me!
And nah mine works so I am sticking with it until it is run in. But will get changed in the future for sure.
Title: Re: Qaz's Mk4 1.8T Project 300bhp
Post by: QazGolf on 14 January 2018, 00:00
Bad news, my current block is shot.
Has a slight lip at top of the bores.
Either source another block or go oversize pistons.
Stupid car.
Title: Re: Qaz's Mk4 1.8T Project 300bhp
Post by: Mr_Orange on 15 January 2018, 22:34
Bad luck. Are you able to go oversize bores/pistons, grab some extra capacity, salvage the block?
Otherwise great reading!
Keep it up!
Title: Re: Qaz's Mk4 1.8T Project 300bhp
Post by: sharki786 on 18 January 2018, 19:57
Wow qaz. Come along way. Been some time. Iv got same ap coilovers on mine. And im rebuilding some octy vrs calipers and building a k03s hybrid stage 2. Jus the core no machining done yet. I wanted to ask you about the fuel pump. Im collecting parts atm. But wanted to know who does that fuel pump perform? I have heard bad stuff about the walbro 225 as it doesnt work properly when 3/4 tank left.

Bro!! Where have you been? Hope you're well. Good to see you're still fiddling, I have a good link for the hybrid you're building however it would require machining. PM me if interested!
My fuel pump is a copy of the DW pump, it works alright so far though my car isn't mapped yet. I have seen that it doesn't flow well past around 320bbhp or something but for your turbo it should be alright. I have read somewhere that it needs 2 O rings at the bottom so it sits properly though

Been doing bits and bobs realy.
Iv done alot to mine since its been on the road for over a year now.
U gota link for that fuel pump?
I hope u got a good link at TPS or the dealer.
Shame the block is shot. So new bottom end??
Nah not going pure hybrid, as iv fitted the core and its a nice snug fit. Just need to fit it on now.
Title: Re: Qaz's Mk4 1.8T Project 300bhp
Post by: QazGolf on 21 January 2018, 20:52
Bad luck. Are you able to go oversize bores/pistons, grab some extra capacity, salvage the block?
Otherwise great reading!
Keep it up!

That was most definitely an option, but it just seemed too out of price at the time. So another block has been sourced I do have an update coming Tuesday/ Wednesday and will update accordingly. Thanks for reading bro I appreciate it, I do read yours too, it needs more pics bro!
I will most definitely try man, if the wallet allows me.


Qaz
Title: Re: Qaz's Mk4 1.8T Project 300bhp
Post by: QazGolf on 21 January 2018, 20:54
Wow qaz. Come along way. Been some time. Iv got same ap coilovers on mine. And im rebuilding some octy vrs calipers and building a k03s hybrid stage 2. Jus the core no machining done yet. I wanted to ask you about the fuel pump. Im collecting parts atm. But wanted to know who does that fuel pump perform? I have heard bad stuff about the walbro 225 as it doesnt work properly when 3/4 tank left.

Bro!! Where have you been? Hope you're well. Good to see you're still fiddling, I have a good link for the hybrid you're building however it would require machining. PM me if interested!
My fuel pump is a copy of the DW pump, it works alright so far though my car isn't mapped yet. I have seen that it doesn't flow well past around 320bbhp or something but for your turbo it should be alright. I have read somewhere that it needs 2 O rings at the bottom so it sits properly though

Been doing bits and bobs realy.
Iv done alot to mine since its been on the road for over a year now.
U gota link for that fuel pump?
I hope u got a good link at TPS or the dealer.
Shame the block is shot. So new bottom end??
Nah not going pure hybrid, as iv fitted the core and its a nice snug fit. Just need to fit it on now.

That is good bro, good to have you updating. Lately the forum has been quiet. I don't but I will try find it for you somehow, badger5 don't sell them anymore. You could always spend a bit extra and get the DW pump, just make sure you fit it with two O rings I believe.
Yeah another bottom end and build it up and then swap them around! Update coming this week though.
Oh ok that should make good power, what engine code are you bro?

Qaz
Title: Re: Qaz's Mk4 1.8T Project 300bhp
Post by: Wazzzer on 22 January 2018, 23:13
Sytec pump works fine for me, £50. Took about half hour to fit to the basket then about 10mins to fit in the car

I used 2 big O rings at the top as the pump is very slightly smaller than the standard pump
Title: Re: Qaz's Mk4 1.8T Project 300bhp
Post by: QazGolf on 26 January 2018, 19:52
Ahh I see, I will keep that in mind if mine turns out to be crappy!

Anyway update time, I have been busy so sorry for not being regular.

But big news.

Engine has been built.

(https://i.imgur.com/YjK8Nfc.jpg)

(https://i.imgur.com/24dMSs8.jpg)

(https://i.imgur.com/avTrfnF.jpg)

In the end I didn't go for oversize pistons and luckily sourced a block that could be used. So everything was built up on this engine.

But wait it gets better.

(https://i.imgur.com/HmbAmDt.jpg)

 :laugh: :laugh: :laugh: :laugh: :laugh: :laugh:

Engine is in with my poly engine mounts!

I am absolutely over the moon. Had a few miles to run in the engine done for me on the dyno and etc. And check this out!

(https://i.imgur.com/4JZ4EiX.jpg?1)

Car is on standard injections which is why you can see the engine not getting any fuel around 5000rpm. But 246 and it is very f**king nippy. And to think there is much more once it is mapped! So that is 246 at around 5000rpm.

I am very excited and cannot wait to be mapped. So close to getting there. Car is absolutely lovely to drive. Highly recommend anyone reading this to do their engine mounts. I do however have some vibration on idle and feel it in the cabin a bin sometimes. But it isn't bad cause I only used 70 poly and not 85.

So I have currently done 400 miles and need to do 600 more!

But I am absolutely enjoying it. Driving the car has never felt more fun, the only thing is I can't go near 5000 rpm so running it in I change around 4000/4500rpm. Car is pulling very strong. Anyone care to join me for a road trip or want to meet up kill off some miles haha.

Thanks for reading guys, once again hope you enjoyed this update as much as I did!
Title: Re: Qaz's Mk4 1.8T Project 300bhp
Post by: sharki786 on 28 January 2018, 19:54
Smashed it brother. Who mapped the car before for u?
Title: Re: Qaz's Mk4 1.8T Project 300bhp
Post by: QazGolf on 30 January 2018, 21:52
Smashed it brother. Who mapped the car before for u?

Safe bro almost there indeed! It is absolutely killing me having to shift at 4k/4 & a half. Cannot wait to be able to full throttle it and let it fly once it's mapped.

That's the thing bro, I think it's stock map, just all these mods have added a little bit more each time. And the result is that the weak link is now the injectors struggling to keep up!

Cannot wait to finish this now.

Qaz
Title: Re: Qaz's Mk4 1.8T Project 300bhp
Post by: QazGolf on 30 January 2018, 22:06
Ok good news and bad news.

Good news, I changed me buggered driveshaft. Getting closer to mapping so trying to take care of as many little niggles I know are there so the car can handle more power and will drive well.

(https://i.imgur.com/7mHbbh9.jpg)

Old one.

(https://i.imgur.com/ofZoMN2.jpg)

Nice new one.

Okay bad news. My oil cooler has been leaking, originally I thought it might be from the build and that it had been taken off. Washed the car and cooler thoroughly took it so a spin and oil was all over the bottom half of it. Not happy.

Cars back off the road until I get it sorted. Done about 400/500 miles now so want to crack on fixing all the niggles so I can get it mapped as soon as I get to 1000 miles. Then I can really open up that engine :laugh:

REALLY tempted to buy bits and pieces I don't NEED. However gonna address all the things that are needed before I do that. Additionally I wanna get an oil temp gauge and oil pressure gauge. I know the oil pressure gauge goes into my sandwich plate. However where do you hook up the temp gauge?

Also anyone running a right hand drive a pillar pod that holds 3 gauges? Please let me know where to find one that actually fits the mk4 rhd and not a universal one.

Once again thanks for reading only a small update until I fix the cooler, I would have undone the sandwich plate and hoses but I currently don't have a jack or time.

Qaz
Title: Re: Qaz's Mk4 1.8T Project 300bhp
Post by: Mr_Orange on 31 January 2018, 20:23
According to audi sport you can fit temperature sensor in existing hole top of oil filter housing. Worth a look

http://www.audi-sport.net/xf/threads/fitting-an-oil-pressure-oil-temp-and-boost-gauge.135574/
Title: Re: Qaz's Mk4 1.8T Project 300bhp
Post by: QazGolf on 06 February 2018, 16:26
I will most definitely look into that once I get them! For now nothing excited, swapped the leaky cooler over and put the new one on. Leak is gone, cars back on the road. However when tightening the new cooler up one of the hoses was a tad loose. Think the old cooler might be okay, will pressure test it soon to see if it lives to see another day. If not it's going in the bin. Would prefer my old cooler as it was 16 row and my new one is 13 row. Won't make much of a noticeable difference but I want the 16 row one on  :grin:

Anyone running a three gauge pod along the A pillar? Or does it need to be custom made?

Qaz
Title: Re: Qaz's Mk4 1.8T Project 300bhp
Post by: QazGolf on 07 February 2018, 20:58
Not much to report but a small step forward.

Oil cooler has been switched out so car is on the road again. However I am still gonna get the old one pressure tested when I drop down to JNL racing at some point next week. Just to make sure it's the cause and not the fittings. Whilst doing so I changed the oil filter because why not, and topped up the oil a little.

(https://i.imgur.com/5PtrGIo.jpg)

(https://i.imgur.com/lYQ1e2k.jpg)

(https://i.imgur.com/9oXy2bK.jpg)

This ones a 13 row, I got impatient and completely forgot mine was a 16 row.

(https://i.imgur.com/FzGUKkA.jpg)

See how the oil is only along half the cooler I am thinking its either split or the loose fitting has allowed the oil

(https://i.imgur.com/sCUygKQ.jpg)

New one fitted and fittings cleaned up.

Additionally got some part worn rears, needed to be done since MOT so finally got round to doing the,

(https://i.imgur.com/sX1Nkyr.jpg)

(https://i.imgur.com/WpzLgiL.jpg)

Getting my moneys worth clearly haha.

That is currently it, almost done 600 miles I feel like the engine is run in. Gonna do a few more miles then swap the oil out.

Once again thanks for reading, hopefully another update will be soon!

Pray I get overtime guys  :laugh:

Many thanks,

Qaz
Title: Re: Qaz's Mk4 1.8T Project 300bhp
Post by: QazGolf on 23 April 2018, 22:36
Alright guys, not the biggest update as always. Will explain along the way, so oil cooler started leaking again because I thought it would be a good idea to put the 16 row back on, not sure if the fitting was loose AGAIN or if the fitting needs welding because it's coming loose. However either way 13 row is back on and well it does the job, I may mock up the 16 row to the front of the car at some point for now it isn't a priority. Which got me thinking I had done enough miles on the mineral oil and it was time to put some proper oil in the car.

(https://i.imgur.com/c9QJLj2.jpg)

(https://i.imgur.com/3Xkau6r.jpg)

Comma 5w50, purely because once the car is mapped I am going to be driving it hard and possibly be doing some track days!

(https://i.imgur.com/MhqFQDU.jpg)

Cooler

(https://i.imgur.com/mC2T0Ym.jpg)

Oil filter to compliment of course.

Ok so, got the old mineral nice and hot so it would all come out, took the 16 row off swapped it with the 13 row. Just to make sure all the old oil was out, used the one litre of oil with the sump nut off and literally for one second it was a touch dirty then it was all clean. Best oil I've ever wasted literally just watched it being poured out haha. Then put the sump nut back on and filled it up, oil is very thick and orange-y!

(https://i.imgur.com/A3aF6jD.jpg)

Okay so additionally, I've always wanted to keep an eye on oil temp and oil pressure, I feel like it's almost obligatory in the modified car scene haha, so I went and got matching Newsouth gauges, both mechanical and needle sweep too! If videos work on here I will post one.

(https://i.imgur.com/hhzSpd1.jpg)

(https://i.imgur.com/ZrYG6KO.jpg)

Love my view so much, some will notice my oil temp is at 0. Basically my mocal sandwich plate doesn't have anywhere to put my oil temp pressure sensor. So originally the oil temp was going to run off the 5mm allen bolt on the oil filter housing but since there was nowhere on the sandwich plate, pressure is more important so that's taken priority. If anyone knows where I can measure oil temp from apart from the sump nut please do let me know!! I been trying to find a banjo bolt which would allow me to put the thread through but cannot for the life of me find the right size.

(https://i.imgur.com/fu2P652.jpg)

(https://i.imgur.com/bk9PkUU.jpg)

Since mapping isn't far I wanted to eliminate as many known issues as possible, so installed the revised recirc valve.

(https://i.imgur.com/t7cyu5T.jpg)

(https://i.imgur.com/LLL64Tx.jpg)

(https://i.imgur.com/ahhxEU5.jpg)

Unfortunately that is all I have at the moment! I am coming to a stage where the car is almost finished and I was going to map it narrowband HOWEVER I think after all this time doing the car it would be best to finish it properly. So I spoke to JP about standalone and wideband, and well I'm not going to tell you the answer. Just make sure you keep reading lol.

Since there hasn't been much to do I have been religiously washing my car and enjoying car meets.

(https://i.imgur.com/5y03wJU.jpg?1)

Thanks for reading as always, update coming soon (hopefully). Giving myself the deadline of June 1st for GTi International at Rockingham, let's try get down there people!
Title: Re: Qaz's Mk4 1.8T Project 300bhp
Post by: QazGolf on 30 June 2018, 16:20
Ok so it has been a while, a lot of head scratching in regards to mapping the route I wanted to take.

SO had a wideband ECU, loom, coils all the rest of it, drive by wire throttle body etc. Undid the old loom from the engine, coils started looking at the accelerator pedal and they are completely different. Seems the me7.5 bodied cars came with the pedal mounted differently. Did I know this? Absolutely not, so guess what it still hasn't been changed.

Will need a bracket made up and then will have to try again.

In other news though I managed to pick the TT front end up very cheap and did some bits to it.

(https://i.imgur.com/ArVkAn2.jpg?1)

Subframe, anti roll bar, wishbones, drop links and the hubs!

(https://i.imgur.com/H9idRpJ.jpg)

Wishbones have one side poly bushed already

(https://i.imgur.com/oZTlPTM.jpg)

Dude I got it from was kind enough to throw in the small side powerflex bushes

(https://i.imgur.com/bZa5EJU.jpg)

(https://i.imgur.com/EEfzxMJ.jpg)

He even threw in his fully polybushed dogbone mount, mine is only half poly wish the diesel variant bush. While I considered doing the small bush on mine, having this thrown makes life so much easier.

(https://i.imgur.com/75uBYTP.jpg)

Stripped the frame down took off the anti roll bar, wishbones, hubs and dogbone for a lick of paint.

(https://i.imgur.com/wq2nO98.jpg)

(https://i.imgur.com/QEdEZau.jpg)

Black hubs, yellow wishbones.  :cool: :cool: 5 extra bhp per wishbone, yellow being a go fast colour & all.

(https://i.imgur.com/jDdUygm.jpg)

(https://i.imgur.com/aYAW2xS.jpg)

Not a show car so no I didn't do it a perfect job, but it will do.

(https://i.imgur.com/GzkAGjT.jpg)

Painted the roll bar black to match the hubs, part of me wanted to do it red. Didn't go to get red paint because I thought these would be put onto the day a couple of days later (which didn't happen and is yet to happen!)

(https://i.imgur.com/FnDbML5.jpg)

Got new hubs too, wanted everything new so I wouldn't have to worry about it. Do it once do it properly...

(https://i.imgur.com/P8HGnTw.jpg)

New bearings to match

(https://i.imgur.com/3MRCAQ7.jpg)

And these are Audi TT mk2 ball joints, with a little modification can be made to fit the mk1 wishbones. Giving some extra camber and caster. Fully looking forward to the difference these make! Can't wait to throw it round some corners.

Now the thing is these will all go on next month or the following month, purely because I want my car mapped. The weather is good and I just wanna be able to go full throttle, it's annoying having to change at 4k. Plus the injectors run lean at 5k so in safety of the engine mapping seems to be the sensible option, this stuff can get fitted later on along with something else  :evil:

Thanks for reading, hopefully another update will be coming soon. Just been mega busy.

Many thanks

Qaz