GolfGTIforum.co.uk

General => Members rides => Golf mk4 => Topic started by: golfyste on 16 January 2013, 15:20

Title: Golfyste's road legal mk4 "project track car"
Post by: golfyste on 16 January 2013, 15:20
Just on my way to pick it up!
Pictures and update to follow!  :grin:
Title: Re: Golfyste's road legal track car
Post by: Prawny on 16 January 2013, 16:18
Top thread man, full of pics and info.

Love it ;)
Title: Re: Golfyste's road legal track car
Post by: SI74 on 16 January 2013, 16:28
Just saw you other post in the mk4 section. Looking forward to seeing some pictures of you picking it up.
Title: Re: Golfyste's road legal track car
Post by: golfyste on 16 January 2013, 16:42
Top thread man, full of pics and info.

Love it ;)

It will be don't worry  :wink:

Just picked it up and on the way home!

A picture from the advertisement ...

(http://i1197.photobucket.com/albums/aa433/golfyste/045978D3-1BAB-4A6C-BDE9-0EB8BE356E6A-1096-00000101F849517F.jpg)

And on the trailer!
(http://i1197.photobucket.com/albums/aa433/golfyste/5296C8D7-B11F-4CF8-B903-951233E874C9-1096-0000010200EF4409.jpg)

All for a whopping great £450  :grin:
Title: Re: Golfyste's road legal track car
Post by: golfyste on 16 January 2013, 16:45
It's already got a couple of bits on it but will probably be irrelevant as I'm going to do every properly!
It's in good nick to say I only paid 450 but its got a suspected blocked pick up pipe so unknown damage to the engine which doesn't bother me to much as it will be having a fully rebuilt engine with large port head etc  :evil:

This mo th it's gonna to be cheap jobs due to just splashing out and Christmas
......
So starting with stripping out the I interior  :smiley:
So if anyone wants to buy some its up for grabs  :laugh:
Title: Re: Golfyste's road legal track car
Post by: Diamond Hell on 17 January 2013, 00:21
Plan your safety upgrades along with the other fiddling about with the engine and suchlike, if it's actually going to be properly made into an actual track car.

See Prawn's A3 for further details. 

Cars for road and track are quite different in their requirements.  :huh:
Title: Re: Golfyste's road legal track car
Post by: golfyste on 17 January 2013, 08:40
Plan your safety upgrades along with the other fiddling about with the engine and suchlike, if it's actually going to be properly made into an actual track car.

See Prawn's A3 for further details. 

Cars for road and track are quite different in their requirements.  :huh:

I've read the whole 80 pages of prawns build thread....that's what inspired me  :laugh:
A roll cage, seats, harnesses, fire extinguisher etc are all planned don't worry  :cool:
Title: Re: Golfyste's road legal track car
Post by: Diamond Hell on 17 January 2013, 08:59
A roll cage, seats, harnesses, fire extinguisher etc are all planned don't worry  :cool:

Good.  Do it properly.  Bored of people starting a 'I'm going to build an amazing track car' threads, only to rip the interior out, bodge a bucket seat in, nail some harnesses to completely the wrong mounting points and then stand back and look pleased with themselves.

(http://www.northloop.co.uk/forum/images/smilies/thumb.gif)

As they say on Northloop.
Title: Re: Golfyste's road legal track car
Post by: golfyste on 17 January 2013, 09:18
 :laugh: don't worry I'm going to take my time and do it right!

Struggling I find somewhere to buy a bolt in cage for a three door though!
Won't be buying one just yet but was just tryin to find a dealer??

Anyway best get out of bed and get stripping the interior  :grin:
Title: Re: Golfyste's road legal track car
Post by: Diamond Hell on 17 January 2013, 10:23
Weld-in 6-point from CustomCages?

http://www.customcages.co.uk/Rollcage/LoadRollCage.castle?manufacturer=Volkswagen&model=Golf%20Mk4%20Clubman&type=6%20Point

£1150 inc VAT installed but looks after cage plus harness bars for the harnesses.  I (and all those who've seen the quality of the welding) can vouch for their install - it's uber high quality.

Or bolt in, what's wrong with this:

http://www.safetydevices.com/motorsport/products/roll-cage/Volkswagen+Golf+Mk4-1997-2004/564/

Note this is a 6-point bolt-in cage where it appears you can order harness bars in the rear section - make sure you do!
Title: Re: Golfyste's road legal track car
Post by: golfyste on 17 January 2013, 11:14
Hmmm I like the look of the safety devices one.
Are the omp cages any good?
I'm not in a rush anyway as I'm doing all free stuff for now haha.

Just took some of the interior out and nearly lost my hands! Ha
Will post pictures later!
Title: Re: Golfyste's road legal track car
Post by: Diamond Hell on 17 January 2013, 11:43
I know people who've had to cut OMP cages up and re-weld the feet back on.  :lipsrsealed:

They're made in Italy.  I don't like to stereotype, but....
Title: Re: Golfyste's road legal track car
Post by: golfyste on 17 January 2013, 15:52
I know people who've had to cut OMP cages up and re-weld the feet back on.  :lipsrsealed:

They're made in Italy.  I don't like to stereotype, but....

Haha ok then  :laugh:

Anyway DAY 1!  :cool:

Started off the day nice and frosty at -3  :laugh:
(http://i1197.photobucket.com/albums/aa433/golfyste/81507E24-4138-47B8-A34C-E86A278C3297-144-0000000F72101941.jpg)

Few of the car before things get crazy  :evil:

Will definitely be lifting it up a little for track use ...
(http://i1197.photobucket.com/albums/aa433/golfyste/4AA30964-E177-4642-BA86-14DE8A6CF7BF-144-0000000F7D1B6D20.jpg)
(http://i1197.photobucket.com/albums/aa433/golfyste/3AA809A0-8E31-43A4-A13F-E8EC1F8B9BF9-144-0000000F823B28DE.jpg)
(http://i1197.photobucket.com/albums/aa433/golfyste/5914D743-4480-4234-B1F3-F750CC114DA4-144-0000000F88C02545.jpg)

Anybody seen these seats before? They have airbags and are in next I mint condition haha
(http://i1197.photobucket.com/albums/aa433/golfyste/C8ACC09B-3E2A-41E8-85C3-8867E300AC62-144-0000000F8D848C1F.jpg)

Started with whipping some of the seats out (which weigh a ton!)
(http://i1197.photobucket.com/albums/aa433/golfyste/EBD191F5-3FA9-493A-A86E-4BD29694CB37-144-0000000F91D128A2.jpg)

And then all the boot stuff!
(http://i1197.photobucket.com/albums/aa433/golfyste/0BB50FE1-B26F-4AC7-B123-29208478B13B-144-0000000F99DC5912.jpg)

Terrible picture haha
(http://i1197.photobucket.com/albums/aa433/golfyste/E84C5E12-EF63-4D56-87E9-2B2AD83E5DA8-144-0000000FA0A89741.jpg)

Then sorted the front carpet and expose all the heavy soundproofing!
(http://i1197.photobucket.com/albums/aa433/golfyste/05C575E8-7F04-44D9-87F1-81B30C22D542-144-0000000FA53F6741.jpg)

A nice pile of interior  :grin:
(http://i1197.photobucket.com/albums/aa433/golfyste/BB129835-E1CE-45E0-AE31-235456D1A477-144-0000000FAA4133D7.jpg)

Ripped all the soundproofing out and also the side panels
(http://i1197.photobucket.com/albums/aa433/golfyste/92C4A6B7-031F-4490-A40C-2919E6B9706F-144-0000000FAFA22015.jpg)

End of the day pictures!
(http://i1197.photobucket.com/albums/aa433/golfyste/647AA0E2-22A6-47E9-B931-C565ED8570C7-144-0000000FC095E50E.jpg)

(http://i1197.photobucket.com/albums/aa433/golfyste/606AC6BC-CE95-4092-B36C-40B61E128DC7-144-0000000FC7CBD7E5.jpg)

(http://i1197.photobucket.com/albums/aa433/golfyste/255E1239-FDAE-415E-8F71-53113AB81B2B-144-0000000FD3BC9228.jpg)

 :cool:
Quite happy with the progress for today  :smiley:

Couple of small questions.

Does anyone recommend leaving the thick soundproofing behind the glovebox you can see on the last picture incase of engine bay fires etc??
I looked at along it out and I will need to cut it up so thought I best ask first as I won't be able to put it back haha

Also how do you remove the trim and handle for the bonnet release? Tried pulling it off with no success haha

I also did a little Weighing o a few parts I took off to see what weight I'm saving
Did weigh everything but here's a little list

Front seats were 22kg each (which I think are lighter then the recaros

Back seats
Parcel shelf
Spare wheel
Some sound proofing (not all of it)
And a few bits of crap (2kg)

All added upto 45kg

So just with that I'm saving 89kg!!
And the car is still full of stuff which i havent weighed inc - carpet, panels and other crap! Haha

Next step is going to be to remove all the sound proofing stuck to the floor and eventually paint all the inside satin black just to tidy it up a little  :cool:

Title: Re: Golfyste's road legal track car
Post by: Wayne on 17 January 2013, 16:07
The bulkhead soundproofing is fitted more to keep the noise out, it can be removed but you will suffer more heat / noise in the cabin.

Only way to remove it complete is to take the dash out.
Title: Re: Golfyste's road legal track car
Post by: golfyste on 17 January 2013, 16:14
The bulkhead soundproofing is fitted more to keep the noise out, it can be removed but you will suffer more heat / noise in the cabin.

Only way to remove it complete is to take the dash out.

Don't mind to much about noise and heat etc
So will just give it a good cutting and pull it out with my magic Stanley  :grin:
Title: Re: Golfyste's road legal track car
Post by: SI74 on 17 January 2013, 18:58
Some work going on there. Good job. I think the seats are base line seat I've see them in 1.4 1.6 cars
Title: Re: Golfyste's road legal mk4 "project track car"
Post by: golfyste on 17 January 2013, 20:21
Cheers mate gonna try get all the sound proofing off the floor next, does anyone know the best way of getting it off?

also going to look at building a platform for the shifter like i put in the other thread
(http://i1197.photobucket.com/albums/aa433/golfyste/393BB12E-F9E2-4B2C-B665-629E94F1054D-502-000000373E927291.jpg)

what site did you see it for sale on mate?
Title: Re: Golfyste's road legal mk4 "project track car"
Post by: Wayne on 17 January 2013, 20:36
Cheers mate gonna try get all the sound proofing off the floor next, does anyone know the best way of getting it off?

Heat gun and a scraper :smiley:
Title: Re: Golfyste's road legal mk4 "project track car"
Post by: dom on 17 January 2013, 20:41
Looks good :afro:

Where in Sheff are you?
Title: Re: Golfyste's road legal mk4 "project track car"
Post by: golfyste on 17 January 2013, 22:26
Cheers mate gonna try get all the sound proofing off the floor next, does anyone know the best way of getting it off?

Heat gun and a scraper :smiley:

Thats what i was thinking....just wondered if anyone had a magical technique  :grin:

Looks good :afro:

Where in Sheff are you?

Frecheville in south east Sheffield mate (Bilrey, Hackenthorpe area)  :smiley:

Where abouts are you? dont recall ever seeing you drivin around....
Title: Re: Golfyste's road legal mk4 "project track car"
Post by: dom on 18 January 2013, 08:18
Cheers mate gonna try get all the sound proofing off the floor next, does anyone know the best way of getting it off?

Heat gun and a scraper :smiley:

Thats what i was thinking....just wondered if anyone had a magical technique  :grin:

Looks good :afro:

Where in Sheff are you?

Frecheville in south east Sheffield mate (Bilrey, Hackenthorpe area)  :smiley:

Where abouts are you? dont recall ever seeing you drivin around....

I live in Treeton so more Rotherham way, not far though
Title: Re: Golfyste's road legal mk4 "project track car"
Post by: golfyste on 18 January 2013, 13:37
Sweet do you go to the lowdown meet?

Ok so went outside today in the snow.... Managed to remove the handles from the roof and then my hands nearly dropped off!!
So I called it a day haha
This weather needs to disappear!
Title: Re: Golfyste's road legal mk4 "project track car"
Post by: markallen on 18 January 2013, 14:08
Sweet do you go to the lowdown meet?

Ok so went outside today in the snow.... Managed to remove the handles from the roof and then my hands nearly dropped off!!
So I called it a day haha
This weather needs to disappear!

Fanny  :wink:
Title: Re: Golfyste's road legal mk4 "project track car"
Post by: golfyste on 18 January 2013, 14:36
Also spent 30 seconds removing the boot plastic haha
Title: Re: Golfyste's road legal mk4 "project track car"
Post by: golfyste on 18 January 2013, 15:39
Just bought a cheap heat gun I help with the removing the sound deadening
Already have one but I think it's at bit past it at 20+ year old  :laugh:

(http://i1197.photobucket.com/albums/aa433/golfyste/87AE234C-4F42-4E7A-B57F-42A86E22E111-1242-000001366C74A463.jpg)
Title: Re: Golfyste's road legal mk4 "project track car"
Post by: Diamond Hell on 19 January 2013, 10:12
I used a blowtorch and a scraper to do the soundproofing in my Golf.

That gets it hot and easy to remove.  You can use it to warm up quite a large area of soundproofing pretty quickly, then get in there with the scraper and peel off a large area of sound-deadening.

TBH unless the plastic panel on the boot is particularly heavy, I'd leave it in there.  You might also like to get a sheet of Foamalux to cover in the rear panels.  You can also use it to make doorcards if you decide to shed them, but that's probably going to result in quite a lot of effort with the electric windows etc!
Title: Re: Golfyste's road legal mk4 "project track car"
Post by: golfyste on 19 January 2013, 12:13
I've also got a blowtorch but was worried about fuel lines under the car so for now will see how I get on with the heathgun and if I get any difficult parts resort to the torch  :smiley:

Hmm I dunno as I see it every bit of weight counts and as I don't really need the boot panel may leave it out for now.

Can't get a good look inside at the moment due to all the interior being thrown back in so will decide when it's out what I'm doing with panels etc... Will probably just leave it bare  :laugh:

As I will be using the front door cards (windows etc as you said) I'm goin to leave them for now but thanks for the advice with the foamalux will keep it in mind!
Title: Re: Golfyste's road legal mk4 "project track car"
Post by: golfyste on 20 January 2013, 17:11
Noticed a nocking on the daily when te wheels spin (snow helped as a way to listen  :laugh:) sounds likes it coming from the n/s front

Had the car up recently and didn't notice anything wrong with wishbones etc and only replaced them about 12 months ago.  :undecided:

Any ideas?
It nicks when it starts spinning and knocks again when it stops...also if I stand on the dry and jolt it forward a little bit using the clutch it knocks once then if I jolt it backwards it knocks once  :undecided:

Gonna have to jack it up and have a good look!
Check all subframe bolts, wishbones, engine mounts etc
Title: Re: Golfyste's road legal mk4 "project track car"
Post by: golfyste on 21 January 2013, 17:58
Ok so had an hour on the golf!
Just got the sound proofing material off the passenger footwell.

It's awkwards working in the car at the minute as all the removed interior is being stored in car bar 1 seat!
(http://i1197.photobucket.com/albums/aa433/golfyste/2AEBACE8-7264-485A-BDA3-8DAE0C98586C-1944-000001BD42634E23.jpg)
 
The tools of choice ....
(http://i1197.photobucket.com/albums/aa433/golfyste/44FCF80C-3AEF-4293-A379-3DDC40217AA5-1944-000001BCFE1B04BF.jpg)

And all done!
(http://i1197.photobucket.com/albums/aa433/golfyste/52FABBE3-2808-4473-81D2-D0DECB6A4E46-1944-000001BD15F1A3F2.jpg)

I bagged it up and it feels like it weighs about 2-3kh
And there is loads more to remove so I can see it as being a nice weight saver!


I couldn't find anything wrong with the daily so I'm thinking it may e the diff but not sure.
I have go a spare box in the garage so will have to see!
Title: Re: Golfyste's road legal mk4 "project track car"
Post by: Diamond Hell on 21 January 2013, 19:22
Check your anti-roll-bar bushes - could just be those.

The blowtorch allows you to work fast because it's a concentrated heat.  I don't think you'll have issues with your fuel pipes etc - just move the flame quickly across the sound deadening.

Another thing worth remembering is that 1kg sprung weight = 7kg unsprung weight.  Look at getting light wheels and whether a brake upgrade would net you lighter calipers.

You might also look at relocating the battery (with a box over it) and the washer reservoir to the back of the car to aid weight distribution - you're taking all of the weight out of the back half of the car.  :wink:
Title: Re: Golfyste's road legal mk4 "project track car"
Post by: SoundillusioN on 21 January 2013, 19:45
^^^ Reminds of a job not on my list that I still want to do.  I want/need to move my battery to the back.  Was tempted to go down to a scrappy and take all the shizzle from an old Beemer as it could work out cheaper but think I'd prefer new copper as it's not that expensive.
Title: Re: Golfyste's road legal mk4 "project track car"
Post by: golfyste on 21 January 2013, 19:52
Will check tem tomorrow!  :smiley:

May try the torch next and compare but the only problem is with the torch I can run out of gas where as the gun is plugged in haha

I have got plans for lights wheels and lcr brakes (not too big so light yet good stopping power).

Wheels wise I'm not I sure what to look for apart form team dynamics and rota force but will probably buy whatever is cheap.
But also need to think about offsets as I'm currently running 20mm spacers note back of my daily  :sick:
Thinking about welding/bolting a spacer onto the rear beam rather then using wheel spacers.

So tempted to go silly and widen the arches and lengthen the rear beam  :laugh:

There's a big list  :wink:
Title: Re: Golfyste's road legal mk4 "project track car"
Post by: Wayne on 21 January 2013, 21:25
Reference the wheel Team dynamics pro race are an excellent choice and really light even in 18" for a track car however 16"s would be the better choice.

No need for spacers if you use the right offset, et35 will be fine.
Title: Re: Golfyste's road legal mk4 "project track car"
Post by: markallen on 21 January 2013, 21:54
Any spacers on at the moment? I will have them if there is?
Title: Re: Golfyste's road legal mk4 "project track car"
Post by: Diamond Hell on 21 January 2013, 23:00
So tempted to go silly and widen the arches and lengthen the rear beam  :laugh:

Try and put stupid ideas like this to the back of your mind and just get the basics right to start with.

Get it stripped down a bit and re-bush the whole thing, then get the alignment done.  Get some good quality discs and pads on and change the fluid out for fresh stuff.

The drive the tits off it and decide what it wants/needs next up.

If it was me I'd run the smallest wheels possible, as they'll be relatively light and tyres will probably be cheaper.

Making a big list to start with is an ar$e about face way of going into this.  Test, evaluate and revise to find direction.
Title: Re: Golfyste's road legal mk4 "project track car"
Post by: golfyste on 21 January 2013, 23:51
Yeah I see where you coming from cheers for the slap in the face  :smiley:

There is a big list but not to all be completed straight away, a lot of it is performance upgrade for the engine which can wait for now I jut want to change all the wishbones, bushes, brakes etc before I start using the car so I know it is all in good condition and then work on the engine and suspension,geometry tweaks from there.

I think I'm going to go for 17" wheels due to weight etc
 
Title: Re: Golfyste's road legal mk4 "project track car"
Post by: golfyste on 24 January 2013, 22:34
Ok so Tuesday put some lowering springs on my brothers subaru legacy.
10x easier then the golf! Front had two bolts at the bottom and 3 13mm bolts at the top and just slipped out! Te backs were about worse tho as the 19mm but and bolt on the bottom just did not want to come off! Ended us using the nut splitter 4 times on one of the bits and then chiseling away the faces and usin the grinder to cut the collor!

(http://i1197.photobucket.com/albums/aa433/golfyste/2BF0C50D-D40B-4563-B40F-486927962F03-408-00000021AC55774A.jpg)

Eventually started turning but is one of the worst nuts have come across....not nice when its -2!

Wednesday changed my rear caliper on the daily as it had seized from a broken dust shield! Came along my road in te slush with the rear wheel locked all the way!

Drive to work this morning and the brakes were really soft so had to be careful, got home and rebled the f n/s and r o/s calipers but the feel still isn't very good!
So gonna have a better look on the weekend!

Also won some Cupra e wishbones on the bay!
(http://i1197.photobucket.com/albums/aa433/golfyste/A6104A83-E26F-4328-991B-1F1F83620089-408-00000021E648D9BF.jpg)

Ok for £36 :D
And also bought some black enamel paint to tidy up them and the subframe I cleaned up.
Don't k is if its any good but we will see!

(http://i1197.photobucket.com/albums/aa433/golfyste/8393F83C-54E8-4A75-9028-9ED73D319877-408-00000021BC443805.jpg)

And last but not least managed I sell the front and back seats out of the track car so there is finally about of space in the car for me to work!
Title: Re: Golfyste's road legal mk4 "project track car"
Post by: SI74 on 25 January 2013, 18:31
Your not hanging mate. Keep it up.
Title: Re: Golfyste's road legal mk4 "project track car"
Post by: golfyste on 25 January 2013, 18:42
 :grin:
Now the front seats are gone I might look at building a platform for the shifter and also so I can mount the petrol cap release  :laugh:
Title: Re: Golfyste's road legal mk4 "project track car"
Post by: golfyste on 27 January 2013, 17:06
Ok so I planned on getting somework done yesterday but my brother asked if I wanted to go out on a ride and I couldn't resist  :grin:

(http://i1197.photobucket.com/albums/aa433/golfyste/25021377-C1DF-4C75-A80E-A5217DAF24B8-4170-0000039F1EC1E071.jpg)

Haha removed about 15kg of sand when I washed it haha   :laugh:

Anyway had a bit of time on the golf today not done much just a little few time consuming things like the sound deadening.
Managed to finish removing it all from the footwells  :cool:

(http://i1197.photobucket.com/albums/aa433/golfyste/0F006A6A-9D32-4D3B-A388-2782766A7ED5-4170-0000039F12D8E2D3.jpg)

I also removed the seat belts and rear speakers which has helped shed quite a bit of weight!

Can't get to the sound deadening in the back due to the carpet and panels in there  :laugh:

So I stated my design of the centre frame that the shift is going to stand on!
I bent some welding wire to the desired shape And got this..

(http://i1197.photobucket.com/albums/aa433/golfyste/6611A463-B99C-466C-83C2-3D9840F2770F-4170-000003A17AB011D2.jpg)

The plan is to make it out of some 10mm tube and use thin plate in the gaps  :smiley:
Title: Re: Golfyste's road legal mk4 "project track car"
Post by: Diamond Hell on 28 January 2013, 09:46
White spirit or turps on a bit of rag will clean that floor up nicely.
Title: Re: Golfyste's road legal mk4 "project track car"
Post by: golfyste on 28 January 2013, 09:52
White spirit or turps on a bit of rag will clean that floor up nicely.

That the plan  :smiley:
I have a big tub of washing thinners I use for the paint gun so will use that and then paint it with some rattle cans  :smiley:
Title: Re: Golfyste's road legal mk4 "project track car"
Post by: golfyste on 01 February 2013, 20:46
Ok so had work over the last week working 12 hour shifts so progress hasn't been too rapid  :laugh:

I managed to clean all the crap off of the rear footwells using thinners, rags and a flat head screwdriver haha
Managed to get them spotless :)

(http://i1197.photobucket.com/albums/aa433/golfyste/001.jpg)

I have also started the fabrication of the frame for the shifter platform
Got along way to go but at least it has some shape!

(http://i1197.photobucket.com/albums/aa433/golfyste/015.jpg)

(http://i1197.photobucket.com/albums/aa433/golfyste/016.jpg)

(http://i1197.photobucket.com/albums/aa433/golfyste/017.jpg)

Bolted on under the dash and got some strong cable clips to hold it at the rear end.

(http://i1197.photobucket.com/albums/aa433/golfyste/021.jpg)

(http://i1197.photobucket.com/albums/aa433/golfyste/022.jpg)

Going to use 1mm plate for in between the frame not fully decided how yet but will make the decisions as I go haha

Also these arrived!
Cupra r wishbones ...

(http://i1197.photobucket.com/albums/aa433/golfyste/025.jpg)

The Enamel paint for subframe and wishbones also arrived! And also various rattle cans - gloss black for the Interior, red for a few bits and primer :)

Got around to clearing all the residue from the front footwells!  Just need to get to the back end now but there is interior in the way!
Anybody want to buy some mk4 Interior? Haha

Passenger footwell before...

(http://i1197.photobucket.com/albums/aa433/golfyste/018.jpg)

And after  :cool:.....

(http://i1197.photobucket.com/albums/aa433/golfyste/020.jpg)

A little picture of both the golf  :grin:

(http://i1197.photobucket.com/albums/aa433/golfyste/024.jpg)

I finished there for the day as i had to go out!

or so i thought!

(http://i1197.photobucket.com/albums/aa433/golfyste/026.jpg)

I went back out a bit later....it may be dark but it wasn't stopping me  :laugh:

All done!  :cool:

(http://i1197.photobucket.com/albums/aa433/golfyste/027.jpg)

just need to get around to doing it all in the back now, need to remove the shifter but that means removing the exhaust ect so i think im just goning to carry on with the interior for now  :smiley:
Title: Re: Golfyste's road legal mk4 "project track car"
Post by: Wayne on 01 February 2013, 21:08
I doubt p clips will be strong enough to support the back tbh.
Title: Re: Golfyste's road legal mk4 "project track car"
Post by: golfyste on 01 February 2013, 21:11
I wondered this when my dad first mentioned them but holding them in place it does seem quite strong but if they arnt good enough I will weld a piece of plate across the bar and to the transmission tunnel  :smiley:
Title: Re: Golfyste's road legal mk4 "project track car"
Post by: Wayne on 01 February 2013, 21:14
I wondered this when my dad first mentioned them but holding them in place it does seem quite strong but if they arnt good enough I will weld a piece of plate across the bar and to the transmission tunnel  :smiley:

I would get it welded, much stronger in the long run.
Title: Re: Golfyste's road legal mk4 "project track car"
Post by: golfyste on 01 February 2013, 21:16
I think I will to be honest! Got a lot to do still so will add it to the list!
Title: Re: Golfyste's road legal mk4 "project track car"
Post by: golfyste on 05 February 2013, 22:41
Ok done a few bits and bobs but will do a update with pictures at some point this week.

But first quick question!

Anyone have a guide for removing the dashboard without destroying it?
Decided To strip the airbag and rear speaker wiring while I have it in bits so going to remove the dash and removing everything that isn't needed

Cheers lads
Title: Re: Golfyste's road legal mk4 "project track car"
Post by: golfyste on 09 February 2013, 20:43
Time for a update!

Just been removing bits and bibs over the last few days tbh

Removed the passenger and driver air bags  :smiley:

(http://i1197.photobucket.com/albums/aa433/golfyste/0162.jpg)

drilled out the rivets to remove the rear speaker plates. going to leave that tiny bit of sound deadening as its really thin compared to the other stuff and dont want to get it to hot due to paintwork on the other side!

(http://i1197.photobucket.com/albums/aa433/golfyste/0182.jpg)

Removed all the sound deadening from the back!

(http://i1197.photobucket.com/albums/aa433/golfyste/0222.jpg)

I have also cleaned up all the residue but didn't get a photo.

I then decided I was going to remove the sound deadening behind the dash and also remove the unwanted wiring including the airbag and rear speaker wiring and I am also going to reroute the wiring for the handbrake switch, fuel filler and alarm disable button.

what it looked like when i remember to take a photo...

(http://i1197.photobucket.com/albums/aa433/golfyste/0272.jpg)

I got as much as the sound deadening as I could without further stipping. and i took all the wiring back until I hit big bundles of wire and then cut and heat shrinked all the ends.

I have also being doing some more weighing!
so up to now we have got....

Front seats were 22kg each (which I think are lighter then the recaros

Back seats
Parcel shelf
Spare wheel
Some sound proofing (not all of it)
And a few bits of crap (2kg)

All added upto 45kg

few bits of trim including carpet - 10kg
stuff from rear side panels and handbrake cover - 2kg
Passenger airbag and control unit - 4kg
rear sound deadening - 5kg
wiring and dash sound deadening - 6kg

so up to now i have saved 116kg  :grin:

There is still loads of bits in the boot that I need to sell and the headlining etc but i will keep track of it all and when i'm done weight the car using the weighbridge at work!

Next up is reseal the drain plugs with new silicone
and try think of some more things I can do before I buy the rollcage which i will be ordering this month :evil:

O yes i also got this  :smiley:

(http://i1197.photobucket.com/albums/aa433/golfyste/0262.jpg)

but that is going to wait untill my shifter platform is finished which i cant do untill i have dropped my shifter which includes dropping the exhaust and heatshield  :undecided:
Title: Re: Golfyste's road legal mk4 "project track car"
Post by: stow1985 on 09 February 2013, 22:50
Love it!  :cool:
Title: Re: Golfyste's road legal mk4 "project track car"
Post by: golfyste on 09 February 2013, 23:57
Cheers mate  :cool:
Title: Re: Golfyste's road legal mk4 "project track car"
Post by: golfyste on 15 February 2013, 16:39
Ok sadly not too much to update on!

wanting to try sell some of the interior piece I have in the back of the car but I cant get rid so i may end up resorting to throwing alot of it away!

going to order the rollcage but need the space in the back of the car to put it in as soon as it comes so sort of stuck untill its all gone!  :undecided:

On a happier note I managed to grap a few bargains on ebay!

Picked a agu inlet manifold up for £24 delivered
(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02526.jpg)

Bought two LED strips which are going to be used for lighting the back of the car when the boot is open and i may use some for the front as the center dome light will be gone.
They are pretty good considering the massive 98p each i bought them for. nice and bright and also seem quite well made.
(http://i1197.photobucket.com/albums/aa433/golfyste/0DEC9259-7BBB-49AC-9CF8-EA50DEE08309-697-000000611E28696C.jpg)

And also found these on the bay!  :grin:

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02531.jpg)

at a nice price of £80 for the pair
one is in as new conidtion and one just has a little dirt splatter on.
they are out of date but there is no damage to them with all the stitching in as new condition and they also came with 12 eye bolts so wont be having to purchase any  :smiley:
Title: Re: Golfyste's road legal mk4 "project track car"
Post by: golfyste on 18 February 2013, 23:15
The cage and seats have been ordered  :grin:

Bought a omp cage with cross bar in the main hoop and v in the roof and door bar reinforcers.
one of the main reasons is due to its bolt in feature. As It just seems more practice for me than having to get someone to weld up all the tubes in the car!

I also read prawns build thread an asn and I think it's a good option.

Also just won some motordrive Kevlar seats on eBay. The covers are a little tatty but at £160 they will do to get me started and upgrading can come at a later date!
Title: Re: Golfyste's road legal mk4 "project track car"
Post by: Diamond Hell on 20 February 2013, 11:44
Does the cage have harness bars in it?  If not you should get these added to it - using the rear seatbelt mounting points to secure the shoulder straps is a really bad idea!
Title: Re: Golfyste's road legal mk4 "project track car"
Post by: golfyste on 20 February 2013, 13:19
It doesn't come with one but I will be adding one don't worry!
Would rather not have a crushed spine  :laugh:
Title: Re: Golfyste's road legal mk4 "project track car"
Post by: Dmonday on 20 February 2013, 18:58
Looks promising dude, what plans you got for the engine bar large port head? Might be worth running NA cams if you're going for a quick spooling turbo, hear the gains are beneficial :)
Title: Re: Golfyste's road legal mk4 "project track car"
Post by: golfyste on 20 February 2013, 19:37
Engine will be having a rebuild with uprated rods and lp head and manifold possibly with a custom plenum.
3" maf with fuel pump and Injectors to suit
Not 100% decided on turbo yet! I know dan beachbuggy turbos is working on a new k04 hybrid so may go that way!
I've not really heard about n/a cams so may talk to niick at r-tech about it as e will be tuning it  :smiley:
Title: Re: Golfyste's road legal mk4 "project track car"
Post by: Dmonday on 21 February 2013, 11:25
Sounds good man :) yeah its the route i'm taking with the large port head and NA cams, lad just made an extra 20bhp and 35ftq on a 300 horse 1.8turd with them! ;)
Title: Re: Golfyste's road legal mk4 "project track car"
Post by: golfyste on 21 February 2013, 21:22
hmm well as said I will talk to the guys at r-tech about it!  :grin:

OK a few little goodies arrived today  :grin:

First off the Motordrive seats arrived!

(http://i1197.photobucket.com/albums/aa433/golfyste/0032.jpg)

Happy to find that they weight a massive........6kgs each  :evil:

and then this beauty arrived  :cool:

(http://i1197.photobucket.com/albums/aa433/golfyste/0022.jpg)

cross brace in main hoop and roof and diagonal bar in the rear! also got door bars  :smiley:

Got a few jobs on tomorrow.
Removing the old seat rails with a drill and chisel and also going by Prawns advice and removing the thin crap on the inner sill (that is used to house the wires that go to the back of the car) so that the mounting points fr the cages feet have a nice and strong  :smiley:
Title: Re: Golfyste's road legal mk4 "project track car"
Post by: golfyste on 22 February 2013, 23:18
Ok so small update.

Done a little prepping today for fitting the cage.
Removed and bagged up everything that was in the back if the car and its being stores on the back garden wrapped in plastic sheeting haha
Took ages as I wanted to keep everything from gettin wet and also weighed it all  :smiley:

Weights -

Driver airbag
Seatbelts
Rear speakers and a couple of small bits
-8kg

Rear door cards - 4kg

Tailgate  and handbrake centre  - 3.5kg

Headlining stuff (abc) and carpet sides - 4kg

Random plastics and rear seatbelts - 4.5kg

So all together another 24kg  :smiley:

I then had to nip out for a spot weld drill bit as I couldn't find mine  :laugh:
(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02542.jpg)

I then set about removing the thin crap on the inner sills where the feet of the cage are going to be welded...
Before...

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02543.jpg)
(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02544.jpg)

After...
(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02547.jpg)
(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02546.jpg)

I then had to go to bed for an hours as I'm working nights  :laugh:
Gonna remove the headlining and try find somewhere to put it and then look at starting to fit the cage!   :grin:
Title: Re: Golfyste's road legal mk4 "project track car"
Post by: whileoceanasleeps on 23 February 2013, 13:19
looking good man!
Title: Re: Golfyste's road legal mk4 "project track car"
Post by: golfyste on 23 February 2013, 23:40
Cheers man  :cool:
Title: Re: Golfyste's road legal mk4 "project track car"
Post by: Wayne on 23 February 2013, 23:45
Might be worth looking at getting some p clips for the loom and fixing it back to the sill
Title: Re: Golfyste's road legal mk4 "project track car"
Post by: golfyste on 24 February 2013, 00:45
Yeah I will look I to but I know prawn had to locate his over the foot of the cage so gonna get it all in then mess with the small bits like that after  :smiley:
Title: Re: Golfyste's road legal mk4 "project track car"
Post by: golfyste on 26 February 2013, 21:44
Ok so a little update  :smiley:

Got a few bits and bobs done over the last couple of days.

Got the headlining out and removed the board on the roof at the front...which was loads of effort and was as light as a feather so I left the back one in  :laugh:
Sadly I didn't get any pictures but its only simple stuff.
I also repaired all the little tears in the seats I bought. only planning on keeping them for a short while to start with before upgrading but didn't want them to get any worse.

Today I set about getting the dash back in and removing all the crap out of the car that wasn't needed!
(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02549.jpg)

Got it all bolted back in fine and lost a few bits I didn't need like the trim above the drivers feet.
(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02550.jpg)

How the car was looking at dinner time today...
(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02550.jpg)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02550.jpg)

Then I spent the afternoon cleaning up the cage including any surface rust and then applied a coat of primer just to protect it...(sorry for the dodgy photos  :undecided:)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02554-1.jpg)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02554-1.jpg)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02559.jpg)

I also painted the sleeves that join the cage together to test the red paint I bought...

Now I don't know what's happened with these pictures put they look orange but they aren't!  :laugh:
They are actually bright red! will get better photos tomorrow!
(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02557.jpg)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02558.jpg)

Then spent the rest of the afternoon getting the cage into the car!
Its in! ish  :laugh:
Sort of in the right place but gonna join it all up tomorrow and get it sitting perfect!

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02560.jpg)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02561.jpg)
Title: Re: Golfyste's road legal mk4 "project track car"
Post by: golfyste on 26 February 2013, 21:54
O yeah.....

I think I may have had somewhat of a influence on my family  :grin:

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02548.jpg)

 :laugh:
Title: Re: Golfyste's road legal mk4 "project track car"
Post by: golfyste on 27 February 2013, 11:10
(http://i1197.photobucket.com/albums/aa433/golfyste/6F6B2679-BE6D-4461-8A15-DB20EC2CBA43-173-0000000550C0C61C.jpg)

There we go  :grin:
Title: Re: Golfyste's road legal mk4 "project track car"
Post by: Diamond Hell on 27 February 2013, 17:29
Get some harness bars welded in that rear section before you go much further!
Title: Re: Golfyste's road legal mk4 "project track car"
Post by: golfyste on 27 February 2013, 17:54
Harness bar and door bars are being welded in once its in and solid  :cool:

Been at it all day but haven't seemed to get loads done haha

Will update later
Title: Re: Golfyste's road legal mk4 "project track car"
Post by: golfyste on 27 February 2013, 22:12
Ok so put a lot of hours in today but didn't seem to get very far!  :laugh:
But i know it's a awkward process and i was on my own for 80% of the day so not letting it get me down.

Started by taking advice from prawn by cutting off the tabs on the main hoop before going any further as they are for if you have a 5 door model and are plaing in the way on a 3 door.
Before..
(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02564.jpg)

During...
(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02565.jpg)

After...
(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02566.jpg)

Not the best job but you see it anyway because of the b pillar  :rolleyes:

I then set about getting the 2 parts of the cage together which was a PITA!  :laugh:
(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02567.jpg)

Because there is a little play when the sleeves are and before you tighten them on to allow fitment it was really awkward on my tod  :laugh:

I eventually got it all together and set about trying to get it in the right position!
Tried using bricks  :laugh:...
(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02568.jpg)

but it was really hard work with alot of pulling, pushing and sliding about but i finally got it in a place which i think is suitable!

Front foot (is actually very slightly different now but kept forgetting to take photos as i was in concentration mode haha)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02569.jpg)

rear foot

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02570.jpg)

Front drivers side foot...
(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02570.jpg)

you can see on the drivers side how it does fit over the sill and this is because it comes into contact with the door so im thinking about ripping the door cards out and making some!

Didn't get any photos but i got it where i wanted it and got the two arch feet secured into place so i can now start fabricating the feet for the front and mid feet  :cool:

This is how i left it at the end of the day!

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02572.jpg)

Title: Re: Golfyste's road legal mk4 "project track car"
Post by: whileoceanasleeps on 28 February 2013, 09:49
good work man keep the updates and photos coming!
Title: Re: Golfyste's road legal mk4 "project track car"
Post by: golfyste on 01 March 2013, 21:37
Cheers man  :cool:

Not to much progress yesterday or today as yesterday I had to finish early to go fix my brothers heating and today I've been on the push iron all day!

But anyway I got a little bit of design done for the feet on the Main hoop!
Just used cardboard to make the required shapes which will be cut out of 3mm steel.

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02573.jpg)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02574.jpg)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02576.jpg)

Think I'm going to use the plasma cutter at work to cut the steel to shape ready for welding  :smiley:
Title: Re: Golfyste's road legal mk4 "project track car"
Post by: jonrandom on 02 March 2013, 17:47
Some good work mate looking forward to more updates  :smiley:
Title: Re: Golfyste's road legal mk4 "project track car"
Post by: whileoceanasleeps on 02 March 2013, 20:21
are you going to weld the cage to the plates or bolt it down?
Title: Re: Golfyste's road legal mk4 "project track car"
Post by: golfyste on 03 March 2013, 16:41
Cheers lads!
Was occupied with a stag do all yesterday so not really been in the mood today haha
....but! I have just fetched a aum engine to start rebuild and messing with!  :grin:

I think I'm just going to bolt it down....someone mentioned something against welding it but I can't remember what....
Title: Re: Golfyste's road legal mk4 "project track car"
Post by: golfyste on 09 March 2013, 18:41
Ok time for a little update

Didn't do much last week dues to going on a stag do and also working (I work 12 hour shifts so don't get any spare time for the car when working but have lots of time off  :grin: )

I made a start on the custom seat rails!
the plan is to make some temporary mounts for these seats as they are base mounted and i will be looking at upgrading later in the year.

So the plan is have two brackets with flat plate going across that the seats can bolt to.

The brackets
(http://i1197.photobucket.com/albums/aa433/golfyste/0263.jpg[/IMGi thought about bolting these to the original seat rails as they are temporary and dont really want to weld anythin in that will be in the way of the side mounted seats i want.....BUT..... i wasnt very happy ...[IMG]http://i1197.photobucket.com/albums/aa433/golfyste/0253.jpg)

as you can see the rails are very slanted and quite far back which makes the seat sit very close to the cage actually hitting it unles you raise the back end up and there isnt really any space to adjust forward...

(http://i1197.photobucket.com/albums/aa433/golfyste/0062.jpg)

(http://i1197.photobucket.com/albums/aa433/golfyste/0072.jpg)

(http://i1197.photobucket.com/albums/aa433/golfyste/0052.jpg)

The original seat rails also don't seem very strong so i think i will be fobbing that idea off and welding some box section across and bolting to that!

I also picked a aum engine up at the start of the week with harness, ecu, lambdas and pretty much everything left on like alternator, coilpacks etc etc for a nice price of £350  :smiley:
(forgot to get a photo before i tucked it away  :laugh:)

then we skip to today where these arrived!  :grin:
(http://i1197.photobucket.com/albums/aa433/golfyste/0092.jpg)

a nice set of AGU pistons.....but on a letter inside he has written AGU/BAM pistons.
Now i know they are both 20mm gudgen pins but if im correct the AGU are 9.5 CR and the BAM are 9 or 8.5 CR so how can i tell the difference??   :huh:

more pics....

(http://i1197.photobucket.com/albums/aa433/golfyste/0102.jpg)

(http://i1197.photobucket.com/albums/aa433/golfyste/0112.jpg)

Then this morning i had a job fixing a s***y corsa  :laugh: (crankshaft sensor and lambda)
Then had some dinner and got on with sorting the feet for the cage  :cool:

Now I need to say Both mine and my dads welding is half decent (dads is better) but our mig welder is a pile of crap (completely packed up later on) so it was a case of welding then grinding then welding etc to make sure we got it all nice and strong  :wink: (so dont worry if you see a crappy weld on one of the photos  :laugh:)

All the template had been cut out oversized by my dad at work on the plasma so was a case of trimming and then tacking.

first one tacked in place....
(http://i1197.photobucket.com/albums/aa433/golfyste/0122.jpg)

and then we skip a while due to me getting stuck in and forgetting about the camera   :rolleyes:

Inside welded up  :smiley:
(http://i1197.photobucket.com/albums/aa433/golfyste/0163.jpg)

Welded up and in place....
(http://i1197.photobucket.com/albums/aa433/golfyste/0142.jpg)

Passenger side all welded up  :cool:
(http://i1197.photobucket.com/albums/aa433/golfyste/0173.jpg)

And in place
(http://i1197.photobucket.com/albums/aa433/golfyste/0173.jpg)

(http://i1197.photobucket.com/albums/aa433/golfyste/0193.jpg)

(http://i1197.photobucket.com/albums/aa433/golfyste/0203.jpg)

(http://i1197.photobucket.com/albums/aa433/golfyste/0213.jpg)

and then when trying to mess with the welder to trying to get it to give a better weld it decided to blow a fuse and then completely pack up so its all on hold to we can sort somethin out  :sad:

Also have this small piece on angle to weld on the transmission tunnel to allow the shifter frame to bolt straight...
(http://i1197.photobucket.com/albums/aa433/golfyste/0232.jpg)

Just a look at how it will sit  :smiley:
(http://i1197.photobucket.com/albums/aa433/golfyste/0243.jpg)

So now I need to decided what i can do while i wait for a welding solution  :laugh:
Title: Re: Golfyste's road legal mk4 "project track car"
Post by: Diamond Hell on 20 March 2013, 19:25
Just looking through this at your feet for the cage.  If you might want to enter any sort of competition in the future I would recommend you get some reinforcement plates laid around the bottom of those foot boxes.

Have a look at page 177 in the Blue Book for correct footplate construction:

http://www.msauk.org/uploadedfiles/msa_forms/bluebooks/11/152-190%20Competitor%20Safety.pdf

Note no vertical bits of 3mm steel pointing down at the floor of the car.

I know it might seem like ballache, but if you're doing something like this you want to get it right - that's why I had an experienced guy come round last week and talk through what we're doing with Dave's install.
Title: Re: Golfyste's road legal mk4 "project track car"
Post by: golfyste on 20 March 2013, 22:15
Hmmm so I could just add some bits to the feet where they all point down to make it bend outward a and sit flat?
Tbh I don't have any plans of competing partly because of the cost of getting all in date seats, harnesses and what not buy it would be nice to know I could if I wanted
Still on hold as I need I sort my welder out  :undecided:

As a side not I purchased some tt225 hubs and quick rack  :grin:
Title: Re: Golfyste's road legal mk4 "project track car"
Post by: Diamond Hell on 20 March 2013, 22:23
You need to pretty much put some strips of metal under where the boxes will land and weld those strips to the floor of the car, to provide a reinforced landing location to spread any forces from the cage feet.  Once that's done, weld the boxes on top of those.

It depends on the discipline you're doing as to whether everything has to be in-date.
Title: Re: Golfyste's road legal mk4 "project track car"
Post by: golfyste on 20 March 2013, 22:36
Ahhh I see
Will look at doin that then doesn't sound like to much work  :smiley:
Hmm possible then but I don't think it's going to be in the near future  :laugh:
Title: Re: Golfyste's road legal mk4 "project track car"
Post by: golfyste on 31 March 2013, 17:59
Ok I haven't update for a while but there has been a reason!  :laugh:

Me and a few friends went to a cafe in the peak on the morning of Friday the 22nd...then went for a little walk...nice little place

(http://i1197.photobucket.com/albums/aa433/golfyste/12622B99-5492-41FE-9589-306AD99628AF-2049-0000021A8F95F58B.jpg)

On the way back had I stop a couple of times to dig the car out due I the snow getting worse!
(http://i1197.photobucket.com/albums/aa433/golfyste/A978CA84-9BDF-4E86-8CC4-99928587888A-4441-000003CF2903AB6B.jpg)

Then came down a road to this!
(http://i1197.photobucket.com/albums/aa433/golfyste/4DE4BFF5-8F4B-4CFA-8632-10EC9EDA30FA-2049-0000021A9B08A04E.jpg)
(http://i1197.photobucket.com/albums/aa433/golfyste/48673EF3-52DE-4708-8A98-28C60D7A2864-2049-0000021A9751E30D.jpg)

Yes there is two cars there!
The snow was drifting really bad and to cut it short we got the car turned around but couldn't get off the road so had to abandon the car.

Couple of 4x4's give us a left to a nearby pub
Can to pick the car up a day later and was met with this....

(http://i1197.photobucket.com/albums/aa433/golfyste/76325B56-B876-475F-8401-D99460E5BCD3-2089-000002549F92DB66.jpg)

The whole road for 500m was 4-8foot under snow  :cry:

Spent a pod while digging over the next few days!
(http://i1197.photobucket.com/albums/aa433/golfyste/3B41DDAE-F370-4EFA-8BF8-E6FF8EFC07E5-4441-000003CEC4960763.jpg)
(http://i1197.photobucket.com/albums/aa433/golfyste/25B83D30-582B-40D0-9E28-EEA2C9A38345-4441-000003CEB999C7A1.jpg)

Went back in Thursday after reporting to council/highways as we met a guy who lived on the road and couldn't get to his house!
As a jcb had been down  :grin:
(http://i1197.photobucket.com/albums/aa433/golfyste/1410BD5A-C9C8-4664-9188-E40A95A4D0BA-4441-000003CF23272E57.jpg)
(http://i1197.photobucket.com/albums/aa433/golfyste/B3E61997-3779-48F8-BE24-30B8FE9FB243-2089-00000254D7E87B57.jpg)
(http://i1197.photobucket.com/albums/aa433/golfyste/14BB3C3A-ACCA-41F0-88B9-B01DE102F220-2089-00000254F150BCB4.jpg)
(http://i1197.photobucket.com/albums/aa433/golfyste/2C624F5C-9FB7-4632-B87C-87F4DDC369E3-2089-0000025507EDB5F9.jpg)

Did some more digging!
(http://i1197.photobucket.com/albums/aa433/golfyste/122AD362-13A9-4520-BBE1-5EFA04858CE5-2089-000002551B1CFBC9.jpg)

And hallelujah!
http://youtu.be/JoOTzNvxaCc

Well that was a fun week  :laugh:
Title: Re: Golfyste's road legal mk4 "project track car"
Post by: Diamond Hell on 31 March 2013, 22:33
Your other half's good with her finger and the lens, isn't she?!

The snow thing happens to the best of us:

http://www.youtube.com/watch?v=vEsrpcEx_J0
Title: Re: Golfyste's road legal mk4 "project track car"
Post by: golfyste on 31 March 2013, 23:02
That's my mother!  :laugh:
Not the best with a iPhone  :grin:
Good effort there what car was it?
Title: Re: Golfyste's road legal mk4 "project track car"
Post by: Diamond Hell on 01 April 2013, 10:03
That's my Passat 4Mo.  It's f*cking great in snow, until it runs out of ground clearance..... in a 4' deep drift.
Title: Re: Golfyste's road legal mk4 "project track car"
Post by: golfyste on 01 April 2013, 10:06
Haha could tell it was doing well but even the landys I had helping me recover the car couldn't get trough it!
Title: Re: Golfyste's road legal mk4 "project track car"
Post by: golfyste on 07 April 2013, 21:51
Ok time for a update
Not been on top of this due to some other thiga getting in the way and tryin to source bits!!

But in the little spare time I have had I have manage to do a few bits!

So got aroun to sorting the cupra r wishbones!
Removed all the old bushes ready for the polybuhes I need I buy.
(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02604.jpg)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02600.jpg)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02601.jpg)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02599.jpg)

Then got around to giving them a coat of paint...

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02603.jpg)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02602.jpg)

Then Give them another

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02605.jpg)

Then cleaned up a spare subframe I had and removed the bushes

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02606.jpg)

Then painted...

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02607.jpg)

Now I just need to order the bushes for everything caster increase for the wishbones and solid fr the subframe.

Also had a pair of seat mounts arrive. Just need to make a angled piece of plate to use them with my bottom mounted seats....

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02608.jpg)
Title: Re: Golfyste's road legal mk4 "project track car"
Post by: golfyste on 10 April 2013, 19:08
More bad news!  :angry:
Looks like the diff has gone on my daily so going to have to find time to switch the gearbox on that .....BUT! There is some good news......

More car parts  :grin:

Agu large port head arrived today  :grin:
(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02612.jpg)

Along with the Cupra r rack and hubs  :cool:
(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02610.jpg)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02609.jpg)

Have a steering wheel an boss comin soon too  :smiley:

Sent the welder off to try and diagnose what's wrong with it

Jobs on the todo list are to strip the hubs and refurb them with new bearings and also drop the sump on the current engine to try suss the damage that had been done so I can fix it up and sell it to make room for the aum engine I will be rebuilding with all the uprated parts  :smiley:
Title: Re: Golfyste's road legal mk4 "project track car"
Post by: golfyste on 11 April 2013, 21:15
Wheel and boss cane today  :cool:

Just a cheap wheel for £20 to get me going  :smiley:
(http://i1197.photobucket.com/albums/aa433/golfyste/2D9450B3-6C28-427C-85AC-DED926F3625E-4038-0000039D8AAE007C.jpg)

And a momo boss for a amazing £12  :grin:
(http://i1197.photobucket.com/albums/aa433/golfyste/C423AB9C-7723-48F5-9120-44EE84D5AAED-4038-0000039D9526D673.jpg)

(http://i1197.photobucket.com/albums/aa433/golfyste/E25B7D0B-779E-41C0-B3D6-942C93F5E67D-4038-0000039D9B98EF8D.jpg)

(http://i1197.photobucket.com/albums/aa433/golfyste/A8DC54CD-F838-49FE-835E-44468D036C71-4038-0000039DA4E64C6C.jpg)
Title: Re: Golfyste's road legal mk4 "project track car"
Post by: golfyste on 17 April 2013, 17:58
Ok time for another update if anyone is reading  :laugh:

Sent the welder to get fixed on the weekend (came back today)
So while that was gone I decided to start striping the cupra r hubs ready for new bearings and a lick of paint.

Did the usual pushed the centre out....
(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02616.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02616.jpg.html)


and of course the inner race of the bearing went with it  :angry: ..... on both!  :angry: :angry:

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02617.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02617.jpg.html)


So anyway set about getting it off so whipped the grinder out! And cut as close as i dared to the shaft  :laugh:

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02618.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02618.jpg.html)

I removed the inner races and then tried removing the rest of the bearing and failed miserably haha so my dad took it to work with him and used the hydro press ... took a full 10tonne!  :grin: so no wonder i couldnt getting it out with a hammer, socket and vice  :laugh:
My dad also took the agu rocker cover with him to sandblast as it was in a sorry state  :sad:

Me and my mate (rylarr off here) then set about stripping the engine to find what was wrong with it
When i originally bought the car the seller wasn't very specific he just said there was some sort of engine damage due to a shortage of oil......What he did say that i didn't acknowledge/forgot about was that it did start but would need trailering......so

we removed the sump and i checked the bigends and the main bearings which were completely spotless with no wear  :cool:

sump off
(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02621.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02621.jpg.html)

I also checked the bores with a torch and there were no marks or ridges. nice and smooth  :smiley:

we then had the rocker cover off and checked the cams were again were completely fine with not much wear  :cool: (only got one photo  :sad:)

ryan removing the rocker cover

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02620.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02620.jpg.html)

So the conclusion was there is no engine damage which i when i actually rethought about what the seller had said (starts etc) and realised i was thinking in the wrong area......so we started to remove the turbo  :grin:

we managed to get the turbo out :smiley:

and found this  :laugh:
http://youtu.be/C6xfI71HBek

So this is where i stood as the start of another day
(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02625.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02625.jpg.html)


Agu head with SB rocker cover

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02622.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02622.jpg.html)


Cupra r hubs with bearing removed

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02623.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02623.jpg.html)


The car with its thinking face  :grin:


(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02626.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02626.jpg.html)


the the turbo was out i removed the downpipe so i could remove the shifter that i have been waiting to remove for a while ha


(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02633.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02633.jpg.html)



The next day I felt like starting another little job before going back outside so i decided i would modify my door card.
i had to remove it due to it not allowing the door to close with the cage in sooooo i took a few measurements and started chopping  :laugh:

Before  :smiley:
(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02627.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02627.jpg.html)

Peeled back the foam/fabric
(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02628.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02628.jpg.html)

Measured/marked and cut  :smiley:
(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02629.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02629.jpg.html)]

I then cut another line (forgot to take a photo) about 75mm to remove a section
I then used small cable ties to stitch  the two pieces back together  :grin:
(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02632.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02632.jpg.html)

And then used some tiger seal to smooth it out
(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02631.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02631.jpg.html)


I then left that dry and set about putting the spare turbo i had onto the car so I could test fire it!  :smiley:
I didnt get any pics putting the turbo back as i was alone and its a simple process haha but here we are afterwards
(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02634.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02634.jpg.html)

Just needing some oil and a start.

So today was D-day  :laugh:

I filled the car with oil and went to start it......Only to find the immobiliser was activated!!  :angry:
Although the car did start straight away (then cut out due to IMMO) and it sounded good.
But i didnt know where to start with the immo so did some reaserch and tried a few things like checking the plugs on the clocks discharging the circuit from battery etc etc eventually what worked was leaving the battery on charge while connected to the car and leaving the ignition on for about 45 min and the immo light stopped flashing  :laugh:
so started her up and it seemed ok  :grin:
no knocking etc but as i had expected as soon as i touched the revs there was low oil pressure so i shut her off.

the pick up pipe was a bit dirty when i dropped the sump but i cleaned it out so im thinking it may be the oil pump so gonna have to get it switch as the next job  :smiley:

I left it at that and decided to finish my door card  :smiley:

The new shortened door card with the fabric stuck back on using fabric spray adhesive
(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02635.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02635.jpg.html)

And the excess cut (Not the neatest but its strong stuff!  :grin:)
(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02636.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02636.jpg.html)

I then set about gluing it back into the door card with some assistance from the missus  :laugh:
(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02637.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02637.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02638.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02638.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02639.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02639.jpg.html)

I think it looks pretty tidy for a bodge job  :laugh:
(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02640.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02640.jpg.html)

I then got it installed back into the car and it fits mm perfect  :grin:
(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02642.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02642.jpg.html)

It still touches but only ever so slightly with no actual pressure  :smiley:
(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02643.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02643.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02641.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02641.jpg.html)


Thats it for now next jobs are change the oil pump in the engine and also the welder came back so finish the feet for the cage, do the shifter frame and also the seat mounts  :grin:
Title: Re: Golfyste's road legal mk4 "project track car"
Post by: Rylarr on 17 April 2013, 19:17
Cheeky photo doing the rocker cover :smug:
Title: Re: Golfyste's road legal mk4 "project track car"
Post by: Dave_IOW on 18 April 2013, 23:55
Fella, I feel your pain on the cage side of things, in, out, in, out!

We're building my feet up inside the car so have to keep testing it at every stage.

Looking forward to seeing updates :smiley:
Title: Re: Golfyste's road legal mk4 "project track car"
Post by: golfyste on 18 April 2013, 23:57
Yeah I know just been pm'ing DH haha

I now have a pretty good idea of what I need to do with them and took some measure measurements today will be doing some more tomorrow so will update... :smiley: cheers pal
Title: Re: Golfyste's road legal mk4 "project track car"
Post by: Dave_IOW on 19 April 2013, 00:00
Yeah I know just been pm'ing DH haha

I now have a pretty good idea of what I need to do with them and took some measure measurements today will be doing some more tomorrow so will update... :smiley: cheers pal

I was told, hadn't posted on here so hadn't seen your build thread since page 4, seems your plans have changed drastically :laugh:
Title: Re: Golfyste's road legal mk4 "project track car"
Post by: golfyste on 19 April 2013, 00:06
 :laugh: they haven't as such changed just I have been making list after list and put all the important things at the top and been doing plenty of research etc
Plus the shift rota I work gives me quite a bit of time off so have been doing as much as possible  :grin:
Title: Re: Golfyste's road legal mk4 "project track car"
Post by: golfyste on 19 April 2013, 23:16
Ok bit of a update.

Something I keep forgetting to mention is i bought i Aum engine with all the loom, ecu, ancillaries, lambdas etc, i wanted the loom, ecu and lambdas and vvt tensioners and the whole lot came up cheaper then waht it would have been to buy them separately so i snapped it all up.

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02644.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02644.jpg.html)

 
So Firstly yesterday i started by testing the oil Pressure. so i removed the oil pressure sensor on the filter housing and to my surprise i had 75 psi at 2000 rpm....but was getting a low OP warning on the dash. I then noticed that the OP sensor i had removed was suspiciously shiny.....

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02658.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02658.jpg.html)

It also had no markings on etc. i then have a little thought train going as i had a dead turbo but had good oil pressure a Op warning and the pick up pipe was pretty much clean (just a bit down the edges)

So what i think has happened with the previous owner is:
pick up pipe blocked and brought up low oil pressure
He changed the oil pressure sensor with a cheap nasty one and was still getting warning light
carried on driving and killed the turbo
Took it to a garage and they had the sump off and cleaned the pick up pipe
was still getting low oil pressure so sold it as spares and repairs.

And all i have had to do is swap the turbo and the OP sensor off my spare engine and all is good  :grin:
So I started up the engine and it purrs like a little kitten!

Engine all back together:
(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02646.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02646.jpg.html)

Running...

(http://i1197.photobucket.com/albums/aa433/golfyste/th_M4H02651.jpg) (http://i1197.photobucket.com/albums/aa433/golfyste/M4H02651.mp4)


So i think the plan is to sell the current ARZ engine as it can be heard running and hopefully get my money back from what i spent on all the AUM stuff (which i should easily and may even make some  :grin:) And then rebuild the AUM block and use that with the AGU head wideband lambda and vvt etc

So i have gone from confused to feeling quite positive i just need to shift the ARZ lump now so i can tidy up the bay with any new fuel lines, heat shielding etc needed and start purchasing bits to do the engine build  :grin:
 
I then spent a good while tidying up the garge and create a space in the corner which will the the engine build area  :laugh:
Its not the biggest area but we are also making a attachment for the engine lift to convert it into a engine stand which will come in handy  :smiley:
not massive but all the bit and bobs around the cloth on the floor (toolboxes fire extinguisher etc) will be moved  :laugh:

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02671.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02671.jpg.html)

Then on to today....it crazy how jobs that you imagine are quite small turn out to take forever!! haha
Been outside from 12 - 9 so a nice long day  :laugh:
started by removing the old seat rail by drilling the spot welds

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02659.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02659.jpg.html)

I think this is my new most hated job haha as it just seemed to drag

I then set about making the plates to weld onto the cage feet to distribute the weight (opinions DH?)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02662.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02662.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02665.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02665.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02666.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02666.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02664.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02664.jpg.html)

I'm just going to spot weld them together in a couple of groups and then fully weld the together and grind them to make them solid then weld them to the boxes and then to the floor

I then ground all the spot weld back as that is where the seat rails shall be welded this took a good while and wasn't a very comfy sitting position!

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02670.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02670.jpg.html)

I then measured and cut the 4 end plates for the seat bars and also two plates to go under the 2 rear points of the cage that go onto the rear wheel wells to help distribute the weight a little.

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02667.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02667.jpg.html)

I then started making the right angle seat rails that will allow me to use normal seat mounts on my bottom mounted seats by cutting some metal i had already fab'd.

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02668.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02668.jpg.html)

I then decide dit was dark and i was hungry so left it there  :grin:

tomorrow ive got a job on a almera that has failed it MOT and then i will be looking at doing some welding of the cages feet boxes and some other bits  :smiley:
Title: Re: Golfyste's road legal mk4 "project track car"
Post by: Diamond Hell on 19 April 2013, 23:29
Remember those rear stays need 60sq cm of 3mm steel under them.

Flares for the floorpan look good, just remember when you're welding them up that the metal may pull around a bit with the heat, so keep an eye on what's happening.

Looks like you're ground the weld back on the foot-boxes - bit of a no-no for any scrutineering  :cry: They really wanna see your beads!

(sorry)
Title: Re: Golfyste's road legal mk4 "project track car"
Post by: golfyste on 19 April 2013, 23:41
Are the rear stays the centre feet or the wheel well points??
Sorry still learning the lingo  :laugh:

The 2 rear points will have 105 sqcm with 190mm x 60mm
An the centre feet come in at about 130 sq cm  :smiley:

Yeah I will just take it slow so it doesn't get to much heat in and give it good few tacks to keep it in place.

Yeah it's because of the problems we were having with the welder I wanted to make sure they were all good welds.
I can always run another Weld down all the corners  :smiley:
Title: Re: Golfyste's road legal mk4 "project track car"
Post by: Diamond Hell on 21 April 2013, 01:30
Sounds all good.  Rear stays are the tubes that go to the rear wheel-wells.
Title: Re: Golfyste's road legal mk4 "project track car"
Post by: golfyste on 29 April 2013, 13:37
Ok so had a fair bit of progress but had a few problems, quite stupid of me and could have been a disaster but all is good and lessons learnt and back on the positive now
Will update later  :smiley:
Title: Re: Golfyste's road legal mk4 "project track car"
Post by: golfyste on 29 April 2013, 21:20
OK update time

Started to get the centre feet welded into car.
I need to say some of the welding at this point is abit crap but since we did this i have been practicing and actually quite happy with the quality of weld i am getting now so will be getting busy with the grinder and redoing the welding so its up to scratch!

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02673.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02673.jpg.html)

And the drivers side

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02674.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02674.jpg.html)

And this is where the disaster happened  :undecided:
As said before i made a rookie mistake and forgot about the fuel lines running underneath the car  :embarrassed:
As a result when welding the foot to the car its melted one of the fuel breather pipes behind it and gave off a few flames! so welding was stopped until the tank was removed and down the garden.
It could have gone alot worse but we were lucky but have learnt a lesson and it wont be happening again!

So while waiting for a full day to get to work on the removing the tank as the rear beam needed to be dropped we got on with messing with the shifter platform.
Managed to get it sitting perfectly.
(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02679.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02679.jpg.html)

we will be welding reinforcement plated to the bars but having it bolted in places is to just locate it so i can make all the sheet steel sides etc and then can remove it to weld on the tabs that the sheet will bolt to  :smiley:

Had a brainstorm and decided we needed to modify the shifter for it all to work
(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02675.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02675.jpg.html)

What the top plate will be like...
(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02680.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02680.jpg.html)

And where the shifter will sit...
(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02681.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02681.jpg.html)

going to weld 3mm steel between the bars for the shifter to bolt too to ensure its rigid  :smiley:


We then got a full day so got on with removing the rear beam and tank so we could carry on welding safely.
Ryan removing the rear shocks   
(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02682.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02682.jpg.html)

Rear beam off
(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02684.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02684.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02685.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02685.jpg.html)

It then started hailing!! so we decided to go in the garage and refurb the rear beam and hope the weather brightened up!

Stripped down, Cleaned up and started to paint it
(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02686.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02686.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02687.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02687.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02688.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02688.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02691.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02691.jpg.html)

Removed all the hubs as im going to purchase new ones so i know they're top notch  :cool:

The weather then cleared up so resumed with removing the tank

exhaust dropped
(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02694.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02694.jpg.html)

And its gone  :smiley:
(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02695.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02695.jpg.html)

And its out!
(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02692.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02692.jpg.html)

the breather pipe that got melted  :undecided:
(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02693.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02693.jpg.html)

luckily it missed the main fuel line!

We then got around to welding the rear stay plates in place.
i made them quite big as the rear stays dont sit perfectly to the rear well so i have had to use a spacer under it for the bolt to go through and then as a extra measure have welded a piece of 3mm plate in there  :smiley:

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02712.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02712.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02713.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02713.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02710.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02710.jpg.html)

Sadly while welding the plates in the arch liner decided to set alight and melt!
Not particularly lucky with the whole melting thing!

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02683.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02683.jpg.html)


We then got around to making up the front feet  :cool:
Offside foot
(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02700.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02700.jpg.html)

Drivers side
(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02702.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02702.jpg.html)

Welding is getting better  :smiley:
(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02696.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02696.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02697.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02697.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02698.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02698.jpg.html)

Main plated for the feet finished  :cool:
Fit nice and snug but during welding there was slight pull from the heat so i have decided to bolt the bottom plate to the floor with a 3mm plate under the car to pull it down slightly and then it will be welded  :smiley:

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02703.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02703.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02704.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02704.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02705.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02705.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02706.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02706.jpg.html)

In position
(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02707.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02707.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02708.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02708.jpg.html)

We have now started making up the side plates but they arn't finished yet but at least we can see a bit of progress now  :smiley:

Last but not least i took some measurement and drew up a diagram
(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02709.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02709.jpg.html)

Any guess as to what its for??  :grin:
Title: Re: Golfyste's road legal mk4 "project track car"
Post by: golfyste on 29 April 2013, 21:26
Also these arrived to aid the engine build  :cool:

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02714.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02714.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02715.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02715.jpg.html)

And also ordered some polys for the rear beam  :cool:

went for the black series bush
(http://i1197.photobucket.com/albums/aa433/golfyste/T2eC16dysE9sy0jLFoBRZk6LbOQ60_12-1.jpg) (http://s1197.photobucket.com/user/golfyste/media/T2eC16dysE9sy0jLFoBRZk6LbOQ60_12-1.jpg.html)
Title: Re: Golfyste's road legal mk4 "project track car"
Post by: Diamond Hell on 29 April 2013, 22:09
We only had to use the extinguisher once last week on Dave's Golf.  :grin:

Unfortunately when there's several hundred degrees of metal being sprayed about fire is pretty likely.

I think Dave might need new fuel lines.  :whistle:
Title: Re: Golfyste's road legal mk4 "project track car"
Post by: golfyste on 29 April 2013, 22:25
We have had a few mini fires from all the underseal!
Think it will need redoing once we are finished!
Title: Re: Golfyste's road legal mk4 "project track car"
Post by: Dave_IOW on 29 April 2013, 22:41
Yes my fuel lines also went up in flames, luckily there wasn't anything in mine :whistle:

These things happen :grin:
Title: Re: Golfyste's road legal mk4 "project track car"
Post by: golfyste on 30 April 2013, 05:54
Guess that makes me feel a bit better  :laugh:
Title: Re: Golfyste's road legal mk4 "project track car"
Post by: Diamond Hell on 30 April 2013, 10:41
Dave spent quite a lot of time while I was welding, giving his car a blowjob due to the underseal getting pretty feisty.  :grin:
Title: Re: Golfyste's road legal mk4 "project track car"
Post by: golfyste on 30 April 2013, 18:18
Dave spent quite a lot of time while I was welding, giving his car a blowjob due to the underseal getting pretty feisty.  :grin:

 :laugh: it is a bit of a nuisance haha
Title: Re: Golfyste's road legal mk4 "project track car"
Post by: golfyste on 30 April 2013, 23:25
DH are these gas welds on the feet ok or am I better running a weld across with the mig?
http://s1197.photobucket.com/user/golfyste/media/DSC02674.jpg.html


Scrap that just seen the feet on daves mk2 and I'm gonna run around it with the mig  :grin:
Title: Re: Golfyste's road legal mk4 "project track car"
Post by: Dave_IOW on 30 April 2013, 23:30
DH are these gas welds on the feet ok or am I better running a weld across with the mig?
http://s1197.photobucket.com/user/golfyste/media/DSC02674.jpg.html


Scrap that just seen the feet on daves mk2 and I'm gonna run around it with the mig  :grin:

:grin:

They came out really well tonight, extremely pleased!
Title: Re: Golfyste's road legal mk4 "project track car"
Post by: golfyste on 30 April 2013, 23:31
I need to get some practice with welding the 3mm to the thinner floorplan as too not burn through it!
I'm sure I will get there......eventually!

Yeah yours are looking very tidy I would be happy!
Title: Re: Golfyste's road legal mk4 "project track car"
Post by: Dave_IOW on 30 April 2013, 23:34
I need to get some practice with welding the 3mm to the thinner floorplan as too not burn through it!
I'm sure I will get there......eventually!

Yeah yours are looking very tidy I would be happy!

I hear it's all about practice, DH's had a lot.

I make good tea :laugh:
Title: Re: Golfyste's road legal mk4 "project track car"
Post by: golfyste on 30 April 2013, 23:36
Nothing can be mastered without a good cup of tea in hand  :grin:
Title: Re: Golfyste's road legal mk4 "project track car"
Post by: Diamond Hell on 30 April 2013, 23:52
The key is quite high power and spend as much time as possible on the 3mm and as little as possible on the car steel and move FAST when you're on it.

Where there was some space to fill I also ran a really quick bead down the car steel where the join would be, to give me a bit more metal to hook the main bead on - stops you blowing holes.  Don't be afraid to pause regularly too to let things cool a little.
Title: Re: Golfyste's road legal mk4 "project track car"
Post by: golfyste on 01 May 2013, 06:09
Ok cheers dude gonna try get some practice with similar metal before I move onto the car  :smiley:
Title: Re: Golfyste's road legal mk4 "project track car"
Post by: golfyste on 06 May 2013, 22:57
Ok so I a little update over the last few days

The rear beam bushes arrived so me any Ryan set about removing the ld bushes by drilling the rubber and then forcing it out with a nice sized screwdriver and a hammer  :laugh:

We then cleaned up the surfaces using a drill and flapper wheel

Before -
(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02718.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02718.jpg.html)

During -
(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02716.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02716.jpg.html)

After  :smiley:
(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02721.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02721.jpg.html)

We then had a bit of worry that the bushes wouldn't fit due to the hole being 69mm and the bush being 72.5mm but after some research it turned out they just need forcing in so they compress

We then did some work on the front cage feet and got the drivers side plates made
(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02722.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02722.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02723.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02723.jpg.html)

Then a day was spent fetching Ryan's new golf "Sargent NEJ"  :grin:
The first fuel up!

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02726.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02726.jpg.html)


Today we got the rear beam polys fitted.
(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02727.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02727.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02728.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02728.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02729.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02729.jpg.html)

We then set about doing some more work on the cage feet!

The idea for the d/s ....
(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02732.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02732.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02731.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02731.jpg.html)

The P/S getting made up....

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02733.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02733.jpg.html)

But we ran out of cutting discs and I don't think I could really get any more out of this one!!
(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02730.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02730.jpg.html)

 :laugh:

Plans are to finish making up the feet and get them all welded in and that will be the cage finished
Then gonna flush out the tank and replace the line
And get it all bolted back up.
Title: Re: Golfyste's road legal mk4 "project track car"
Post by: Rylarr on 07 May 2013, 19:05
NEJIIII  :cool:
or Sargent NEJ to you lower ranks  :smug:
Title: Re: Golfyste's road legal mk4 "project track car"
Post by: golfyste on 18 May 2013, 22:30
Ok once again I have left it too long to update the thread and i am faced with a load of pictures i have taken and have to try and remember what i have done  :laugh:

So i will just carry on from where i left off

i set about

One of the plates made up for the front feet...
(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02734.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02734.jpg.html)

The seat rails and side plates for the cage feet made up
(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02736.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02736.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02735.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02735.jpg.html)

And also the bottom mount - side mount plates made up...
(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02738.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02738.jpg.html)


Onto another day!
I got these made to the spec of the drawings a made on a earlier page. :grin:
(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02739.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02739.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02740.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02740.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02741.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02741.jpg.html)

They are bush sleeves for the front wishbone bush to take it down from 45mm to 30mm  :cool:
Hopefully they are going to fit Ok but i will have to wait and see  :smiley:


Title: Re: Golfyste's road legal mk4 "project track car"
Post by: golfyste on 18 May 2013, 22:43
Ok so i dont know if anyone is interested in bikes but i am and this is my thread so tough luck if not  :grin:

I went on the bike on the weekend and i started getting a rather loud tapping noise so i decided i needed to investigate.I went to check the tappets and found that one of the retaining nuts had decided to come loose and remove itself falling down towards the crank  :undecided:

soooooooo

we went from this....
(http://i1197.photobucket.com/albums/aa433/golfyste/CAAF1455-6486-4E1D-9669-A33350E94608-4441-000003CF35C670F0.jpg) (http://s1197.photobucket.com/user/golfyste/media/CAAF1455-6486-4E1D-9669-A33350E94608-4441-000003CF35C670F0.jpg.html)

to this...
(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02744.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02744.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02742.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02742.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02745.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02745.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02746.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02746.jpg.html)

And i managed to get to this point in just over a hour which i was quite impressed with

(Dont worry there is some engine pics now  :grin:)

Started stripping

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02747.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02747.jpg.html)

The dreaded missing nut
(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02748.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02748.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02749.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02749.jpg.html)

Cam chain and cams all looked in good condition
(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02750.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02750.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02753.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02753.jpg.html)

Spent ages (over 1.5 hours) trying to find the nut and was starting to get very confused until...

.... voilà!

i found it wedged inbetween the cam chain guide and the casing
(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02751.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02751.jpg.html)

A hour with a magnet and some welding rod and it was out!
(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02754.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02754.jpg.html)

Had a very lucky escape as the only damage was the tappet adjusting screw was bent so i ordered a new one at £8!!   :laugh: but i guess its better then a engine rebuild  :grin:

got the engine back in just awaiting parts  :cool:
(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02755.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02755.jpg.html)
Title: Re: Golfyste's road legal mk4 "project track car"
Post by: golfyste on 18 May 2013, 22:54
Ok so back on topic with "Project track car"!  :grin:

I placed the seat bars in their rough locations and got the seat in so i could sit and try get the seat where i wanted it

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02763.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02763.jpg.html)

After alot of messing with the seat (in-out-in-out etc) i managed to get the front rail exactly where i wanted it so i tack it in place  :smiley:
(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02756.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02756.jpg.html)

While i had the welder on i decided to tack the side plates together on the passenger cage foot and start welding it but i ran out of gas  :sad:
(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02757.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02757.jpg.html)

Another pic of what the drvers side will look like
(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02759.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02759.jpg.html)


After more messing with the seat and rails i managed to get the rear rail where i wanted it...
I then tacked it and proceeded to make it up and drill it.
i then mounted the seat with the bolts and got it in my driving position and this is the result  :grin:

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02760.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02760.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02761.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02761.jpg.html)

Just enough Clearance on the cage

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02762.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02762.jpg.html)


I then had a look at the door bars and measured it up making sure it wasn't higher then half of the full aperture of the door.
i then cut it to length and this is what it should look like  :cool:

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02765.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02765.jpg.html)

 :evil:
Title: Re: Golfyste's road legal mk4 "project track car"
Post by: golfyste on 18 May 2013, 23:01
Ok on onto tonight

Got the gas bottle refilled so managed to do a bit more welding  :cool:

got the side plates for the cage feet fully welded up  :evil:

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02766.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02766.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02767.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02767.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02768.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02768.jpg.html)


I then cleaned up around the seat rail plates ready for welding...
(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02769.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02769.jpg.html)

And got the majority of them welded

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02773.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02773.jpg.html)

I then got the side plates of the feet in position and tacked them all in place

passenger side
(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02771.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02771.jpg.html)

All ready for welding up  :smiley:
(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02774.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02774.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02775.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02775.jpg.html)


And thats it for now, i will try and keep it up to date from now on  :laugh:

one think i will say is i made quite i nice little order of parts so i will update on their arrival  :evil:
Title: Re: Golfyste's road legal mk4 "project track car" *cage is nearly there!*
Post by: golfyste on 21 May 2013, 22:10
Managed to get the front feet welded up now i just need to grind the bottoms flat so they sit flush again and then get them fitted and welded in  :grin:

Welding could be better but i think they are good enough and happy with them considering I'm a amateur

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02777.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02777.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02780.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02780.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02776.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02776.jpg.html)

 :smiley:
Title: Re: Golfyste's road legal mk4 "project track car" *cage is nearly there!*
Post by: Diamond Hell on 21 May 2013, 22:24
Looks good.... although I'd have welded them into the car tacked and then zipped them up in situ. 

Let's hope the feet haven't distorted too much when you were welding them up.  :huh:
Title: Re: Golfyste's road legal mk4 "project track car" *cage is nearly there!*
Post by: golfyste on 21 May 2013, 22:30
I think they should be ok
Gave them plenty of tacking in opposite locations etc to try hold it in place and are welded both from and back so hope fully it will be ok..... Hopefully  :laugh:
And of they have I will make them work  :smiley:
Title: Re: Golfyste's road legal mk4 "project track car" *cage is nearly there!*
Post by: Dave_IOW on 22 May 2013, 12:21
Looks good fella, I'd be happy with them :afro:
Title: Re: Golfyste's road legal mk4 "project track car" *cage is nearly there!*
Post by: jamie16v on 22 May 2013, 13:29
Wow, only just spotted this thread. alot of hours gone into this.. can`t wait to see more progress..
i didnt realise fitting a cage was so much of a ball ache. :sad:
keep up the good work mate..
Title: Re: Golfyste's road legal mk4 "project track car" *cage is nearly there!*
Post by: golfyste on 22 May 2013, 14:44
Looks good fella, I'd be happy with them :afro:

Cheers man yeah I am just gonna go out and try fit them  :grin:

Wow, only just spotted this thread. alot of hours gone into this.. can`t wait to see more progress..
i didnt realise fitting a cage was so much of a ball ache. :sad:
keep up the good work mate..

Yeah really getting the hours in now the weather has picked up a bit (aka not freezing to fetcher after 6pm  :laugh: )

It's not as much a balls he just takes some patience  :smiley:
Cheers dude  :smiley:
Title: Re: Golfyste's road legal mk4 "project track car" *cage is nearly there!*
Post by: golfyste on 22 May 2013, 16:59
There in!

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02781.jpg)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02782.jpg)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02783.jpg)


Just need to be welded in and they are done.  :cool:

Then it's passenger seat bars, door bars and harness bar.

Is it ok to attach the harness bar too the cage in the same way as the door bars?
Need to order the bits for it then get it in!

Also gonna weld in some gussets/stiffeners around the cage (roof, pillars etc)
Title: Re: Golfyste's road legal mk4 "project track car" *cage is nearly there!*
Post by: Diamond Hell on 22 May 2013, 23:22
Is it ok to attach the harness bar too the cage in the same way as the door bars?
Need to order the bits for it then get it in!

harness bars have a set of specs in the Blue Book.  Go by them.  Want to be welded in with the right strengthening.

Also gonna weld in some gussets/stiffeners around the cage (roof, pillars etc)

Be very careful with that - you want to get it right and not transfer loads somewhere unexpected in the event of a crash.
Title: Re: Golfyste's road legal mk4 "project track car" *cage is nearly there!*
Post by: golfyste on 23 May 2013, 00:34
Is it ok to attach the harness bar too the cage in the same way as the door bars?
Need to order the bits for it then get it in!

harness bars have a set of specs in the Blue Book.  Go by them.  Want to be welded in with the right strengthening.

Also gonna weld in some gussets/stiffeners around the cage (roof, pillars etc)

Be very careful with that - you want to get it right and not transfer loads somewhere unexpected in the event of a crash.

I have looked through but can only find spec of tube etc not mounting specs.
Will have another read.

Hmmm will have to have a think about it  :smiley:
Title: Re: Golfyste's road legal mk4 "project track car" *cage is nearly there!*
Post by: Dave_IOW on 24 May 2013, 00:51
Is it ok to attach the harness bar too the cage in the same way as the door bars?
Need to order the bits for it then get it in!

harness bars have a set of specs in the Blue Book.  Go by them.  Want to be welded in with the right strengthening.

Also gonna weld in some gussets/stiffeners around the cage (roof, pillars etc)

Be very careful with that - you want to get it right and not transfer loads somewhere unexpected in the event of a crash.

I have looked through but can only find spec of tube etc not mounting specs.
Will have another read.

Hmmm will have to have a think about it  :smiley:

Do what we've done and stick in a brace between the rear turrets.

Seatbelts shouldn't be over a 15degree angle the book says, you also have loads of room for landings for the brace and will also stiffen up the rear end, considerably, by the accounts of someone down here that's already done it.
Title: Re: Golfyste's road legal mk4 "project track car" *cage is nearly there!*
Post by: golfyste on 25 May 2013, 21:51
Hmmm I think I will definitely have a look at doin it that way cheers  :smiley:
Title: Re: Golfyste's road legal mk4 "project track car" *cage is nearly there!*
Post by: golfyste on 25 May 2013, 22:13
Ok time for another update  :cool:

Had a few deliveries lately  :grin:

New turbo intake pipe arrived as Even though next year I will be going bigger turbo I want to make sure I'm getting the most out f the setup I already have so got this as apparently they flow a little better the the Cm one.

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02784.jpg)

It's great quality and very sturdy but I'm not sure if its genuine  :undecided:

Is the forge writing supposed to be a sticker?

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02785.jpg)


The silicone is strong and good quality and I wasn't even thinking of questioning it until I saw the sticker

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02786.jpg)
 

Also two febi Cupra r ball joints  :smiley:

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02787.jpg)


And these arrived  :grin:
 Wishbone bushes, small dogbone mount bush, steering rack bush and main dogbone bush.

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02788.jpg)

Gone for the powerflex black series throughout apart from some superpro caster rear wishbone bushes.
I also have some black series top mounts coming but he Messaged me sayin they are low on stock but should be sent in the next week or so  :smiley:

30mm wishbone bush with the 45-30mm inserts I had made

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02789.jpg)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02790.jpg)

The superpro bushes...
For some reason I have different ones to what everyone else seems to have  :undecided:
I don't know the difference of if one are better then the other


(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02792.jpg)


Another pair of seat mounts

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02793.jpg)


The lot  :grin:
(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02794.jpg)


Ok onto some work.
Started welding the n/s foot in place
Pretty awkward with the floor only being 1mm thick so I was running a small weld on the floor and then welding to the weld 1.5inch at a time to prevent overheating of the metal.

 (http://i1197.photobucket.com/albums/aa433/golfyste/DSC02795.jpg)


Also drilled the mounting plates for the shifter.
Have also cut out 8 other pieces of plate that will e welded as braces to stiffen the platform up.
Around where it will be welded in place....

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02796.jpg)


I then got around to fitting the wishbone sleeves and bushes

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02798.jpg)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02799.jpg)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02800.jpg)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02801.jpg)


And the bush fitted

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02802.jpg)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02803.jpg)


That was it for today I had to stop welding as I started running out of gas again so need I refill it....again  :laugh:
Title: Re: Golfyste's road legal mk4 "project track car" *cage is nearly there!*
Post by: golfyste on 28 May 2013, 09:55
Ok so a little update from yesterday

Spent half the day putting the bike back together so didn't get too much done on the car.

Basically I'm going to get it on the road with the standard engine aiming for the end of July and all that has to be done is the seats cage, shifter and also gonna try and get the suspension changed.
So I'm concentrating on these areas as everything else ( rebuilding the spare engine and brakes etc) can be done when I'm driving it and then put on over a single day or long weekend etc so I'm going that way with it.

Did some work on te shifter frame yesterday.
Had just enough gas left in the welder to do he work on it.

Tacked and welded the shifter in place.

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02804.jpg)

Started tacking the brace bars in place

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02805.jpg)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02806.jpg)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02807.jpg)


Then with all the braces tacks I removed it from the car and welded it all up.

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02808.jpg)

Then cleaned it up and give it some primer (excuse the crap picture)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02809.jpg)

And a lick of paint  :smiley:

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02811.jpg)


I then moved on to the passenger seat
I got the front bar located and tacked in and then the rear bar is where it wants to be but I have well and truly run out of has for te welder so it's going to have to wait  :laugh:
Title: Re: Golfyste's road legal mk4 "project track car" *cage is nearly there!*
Post by: golfyste on 28 May 2013, 22:56
Ok so another little update

Cleaned up the quick rack and fitted the uprated bush.

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02818.jpg)

I didn't get many pictures of the progress but I spent a while Fabing a metal sheet to go on the top of the shifter platform
Also planning on making some side plates but can do then at a later date.

After bending and cutting

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02819.jpg)

Approximately how it sits.

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02820.jpg)


Some primer

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02821.jpg)

And had to touch up frame from where I scratched it

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02822.jpg)


I have also got the gas refilled so tomorrow I will be getting some welding done  :evil:
Title: Re: Golfyste's road legal mk4 "project track car" *cage is nearly there!*
Post by: golfyste on 28 May 2013, 23:48
I also noticed why my caster bushes looked different.....was because I had ordered them for a golf and not a Cupra r/s3/r32 ...... DOH  :rolleyes:

Never mind new bushes have been ordered  :cool:
Title: Re: Golfyste's road legal mk4 "project track car" *cage is nearly there!*
Post by: golfyste on 29 May 2013, 22:31
Ok so another little update.

Got the passenger seat bars tacked in.

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02823.jpg)


Got the front feet for the cage completely finished  :grin:

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02824.jpg)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02825.jpg)


Made a plate for the original shifter hole and welded it in place then gave it a lock of primer

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02826.jpg)


Welded up the door bar pin

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02827.jpg)

One door bar done  :cool:

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02828.jpg)

Other one won't take long and have ordered a 1400mm length tube to make a harness bar out of.


Also did a little bit of painting...

The shifter platform top plate

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02829.jpg)


The shifter platform

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02830.jpg)


And the standard shifter tower.

I have also ordered a b&m replica shifter off of eBay  :cool:


That's it for today.....more tomorrow!.....I do like my days off   :grin:
Title: Re: Golfyste's road legal mk4 "project track car" *cage is nearly there!*
Post by: golfyste on 30 May 2013, 22:18
Ok so another update  :cool:
(your going to have to excuse some of the photos as my camera is playing up  :undecided:)

Welded in the passenger seat bars

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02832.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02832.jpg.html)


Also finished welding the rear feet so thats all the feet on the cage finished all that is left to do is weld the door bar brackets in place (which i have marked up) and weld the harness bar in place (which i have ordered some more length of tube for  :smiley:).

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02833.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02833.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02834.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02834.jpg.html)

I cut the the door bar to length and welded the end pin in place and then cleaned up the tubes and gave them a layer of primer to stop any surface rust.

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02835.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02835.jpg.html)


Cleaned up all the feet and seat bars and then Threw some primer on to stop any further surface rust etc.

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02836.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02836.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02837.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02837.jpg.html)


Also the new set of superpro caster bushes i ordered arrived!! Very quick delivery from PSI tuning.

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02838.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02838.jpg.html)


I fitted the seats into position and placed the belt in place to figure out what to do with the anchor locations

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02839.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02839.jpg.html)


Am i right in thinking you can use the original seat belt mount (the on the the RHS if in drivers seat) for the lap belt as the angle looks pretty good.
Also is this too close for the seat to be from the cage??
I may have to do some messing with position and angle etc once the car is on all 4 wheels

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02840.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02840.jpg.html)


A Rough guide of how the shifter platform will look  :grin:

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02841.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02841.jpg.html)


I then moved onto the caster bushes
Started by marking them up...

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02843.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02843.jpg.html)


and in place

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02844.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02844.jpg.html)


all together  :smiley:

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02845.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02845.jpg.html)


One for DH...
Does this look of for the crotch straps to mount to??
I was thinkg of bolting to the floor with reinforcement plates underneath but the floor is uneven and on the drivers side the fuel pipe run underneath just where the bolts want to go.
So with this welded to the seat bars would it be a good option??

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02846.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02846.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02847.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02847.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02849.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02849.jpg.html)


Also welded on top, with one side under or both?

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02850.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02850.jpg.html)


Another update tomorrow  :grin: :cool:
Title: Re: Golfyste's road legal mk4 "project track car" *cage is nearly there!*
Post by: Diamond Hell on 31 May 2013, 11:01
We used a single eye for the two straps of the crutch strap, with the correct spec plate welded on the underside of the floorpan. 

These straps shouldn't be taking a massive load - that's the two sides and the shoulder straps.  These are to stop the harness being adjusted up too far and to stop you sliding out under the top straps in an impact.

I would definitely go for the plate being welded in under the floor vs what you're proposing there.  Why are you using that box section instead of a proper seat-mounting kit with CDS from a motorsport supplier?  I'm especially not loving the holes drilled through the box section to take the bolts - that's going to weaken the box significantly - as a minimum you should really sleeve the holes and weld the sleeve in... although it's a bit late for that now  :sad:.

For the hip straps the outer mounts should be good, then the inners you want the correct plates welded into the tunnel, with the nuts on the outside of the plates.  Lots of uncomfortable welding, but necessary.
Title: Re: Golfyste's road legal mk4 "project track car" *cage is nearly there!*
Post by: golfyste on 31 May 2013, 12:40
Hmmm  :undecided:

I was going off of omp supply as a weld in seat mounting kit like this one....

(http://i1197.photobucket.com/albums/aa433/golfyste/BBBF3E29-170B-4653-8F17-34E6ADA5DC6D-642-000000BCCBD46B73.jpg)

It classes as fia approved and is made of box with the holes drilled in it.


I was wanting to go through the floor with the crutch strap mount but the fuel lines are in the and as sai they aren't load bearing so have used the plate welded to the seat mount which I'm sure should be ok.

I have been trying to follow the blue book but couldn't find anything about the crutch straps or seat mount apart from then ring adequately secure. And having 40 sqcm of mounting area and be made of 3mm steel so figured it would be good  :undecided:

Title: Re: Golfyste's road legal mk4 "project track car" *cage is nearly there!*
Post by: golfyste on 31 May 2013, 13:37
A small lunch time update as too whats been done today.

Routed the gear linkage cables ready for the modified shifter tower

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02853.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02853.jpg.html)

Did the Crutch strap mounts

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02853.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02853.jpg.html)


And welded the door bar brackets in place

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02855.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02855.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02852.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02852.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02851.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02851.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02856.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02856.jpg.html)


Any Advice DH? will the mounts be ok or do i need to look at reinforcing them?
cheers dude

I also had some "roll cage tube" arrive....which turned out not to be seamless  :angry:
So not going to be able to do the harness bar today as planned as i need to send it back and reorder some CDS.

DH...Do you how much surfaces area the harness bar has to cover when welded to the wheel wells?

Cant find anything about it.

any comments or advice welcome  :cool:
Title: Re: Golfyste's road legal mk4 "project track car" *cage is nearly there!*
Post by: Diamond Hell on 31 May 2013, 17:37
H'mmm, not sure about those crutch strap mounts.  the issue is that it's just a strip of steel, rather than part of the whole floorpan.  They'll be fine, I suspect.

Also the tubing supplied by OMP says it's 'squared pipes' which suggests it might be a bit 'special' vs yer regular box.  Pictures of it don't really offer much detail because they're so pixelated!  Definitely can't see if they have sleeved the holes or not.

On the turret harness bar front, we discussed it with a guy who's installed a number of cages and talked through the other specs in the Blue Book.  We worked on the basis that 120cm sq is sufficient for the main hoops, so cut a similar area and positioned the harness bar in the middle of the piece of 3mm steel cut as close to square as possible.  Good luck bending in to shape.  :grin:  We used a fencing strainer, some box section and coach-bolts, coupled up with a big sledge hammer, then tacked in place and completed the forming in situ.
Title: Re: Golfyste's road legal mk4 "project track car" *cage is nearly there!*
Post by: golfyste on 31 May 2013, 18:32
I'm not too worried about the crutch straps with them being non load bearing its more the seat mount bars im concerned with.
i'm pretty sure they will be fine and i cant see them moving any times soon but its more the scrutineers point of view i'm worried about.

Yeah i saw on Daves thread  :grin: but luckily the mk4s wheel wells are pretty much flat  :grin:
I have a 140mm x 110mm plate that i placed against it and it sits flush all the way around so no need for any bending  :grin:



Ok mini update

I spent the rest of the day removing the floor pugs i had siliconed in as the silicone was rubbish and then redid them with tiger seal and then used the tiger seal on the holes for the gear linkage cables, the rivets i had drilled out and then on the out side under the car where all the welds were to keep it weatherproof and then went around with some underseal  :smiley:

I then fixed the fuel line that i had melted through and then wandered around for a while trying to think of something to do as im now waiting on parts for the harness bar and my new short shifter arriving
Title: Re: Golfyste's road legal mk4 "project track car" *cage is nearly there!*
Post by: golfyste on 31 May 2013, 18:35
Where its at  :cool:

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02857.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02857.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02858.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02858.jpg.html)
Title: Re: Golfyste's road legal mk4 "project track car" *cage is nearly there!*
Post by: golfyste on 03 June 2013, 21:35
Ok little list of a few things for over the last few days.

Spent a day on Ryan's car fitting his 3" system and new rear springs.
Also welded the seatbelt eyebolt plates in place etc so all the seatbelt mounting points are done.

Also this arrived

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02861.jpg)


So I got around to fitting it and getting the frame in place  :cool:

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02862.jpg)


I also welded up the shifter frame braces.
I then tiger sealed all the welding under the car in the transmission tunnel to keep everything weather protected.


This lot arrive today  :grin:

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02864.jpg)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02865.jpg)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02868.jpg)


DM forged rods and install package from ina engineering  :cool:
And also new tie rod ends and top mount bearings


The spend a lot of today masking up the inside of the car ready to get happy with the black paint  :grin:
Just going to start with the front end as I need to get the harness bar installed in the rear which should be arriving on Wednesday but trying not to waste days while waiting for things.

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02866.jpg)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02867.jpg)
Title: Re: Golfyste's road legal mk4 "project track car" *cage is nearly there!*
Post by: Dave_IOW on 04 June 2013, 17:10
How much were your rods mate?
Title: Re: Golfyste's road legal mk4 "project track car" *cage is nearly there!*
Post by: Diamond Hell on 04 June 2013, 17:11
BEHAVE!
Title: Re: Golfyste's road legal mk4 "project track car" *cage is nearly there!*
Post by: golfyste on 04 June 2013, 19:11
BEHAVE!

 :laugh:

How much were your rods mate?

The full kit including the rods being rifle drilled came to about £600  :cool:
Title: Re: Golfyste's road legal mk4 "project track car" *cage is nearly there!*
Post by: golfyste on 04 June 2013, 19:54
Little update for today.

Down the morning cleaning the inside of the car hovering and then rubbing with thinners ten Hoovering he bit I had out haha
Then went round with the liner and touch up any bit that's needed doing.

I then took the rear coilovers off of the daily and Pu standard suspension back on as I want the weitecs for the project.

While doing this I got a nice little delivery  :cool:

Front and rear wheel bearings

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02869.jpg)


I then spent a good while doing some painting.
Did the whole front end including the footwells and roof and also did the side panals and part of the roof at the rear.
I stopped there as I still need to weld in the harness bar that shall hopefully be arriving soon!
I also removed and painted the set mounts while I was at it

A few pictures  :cool:

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02870.jpg)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02871.jpg)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02872.jpg)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02873.jpg)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02874.jpg)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02877.jpg)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02875.jpg)

I also got around I fitting the front wheel bearing that had arrived and painted up the hub  :smiley:

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02876.jpg)

I also had a massive tidy up in the garage an around the car as it was a little bit of a mess....  :whistle:

Going to be busy at work now for a few days but hopefully I will e able to squeeze in gettin the harness bar started when it arrives  :cool:

But progress is good at the minute all I need to do it do the harness bar then put the tank, rear beam and exhaust on and then change all the front suspension over including subframe, hubs, wishbones, steering rack and coilovers and ten it's ready to go on the road with the standard engine.
And then the engine rebuild will start  :grin:
Title: Re: Golfyste's road legal mk4 "project track car" *cage is nearly there!*
Post by: Dave_IOW on 04 June 2013, 22:18
BEHAVE!

:grin:

Always good to know these things :laugh: :whistle:

Good stuff Ste, keep it coming :afro:
Title: Re: Golfyste's road legal mk4 "project track car" *cage is nearly there!*
Post by: golfyste on 04 June 2013, 22:19
Need to know for future reference  :whistle:

 :grin:
Cheers pal  :cool:
Title: Re: Golfyste's road legal mk4 "project track car" *cage is nearly there!*
Post by: Dave_IOW on 04 June 2013, 22:38
Need to know for future reference

Exactly, you never know if/when they'll be needed :wink:
Title: Re: Golfyste's road legal mk4 "project track car" *cage is nearly there!*
Post by: Dave_IOW on 04 June 2013, 22:40
What you paint it with also, looks decent finish?

I've got some hammerite clone and a brush to do mine  :grin:
Title: Re: Golfyste's road legal mk4 "project track car" *cage is nearly there!*
Post by: golfyste on 04 June 2013, 22:46
What you mean if??  :grin:

It's Simoniz spray paint
The finish is pretty good for aerosol to be fair. I'm thinking about laying some lacquer on as I imagine its going to scratch and chip quite easily as it is.
Title: Re: Golfyste's road legal mk4 "project track car" *cage is nearly there!*
Post by: Wazzzer on 06 June 2013, 19:36
Cheers for the insert dimensions mate, will get them made up at work
Title: Re: Golfyste's road legal mk4 "project track car" *cage is nearly there!*
Post by: golfyste on 06 June 2013, 22:59
No worries wazzzer  :cool:

Ok little update from last 2 days.
Been working 12 hours so not had much time but managed to get some progress with the harness bar  :evil:


As usual the pics will do most of the talking.

Made the mounting plates for the harness bar just needed a slight bend in the to sit flush.
Just takes them in place so I could get the harness bar made up.

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02878.jpg)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02879.jpg)


Did plenty of measuring to make ire I got it perfect and cut the harness bar to size/shape and it got perfectly  :cool:

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02880.jpg)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02881.jpg)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02882.jpg)


I then Tacked the bar in place

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02883.jpg)


Then removed the bar from the car to weld the bar too the plates and the. Got it back in the car and welded two sides on each plate before it got a bit dark haha


(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02885.jpg)


Then onto to tonight!

Managed to get the harness bar finished  :cool:
Completely welded on and got some nice penetration with the welding so nice and happy  :smiley:

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02888.jpg)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02889.jpg)


I the cleaned it all up and gave any necessary primer

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02890.jpg)


And after it had all dried have it all a coat of black

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02895.jpg)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02894.jpg)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02893.jpg)

At this point it was quite dark and couldn't really see what I was doing so packed up.
Will give it a
Couple more coats of black and then will give it all some lacquer to toughen it up abit  :cool:

Also got a few more deliveries so I will get some photos tomorrow and update  :cool:
Title: Re: Golfyste's road legal mk4 "project track car" *cage is nearly there!*
Post by: Dave_IOW on 07 June 2013, 00:25
Good stuff mate :afro:
Title: Re: Golfyste's road legal mk4 "project track car" *cage is nearly there!*
Post by: golfyste on 08 June 2013, 23:50
Ok another nice little update  :cool:

Will start with what's delivered althought I don't have all the pics
Got a Cupra r bam fuel pump which has been fitted today after we had flushed put the too and it rid of that nasty non v-power rubbish that was in there  :laugh:

Also got some 034 solid subframe bushes that I got off of ReDBull from here.

Also a h&r 25mm cupra r front arb  :cool:

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02928.jpg)

Ok main was yesterday i got all the rear floor/sides lacquered  :cool:

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02896.jpg)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02898.jpg)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02899.jpg)


Today has been masking up the whole car to paint the cage!  :grin:
Once again I will let the pictures do most of the talking.

Cheeky photo of Ryan doing some masking

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02901.jpg)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02902.jpg)


A few hours later an we were here!

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02903.jpg)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02905.jpg)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02907.jpg)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02908.jpg)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02909.jpg)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02913.jpg)


The spraying begins!


(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02916.jpg)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02917.jpg)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02918.jpg)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02919.jpg)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02920.jpg)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02922.jpg)


Just trying to start with the hard to reach places

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02923.jpg)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02924.jpg)


After a nice coat!

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02925.jpg)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02927.jpg)


And it's done!!  :cool:

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02930.jpg)

The door bars have also been painted  :smiley:

Painted up a piece of metal and going to lacquer it to or tomorrow to see how it takes....if all is well I will be lacquering the cage  :cool:
Title: Re: Golfyste's road legal mk4 "project track car" *cage is nearly there!*
Post by: Diamond Hell on 09 June 2013, 00:19
Don't forget - paint is weight.

 :grin:
Title: Re: Golfyste's road legal mk4 "project track car" *cage is nearly there!*
Post by: golfyste on 09 June 2013, 07:57
Don't forget - paint is weight.

 :grin:

......I'm sure I will live  :rolleyes:

:grin:
Title: Re: Golfyste's road legal mk4 "project track car" *cage is nearly there!*
Post by: whileoceanasleeps on 09 June 2013, 12:13
nice to see how much work is going into this.. keep it up (im sure you will tho..)
Title: Re: Golfyste's road legal mk4 "project track car" *cage is nearly there!*
Post by: golfyste on 09 June 2013, 16:22
Cheers dude
Will do don't worry
Looking forward to getting it on the road ..... It more importantly the track  :wink:
Title: Re: Golfyste's road legal mk4 "project track car" *cage is nearly there!*
Post by: Dave_IOW on 09 June 2013, 18:49
Cracking progress mate, bet all that masking was a right ball ache though!

Still in two minds about the colour of my cage :sad:
Title: Re: Golfyste's road legal mk4 "project track car" *cage is nearly there!*
Post by: Wayne on 10 June 2013, 09:45
Nice choice with the colour of the cage :smiley:
Title: Re: Golfyste's road legal mk4 "project track car" *cage is nearly there!*
Post by: golfyste on 10 June 2013, 10:23
Cracking progress mate, bet all that masking was a right ball ache though!

Still in two minds about the colour of my cage :sad:

Cheers dude, yeah only took about 4-5 hours! Haha  :laugh:

What colours are you thinking? I wanted something quite in your face  :evil:


Nice choice with the colour of the cage :smiley:

Cheers dude can't wait to rip all the masking out and see it in the sunlight in contract to the black inside  :cool:
Title: Re: Golfyste's road legal mk4 "project track car" *cage is nearly there!*
Post by: golfyste on 11 June 2013, 20:16
Just been round with fresh eyes and a torch and touched up any little areas that were abit thin  :cool:
The 3m helicopter tape I ordered arrived and also my padding which looks rather pink so I will have to hae to see how it looks  :laugh:

May look at lacquer tomorrow night  :cool:
Title: Re: Golfyste's road legal mk4 "project track car" *cage is nearly there!*
Post by: scarr89 on 11 June 2013, 20:48
Keep up the hard work mate, it will pay off  :wink:
Title: Re: Golfyste's road legal mk4 "project track car" *cage is nearly there!*
Post by: Dave_IOW on 12 June 2013, 20:45
What colours are you thinking?

Candy pink :afro:
Title: Re: Golfyste's road legal mk4 "project track car" *cage is nearly there!*
Post by: golfyste on 12 June 2013, 23:23
What colours are you thinking?

Candy pink :afro:

Awesome  :cool:
Get it done  :wink:
Title: Re: Golfyste's road legal mk4 "project track car" *cage is nearly there!*
Post by: golfyste on 14 June 2013, 14:37
Ok time or another update
Did some more you touching up of the cage and yesterday I lacquered it  :cool:

I also got around to cutting my padding down to size for the door bars and other parts if the cage

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02932.jpg)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02933.jpg)

When the lacquer had dried I got around to ripping all of the masking out and this was the result  :evil:

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02934.jpg)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02935.jpg)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02936.jpg)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02937.jpg)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02938.jpg)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02939.jpg)


I then Got around to fitting the seats, door bars, steering wheel and padding.

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02940.jpg)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02941.jpg)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02942.jpg)


Harnesses in place

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02943.jpg)


And adjusted up!

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02944.jpg)


Love this shot  :cool:

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02947.jpg)


All in all its comin along nicely! Just need to wire up some lights, handbrake sensor and fuel filler cap switch and the Inside ready to go.
Obviously a lot of other things to do but just concentrating on getting it road worthy.

 :cool:
Title: Re: Golfyste's road legal mk4 "project track car" *cage is nearly there!*
Post by: Diamond Hell on 14 June 2013, 15:00
When we have recovered Dave from the IW Festival site I will show him your progress and point out what a slack c*nt he is.  :cool:
Title: Re: Golfyste's road legal mk4 "project track car" *cage is nearly there!*
Post by: Dave_IOW on 14 June 2013, 15:20
When we have recovered Dave from the IW Festival site I will show him your progress and point out what a slack c*nt he is.  :cool:

Somebody call?!

Looks great that mate, bet your really happy with that :smiley:
Title: Re: Golfyste's road legal mk4 "project track car" *cage is nearly there!*
Post by: golfyste on 14 June 2013, 16:44
 :laugh:
Cheers lads!
Yeah it's not perfect but its not bein built as a show car so I don't mind  :grin:
Title: Re: Golfyste's road legal mk4 "project track car" *cage is nearly there!*
Post by: Prawny on 14 June 2013, 21:35
Ste!

I've not logged in here for months to be honest, because there never seemed to be that much interesting going on.

I was wrong. This build is looking great!

Really nice to see you doing such a decent job of it all, and hopefully you've learnt from a few of my mistakes along the way, I'm spotting a lot of things very similar, and those that are different to mine, are improved for sure, top attention to detail man!

Loving the build, and can't wait to see it come to completion and get to a trackday together at some point :)
Title: Re: Golfyste's road legal mk4 "project track car" *cage is nearly there!*
Post by: Wayne on 14 June 2013, 21:37
Respect to you that is looking really good inside :cool:
Title: Re: Golfyste's road legal mk4 "project track car" *cage is nearly there!*
Post by: golfyste on 17 June 2013, 08:32
Cheers prawn!

Yeah reading your thread is what inspired me to start the build and I'm loving it upto now and I haven't even driven it yet!  :laugh:

Cheers man and yeah looking forward to seein the a3 in action  :wink:


Respect to you that is looking really good inside :cool:

Cheers Wayne  :cool:
Title: Re: Golfyste's road legal mk4 "project track car" *cage is nearly there!*
Post by: Granta Gti on 18 June 2013, 12:55
Top work it looks great!
Title: Re: Golfyste's road legal mk4 "project track car" *cage is nearly there!*
Post by: golfyste on 18 June 2013, 19:32
Top work it looks great!

Cheers dude


Just a small update as I'm quite busy with work at the minute and spent the weekend in wales on the mtb so not too much progress

Took the weitecs off the front of te daily and replaced the with standard an also wired in my alarm disable button and also my fuel cap release. Turin which I will get a picture of tomorrow.
Title: Re: Golfyste's road legal mk4 "project track car" *cage is done!*
Post by: golfyste on 19 June 2013, 21:23
Little update with some photos

The said buttons in their new location

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02949.jpg)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02950.jpg)


Also got messing with all the sticky wiring for the interior lights
Split it all apart got rid of what I don't want an the. Wired in my new interior light which work off of the door :grin:

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02952.jpg)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02953.jpg)

Job for tomorrow is to put the fuel tank and rear axle back on  :cool:

Title: Re: Golfyste's road legal mk4 "project track car" *cage is done!*
Post by: jamie16v on 19 June 2013, 21:42
i love what you`ve done with the interior light and switches ste, thats given me some inspiration!
 :cool:
Title: Re: Golfyste's road legal mk4 "project track car" *cage is done!*
Post by: golfyste on 19 June 2013, 22:01
Cheers dude
Also got the under wingmirror lights working with them as they were already installed
Will get a night shot inside when I finish the night shifts.

Pretty simple yet I think it's quite effective.  :cool:
Title: Re: Golfyste's road legal mk4 "project track car" *cage is done!*
Post by: Rylarr on 20 June 2013, 17:57
Cheers dude
Also got the under wingmirror lights working with them as they were already installed
Will get a night shot inside when I finish the night shifts.

Pretty simple yet I think it's quite effective.  :cool:

That will be no good, its light when you finish the night shift!

ill pop up in the small hours  :wink:
Title: Re: Golfyste's road legal mk4 "project track car" *cage is done!*
Post by: golfyste on 20 June 2013, 18:19
Do it dude
Nip to mine later and post a few photos up here  :wink:
Title: Re: Golfyste's road legal mk4 "project track car" *cage is done!*
Post by: golfyste on 25 June 2013, 21:13
Ok i have done it again with not updating often enough so now im going to have another monster update  :laugh:

Been very busy lately and made quite a bit of progress!

Start with something small...

i went around the car and fitted cable protections to all the wires in the car

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02977.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02977.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02976.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02976.jpg.html)



Im going to say now i have done quite a bit but ave been so caught up in the work i haven't really taken that many pictures as i always forget  :laugh:

i refitted the tank and then fitted the rear axle

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02954.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02954.jpg.html)


I then fitted the suspension, wheel bearings and the standard rear brakes (these will be getting upgraded shortly to 255mm discs when i get hold of some carriers but these will do for now)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02955.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02955.jpg.html)


I removed the ecu from the daily on saturday and sent it off along with the spare standard aum ecu i have  to R-tech to have them both deimmo'd

i then over the last few days have been returning the daily to standard and switching all the bits onto the track car

i removed the 3" system off the daily leaving a nice space and a crappy looking rear valance

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02958.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02958.jpg.html)


I then Spent quite a while (with very few pictures  :embarrassed:) switching the turbos from one car to the other aswell as loads of other bits
this was the end result - a nearly standard looking engine bay!

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02956.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02956.jpg.html)


I then fitted the standard zaust to the daily, the centre bracket had broken off so had to weld it...

first ever attempt at gas welding! Pretty messy but its stuck ok   :laugh:

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02959.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02959.jpg.html)

I also switched the valances so the dailys is standard and recut the modified one to neaten it up a bit!

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02973.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02973.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02974.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02974.jpg.html)


I then moved onto switchingover the intercoolers, switching the injectors and also painting the inner part of the drivers wing as it had a slight bit of rust

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02962.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02962.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02961.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02961.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02963.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02963.jpg.html)


I then switched over the headlights....track car starting to look mean  :cool:
the ths intercooler will be getting swapped for a wellycooler setup when i do the engine switch once the spare engine is rebuilt

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02964.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02964.jpg.html)


A cheeky pic of the cold air feed

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02965.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02965.jpg.html)


And with a mounting bracket made up (made need the position adjusting when i put the bumper on)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02966.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02966.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02967.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02967.jpg.html)


I then fitted all the boost pipes, tip, recirc, air filter etc to the track car

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02968.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02968.jpg.html)


I then started looking at how i was going to convert the narrowband lambdas to wideband.
i found a guid but it had no pictures but managed to sort of sus it out  :grin:

Luckily i have the spare engine loom that came with the engine i bought so looked in the plug and found where the two extra wires goto in the plug and found the empty spaces on the arz plug so that may be tomorrows job

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02969.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02969.jpg.html)

Also while trying to remove the wipers and scuttle panel to get to the ecu i managed to break the windscreen  :cry: :embarrassed:
An expense added to the list that i could do without but sh*t happens i guess

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02975.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02975.jpg.html)

Also i order some new arch liners as i had melted mine  :whistle:
They arrived so i got them fitted rear wheels can now go on and that's the back end done  :cool:

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02970.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02970.jpg.html)


I also swapped my bora vents from the daily

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02971.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02971.jpg.html)


And a final pic showing the car starting to look pretty mean  :evil:
im sure it will look even meaner with a wellycooler on  :evil:

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02972.jpg)


Some more work to do tomorrow so will try keep upto date  :cool:
Title: Re: Golfyste's road legal mk4 "project track car" *cage is done!*
Post by: golfyste on 25 June 2013, 23:50
Couple of night shots with the interior led's :cool:

(http://i1197.photobucket.com/albums/aa433/golfyste/IMG_1153.jpg) (http://s1197.photobucket.com/user/golfyste/media/IMG_1153.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/IMG_1156.jpg) (http://s1197.photobucket.com/user/golfyste/media/IMG_1156.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/IMG_1155.jpg) (http://s1197.photobucket.com/user/golfyste/media/IMG_1155.jpg.html)
Title: Re: Golfyste's road legal mk4 "project track car" *cage is done!*
Post by: Dave_IOW on 26 June 2013, 07:38
Looks the bollocks that mate :afro:
Title: Re: Golfyste's road legal mk4 "project track car" *cage is done!*
Post by: golfyste on 26 June 2013, 21:54
Cheers dave  :cool:

Another small update
finished panting the wing on the current daily and finished putting it back together (bumper, driveshaft) and also removed the eibach RARB, we then towed it up the drive out of the way untill my ecus come back

The anti roll bar

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02980.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02980.jpg.html)


i decided to take a look at the adding the wiring for the wideband lambda.
its only temporary as after i have rebuilt the spare engine i am going to try cut down the spare engine loom i have to get rid of anything i dont need and then i will be swapping the whole loom.

but for now....

Trying to figure it all out

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02981.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02981.jpg.html)


used some telephone cable to run the two extra wires to the ecu, not the perfect solution but as said it only temp

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02982.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02982.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02983.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02983.jpg.html)


New plug all soldered on

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02984.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02984.jpg.html)


Splitting the ecu plug

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02985.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02985.jpg.html)


and after had installed the wires into the pins

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02987.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02987.jpg.html)


I then spent the rest of the day changing ryans cambelt and water pump as his water pump had decided to explode into

(http://i1197.photobucket.com/albums/aa433/golfyste/943506_434369769993829_1082072206_n.jpg) (http://s1197.photobucket.com/user/golfyste/media/943506_434369769993829_1082072206_n.jpg.html)


Tomorrow i will be installing the rear anti roll bar, Heat wrapping my exhaust as the heat wrap arrived and i may also look at dropping the subframe and fitting the front coilovers and polybushed wishbones etc  :cool:
Title: Re: Golfyste's road legal mk4 "project track car" *cage is done!*
Post by: Granta Gti on 26 June 2013, 22:22
Love the work mate. You selling the daily then? Also your track car would love the n249 bypass  :wink:
Title: Re: Golfyste's road legal mk4 "project track car" *cage is done!*
Post by: golfyste on 26 June 2013, 22:25
Yeah its pretty much standard now so when the insurance is up I'm gonna sell it on and drive te trackcar for a while and then look into a gettin another daily ( 320d etc)

Yeah I'm going to do all the bypasses etc when I do the engine rebuild but I'm leaving the current engine as it is as its only temporary  :cool:
Title: Re: Golfyste's road legal mk4 "project track car" *cage is done!*
Post by: Diamond Hell on 26 June 2013, 23:15
Remember to wrap the manifold so the joints are 'flushed', not open when the car is going forwards, if that makes sense?

Also dunk it in a bucket of water and wrap wet - keeps things a lot cleaner and it'll tighten up a touch when it dries.

You probably knew that lot, but worth a reminder  :wink:
Title: Re: Golfyste's road legal mk4 "project track car" *cage is done!*
Post by: golfyste on 26 June 2013, 23:20
Sorry but I don't know what you mean by that first point whatsoever :laugh:

May just be me being knackered  :laugh:

And yeah I will  :cool:
Title: Re: Golfyste's road legal mk4 "project track car" *cage is done!*
Post by: Diamond Hell on 26 June 2013, 23:54
Not sure how to describe it better, so let's try and explain... if you wrap from the bottom upwards the 'open' side of the tape will be at the back of the car.  If you wrap 'top down' then you'll have the open side at the front of the car - so it'll catch and tear much easier if you have an off (going forwards) or if it's low enough to scrape when you're driving.

Capiche?
Title: Re: Golfyste's road legal mk4 "project track car" *cage is done!*
Post by: golfyste on 27 June 2013, 11:22
Ahhh yeah I understand haha

Cheers for the advice  :cool:
Title: Re: Golfyste's road legal mk4 "project track car" *cage is done!*
Post by: golfyste on 27 June 2013, 23:05
Ok so a little update

All i can say is I hate way wrap! Feel like I've been rolling on anthill!  :laugh:
I managed to get the exhaust all wrapped. Used 20m if wrap I bought a ran out so used some thermal ladder tape to wrap the box.

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02988.jpg)


Also whipped the dogbone off cleaned it up and changed both the bushes

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02989.jpg)


Disassembled

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02990.jpg)


The old rubber bushes had started falling apart and bits were stuck everywhere!  :laugh:

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02991.jpg)


So cleaned everything up

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02992.jpg)


And installed the new bush

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02993.jpg)


Then got around to doing the other bush
Old one out.....

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02994.jpg)


New one in

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02995.jpg)


That's all I got round to doing as the missus decided I wasn't spending enough time with her so dragged me out shopping  :laugh:

Anyway tomorrow I should be dropping the old subframe and doing the front suspension etc  :evil:

I also need I look at a way of turning off the tracking control when I put my me7.5 Ecu on as the arz doesn't have a button for it!  :laugh:

Title: Re: Golfyste's road legal mk4 "project track car" *cage is done!*
Post by: golfyste on 28 June 2013, 13:27
A Quick dinner time update!

Managed to drop the hubs, wishbones, front struts, subframe and steering rack.
just got the quick rack in position ready to bolt up and then will be bolting all my new stuff up.

Few pics...

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02999.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02999.jpg.html)


Car bits everywhere!  :laugh:

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02997.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02997.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC02998.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC02998.jpg.html)


About to drop the steering rack

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC03000.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC03000.jpg.html)


New subframe and wishbones

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC03002-1.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC03002-1.jpg.html)


Hubs and subframe in the background, ready to switch over the racks  :cool:

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC03001.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC03001.jpg.html)


Just finished my dinner so time to get back out and finish bolting everythin back together  :cool:
Title: Re: Golfyste's road legal mk4 "project track car" *cage is done!*
Post by: golfyste on 28 June 2013, 22:28
Ok end of day update  :grin:

Cupra r rack held up in position and bolt in

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC03003.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC03003.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC03004.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC03004.jpg.html)


034 Solid subframe bushes ready to install

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC03005.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC03005.jpg.html)


Bushes and 25mm h&r arb installed

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC03006.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC03006.jpg.html)


Then it came to bolting the subframe in position, jacked it up and started all the bolts, i then found that the steering rack would go in position as the arb was in the way so abit of messing detaching the arb then bolt the rack in place then again bolting the arb in place
i then bolted the subframe up pulling it forward as much as possible to give as much caster as possible.

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC03007.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC03007.jpg.html)


Then installed the new febi bearings and powerflex top mounts to the weitecs

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC03008.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC03008.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC03009.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC03009.jpg.html)


Hubs and coilovers installed with new febi ball joints

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC03010.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC03010.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC03011.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC03011.jpg.html)


S3 drop links and tie rod ends attached

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC03012.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC03012.jpg.html)


Also decided to install the eibach rear anti roll bar

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC03013.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC03013.jpg.html)

Then attached the downpipe

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC03014.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC03014.jpg.html)

 
And the newly polybushed dogbone mount

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC03015.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC03015.jpg.html)


I then attached the backbox but am having to wait to install the rest of the system as i am awaiting the arrival of some more exhaust clamps!

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC03016.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC03016.jpg.html)


And finally i installed the temporary 312mm brake setup i had in the shed until i can order some cupra r brembos  :cool:

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC03017.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC03017.jpg.html)


That's it for today and back at work till mid next week so glad i managed to get quite a bit done  :cool:
Just need to finish installing the exhaust and bleed the brakes and then i can wack the wheels on and drop her on the ground and then tighten a few bolts (hubnuts, top mounts) and then when my ecus come back from r-tech install the mapped ecu and get her started so i can bleed the power steering.

got a few more bits coming i have ordered but i think the next job may be relocating the battery but we will see what happens  :cool:
Title: Re: Golfyste's road legal mk4 "project track car" *cage is done!*
Post by: dom on 29 June 2013, 21:17
Just caught up on this, not checked in for a few weeks. Great progress :afro:

Cage is looking great and the engine is going to be a monster when complete, you decided on a turbo yet?

I'll have to swing down and say hello sometime!
Title: Re: Golfyste's road legal mk4 "project track car" *cage is done!*
Post by: golfyste on 29 June 2013, 21:22
Cheers dude!  :cool:


Well for the time being its my k04-001 but early next year I will either be looking at a k04 hybrid or depending how prawns r&d goes a k04 tfsi hybrid  :cool:

No worries mate your welcome whenever  :cool:

How long have you been with the dubfiction crew?
My next door neighbour has a beaut lhd g60 and you to attend regular but it hasn't been on the road in 6 years he just rolled it out, starts it and cleans it haha
Title: Re: Golfyste's road legal mk4 "project track car" *cage is done!*
Post by: dom on 29 June 2013, 21:25
Cheers dude!  :cool:


Well for the time being its my k04-001 but early next year I will either be looking at a k04 hybrid or depending how prawns r&d goes a k04 tfsi hybrid  :cool:

No worries mate your welcome whenever  :cool:

How long have you been with the dubfiction crew?
My next door neighbour has a beaut lhd g60 and you to attend regular but it hasn't been on the road in 6 years he just rolled it out, starts it and cleans it haha

I wouldn't say I'm part of the crew, been down to a few meets and going to their show. They're a good bunch of guys with some serious motors! Sounds like a waste of a G60 to me :grin:
Title: Re: Golfyste's road legal mk4 "project track car" *cage is done!*
Post by: golfyste on 29 June 2013, 21:26
Well he has owned it for 15 years and spent near on 20k on it over the years! Plus I think there is abit of a emotional attachment  :laugh:
Title: Re: Golfyste's road legal mk4 "project track car" *cage is done!*
Post by: dom on 29 June 2013, 21:34
Well he has owned it for 15 years and spent near on 20k on it over the years! Plus I think there is abit of a emotional attachment  :laugh:

 :shocked:

G60's should be driven hard :grin:

A mate of mine runs Only Charged Dubs and he specialises in G40/G60s, he's got a heavily modded G60 which has been off the road for about a year now, when it was on the road he would leave me for dead in mine.
Title: Re: Golfyste's road legal mk4 "project track car" *cage is done!*
Post by: golfyste on 29 June 2013, 21:37
From the stories he tell it doesn't sound like its exactly a easy life  :laugh:
The main reason for it not being driven is when they moved in it took 5 of us 2.5 hours to get it down the drive as the gap between the house and the wall is only about 1" wider then the car!

I would love one but you can't have everything I guess haha
Title: Re: Golfyste's road legal mk4 "project track car" *cage is done!*
Post by: golfyste on 03 July 2013, 23:00
OK update time  :cool:

A few bits arrived on the weekend....

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC03018.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC03018.jpg.html)

for some reason i got a free maoam with my exhaust gasket haha  :laugh:

Don't get much time after work but managed to sort the tow strap
used the original toeing eye as a bolt as its a left hand thread and dont have many LH bolts lying around ha

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC03018.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC03018.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC03021.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC03021.jpg.html)
(http://i1197.photobucket.com/albums/aa433/golfyste/DSC03023.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC03023.jpg.html)


Installed

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC03029.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC03029.jpg.html)


Also decided i would start relocating the battery

A bit of a mess but you can see im running the cables through the firewall and beneath the shifter platform so i can install a isolator when i acquire one. and then back outside behind the drivers seat and along the tank, over the axle on the inside of the plastic tray and into the wheel well.

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC03026.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC03026.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC03027.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC03027.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC03028.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC03028.jpg.html)


had today off work so managed to knuckle down a bit and get a few decent hours on it.

managed to finish routing the battery cables...the holes have been drilled then fitted with grommets and tiger sealed  :cool:

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC03034.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC03034.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC03035.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC03035.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC03036.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC03036.jpg.html)


Had a brainstorm with the old man about what else we need and instead of buying a battery box as i was going to i have have bought a lighter battery and am going to clamp it down in the wheel well with a homemade bracket  :cool:

Also getting all the connections i need tomorrow so may be able to get it to the point when i just need to bolt the battery in


I then got around to fitting the exhaust  :cool:

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC03037.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC03037.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC03038.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC03038.jpg.html)


While the seat was out i decided to adjust it forward one and lean it back one as they were very upright and didnt feel right.

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC03039.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC03039.jpg.html)


You can see the drivers seat is just ever so slightly more leant back but it makes quite a difference to the feel

I then bled the brakes with some help from ryan and that was about it for the day  :cool:


......o yeah i couple of other things arrived  :grin:

My bmx grips

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC03032.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC03032.jpg.html)
   


And also some polyurethane mix for the engine mounts  :cool:
Title: Re: Golfyste's road legal mk4 "project track car" *cage is done!*
Post by: Diamond Hell on 04 July 2013, 10:42
Battery box is still necessary to protect you from exploding battery incidents - it's good practice.  I have a plastic tub that goes over my battery.
Title: Re: Golfyste's road legal mk4 "project track car" *cage is done!*
Post by: Rylarr on 04 July 2013, 20:08
Next on the list WMI???  :laugh:
Title: Re: Golfyste's road legal mk4 "project track car" *cage is done!*
Post by: golfyste on 04 July 2013, 22:12
WMI will soon be on the cards but first I wanna gettin it running and tune any little problems out
Then it will be WMI, diff and engine build  :cool:

Jut trying to find a battery box the right size!
Considering making one.

Don't some more today will update in a sec
Title: Re: Golfyste's road legal mk4 "project track car" *cage is done!*
Post by: golfyste on 04 July 2013, 22:48
OK so today i got on with removing the vr6 clutch and g60 flywheel setup off of the daily and return it backl to standard with one of the many clutches i have lying around  :laugh:

Managed to wrestle the gearbox out and get the standard clutch and dmf installed

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC03049.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC03049.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC03048.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC03048.jpg.html)


Also the vr6 friction plate looks pretty good. so should hopefully last me untill the turbo upgrade next year.

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC03047.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC03047.jpg.html)


putting it all back together was a bit of a pain as it just didnt seem to want to go but it eventually went.


got on with finishing the batter relocation at the front end.
I didnt have any connector blocks but i had a isolator lying around so used that to join the live coming from the battery and the starter and fuse board lives.

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC03050.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC03050.jpg.html)


And finished

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC03051.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC03051.jpg.html)

Have ordered a battery but need to try find a box to fit it..

tomorrow i have a load of holiday stuff to get sorted as im going away for 2 weeks but gonna try get a bit of time in there to remove the ths mount from the drivers side of the daily and then maybe looking at filling them with the poly resin.
Title: Re: Golfyste's road legal mk4 "project track car" *cage is done!*
Post by: Dave_IOW on 05 July 2013, 17:07
I'm going to use the standard battery in the wheel well and bolt the standard mk4 battery tray to the floor, in the back.

Don't know if your lighter battery is smaller, presumably, but might help you :smiley:

Title: Re: Golfyste's road legal mk4 "project track car" *cage is done!*
Post by: Diamond Hell on 07 July 2013, 17:43
Have you put the third wire and resistor on the kill switch?
Title: Re: Golfyste's road legal mk4 "project track car" *cage is done!*
Post by: golfyste on 07 July 2013, 20:03
Yeah it is quite a bit smaller Dave will post some pics up tomorrow
I will sort a box don't worry  :cool:

DH the kill switch is literally just being used as a connector block as i could be bothered to buy one and is t fia approved with the extra point on the back for resistors etc but I will be installing a proper kill switch later on.
Title: Re: Golfyste's road legal mk4 "project track car" *cage is done!*
Post by: golfyste on 08 July 2013, 22:16
Ok a small update before I go on holiday tomorrow!

The battery arrived  :cool:

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC03055.jpg)


I wanted to get the car road worthy so i made a clamp to fit the battery for the time being but will definitely be looking at making a box or it when I get back off of holiday but this just means I will be able to get it started and insured, mot'd etc while I make a box.


Drilled the spot welds on the old spare wheel locator

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC03056.jpg)


Made the clamp

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC03057.jpg)


Painted the clamp, laid some stick on foam where the battery was going and bolted it all up with some threaded bar.

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC03058.jpg)


Obviously they're wot be any update for near on two weeks now but when I get back I will be looking at replacing the windscreen and getting it insured and mot'd and then sorting any niggles that may appear when it's on the road  :laugh:

Then it's battery box, heat shield for filter, brakes, will bits like fire extinguisher and then maybe try get on a track day  :cool:

Any suggestions/tips/things I need to do

Let me know  :cool:

Cheers lads
Title: Re: Golfyste's road legal mk4 "project track car" *cage is done!*
Post by: Diamond Hell on 10 July 2013, 08:06
Although I appreciate that you're just using it as a cut-off I would absolutely recommend you ensure you put that resistor and earth on in the correct position, or if you use it when running you'll fry the alternator, as it's still generating while the motor comes to a stop with the cut off shut off: the charge generated has nowhere to go.
Title: Re: Golfyste's road legal mk4 "project track car" *cage is done!*
Post by: Wayne on 10 July 2013, 11:10
Battery needs to a sealed unit in a box with a vent to the outside, much safer.
Title: Re: Golfyste's road legal mk4 "project track car" *cage is done!*
Post by: golfyste on 20 July 2013, 17:49
Ok so back off holiday and back to work!

 Both myaum ecus arrived back from r-tech after have the immo defeated whiles i was away so got around to fitting them.

i fitted the standard one on to the daily and it runs perfect  :smiley:

but i have fitted my mapped one to my arz track car with wideband conversion and as soon as i put the ignition on the fans kick in....then go off....then kick in....then off....then in and so on

with the original arz ecu plugged in the car is fine but its does the fan thing with both of my aum ecu's!!  :sad:

from what i can see on autodata the ecu pin outs on both the arz and aum ecus are the same or am i missing somethin??

i have full vagcom and autodata so can look into things but dont know what to look for!

its confusing the hell out of me!!

can anybody help?

good news is it runs with the mapped aum ecu plugged in and sounds nice and smooth
i brought up block 31,32,33 on vcds and the lambda specified is flutuating around .95 on idle that about right?


i also got around to making a box for the battery. Haven't got any photos buts its not finished yet so will take a few tomorrow  :cool:

i have also decided i am going to switch the isolator for a connector block as i dont have a need to isolate it at that point and it doesnt have any pins oin the back etc like the fia ones so would need to change it anyway!
Title: Re: Golfyste's road legal mk4 "project track car" *cage is done!*
Post by: golfyste on 21 July 2013, 21:22
Solve the problem of the fans kicking in!

With a little help from a few lads on vagtalk and trawling through autodata I found 3 extra wires on the arz Ecu plugs

Two are spare cable and one ( pin 61) is somethin to do with the aircon. Removing this pin (as advised ) has solved the problem  :cool:

Also got the battery box to the point where it needs welding

Also Cut the exhaust tip to get rid of the rolled edge

Then a new problem!
Bleeding the brakes  :sick:

Bled the whole system starting furthest away from MC
Bled MC
Bled abs pump on vcds
 Brakes feel crap and spongy

Bled it all again, and again and again and still I can't get then right  :undecided:

I hate brakes! Haha

Been messing with vcds and did a full scan and good news being there isn't excessive codes! Just the expected ones:

Vvt as its missing on the arz
Airbag codes as its all missing
And another minor one which I can't remember  :laugh:


Can I get rid of the airbag light using full vcds 11?

Also I noticed my coilpacks seem to be acting strange.....
With ignition on bolts across all 4 are the same (about 3.3v)
But at 2000rpm 2 are 2v ish and 2 are 0.9v surely this isn't right??


Working shifts for a few days now so won't get much time to do anythin but any help/advice is highly appreciated!


Title: Re: Golfyste's road legal mk4 "project track car" *cage is done!*
Post by: golfyste on 25 July 2013, 23:23
Small update, new windscreen has been fitted by Autoplus windscreens  :cool:

Also returned all the brakes and wheels on the daily back to standard

Adjusted the passenger seat so it's a better position now and also been messing switching radios over etc
Have got some pictures but just need to upload them!
Title: Re: Golfyste's road legal mk4 "project track car" *cage is done!*
Post by: golfyste on 26 July 2013, 18:21
Update with a few pictures  :cool

Exhaust after cutting tip

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC03059.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC03059.jpg.html)


The battery box!
Just needs the edges of the lid welding together and then a few hols drilling to bolt it all up and to vent it to atmosphere

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC03060.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC03060.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC03061.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC03061.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC03062.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC03062.jpg.html)


Windscreen got replaced by Autoplus  pretty cheap at £98 fitted so I guess its the best of a bad situation  :laugh:

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC03063.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC03063.jpg.html)


Also the interior trim around the stereo was a mess but i couldnt be bothered to paint it so i bought some 4D carbon wrap nice and cheap and wrapped it all up! came out quite nice  :cool:
Also decided to get rid of the protective film i had and the cage bars to stop me scuffing the paint with my feet and replace it with carbon wrap as it looked rubbish  :cool:

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC03064.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC03064.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC03065.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC03065.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC03066.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC03066.jpg.html)


I then got around to making the heat shield i have been planning
Cutouts and the template

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC03068.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC03068.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC03069.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC03069.jpg.html)

In position!
(http://i1197.photobucket.com/albums/aa433/golfyste/DSC03070.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC03070.jpg.html)


Just need a nice big holesaw now  :grin:

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC03071.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC03071.jpg.html)


Thats it for now need to get the battery box sorted
fit the boost gauge
and then try get some insurance and MOT it  :cool:
Title: Re: Golfyste's road legal mk4 "project track car" *cage is done!*
Post by: Dave_IOW on 27 July 2013, 17:34
Loads more room without a battery in the way! :grin:
Title: Re: Golfyste's road legal mk4 "project track car" *cage is done!*
Post by: golfyste on 27 July 2013, 18:04
Yeah big time!
Just need a nice big filter now  :grin:
Title: Re: Golfyste's road legal mk4 "project track car" *cage is done!*
Post by: golfyste on 28 July 2013, 17:08
Removed my boost gauge from the old daily, painted the pod black and fitted it to the track car  :cool:

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC03072.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC03072.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC03074.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC03074.jpg.html)
Title: Re: Golfyste's road legal mk4 "project track car" *cage is done!*
Post by: golfyste on 01 August 2013, 23:11
Ok so another update!
Been busy with training courses at work so not had loads of time lately but managed to get a bit done!

Did some cutting of the bumper so it now fits with the intercooler.
How it looks  :cool:

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC03075.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC03075.jpg.html)


Also some more goodies arrived!

Ordered a afff foam extinguisher and some driving shoes from jjc rally  :cool:
The shoes were only cheap compared to the likes of sparco etc but seem very comfy and are also very lightweight and have quite abit of flesh to keep your feet cool  :smiley:

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC03076.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC03076.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC03077.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC03077.jpg.html)


Also i ordered a set of holesaws and some rubber seal....with a bit off playing with the heatshield this is what i came out with!  :grin:

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC03078.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC03078.jpg.html)

I will be getting a new *Bigger* air filter but this one is ok for now  :laugh:

And installed  :cool:

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC03080.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC03080.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC03079.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC03079.jpg.html)


I also got around to fitting the fire extinguisher ....

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC03081.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC03081.jpg.html)


And then managed to give the wheels a clean and get them all fitted!!

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC03082.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC03082.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC03083.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC03083.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC03084.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC03084.jpg.html)


I'm happy to say that if i'm correct the car is ready for MOT!
just need to have a last check around tighten a couple of things etc and its ready  :cool:
And another piece of good news i managed to sort the insurance!!
20 year old, 3 years ncb, all mods declared with adrien flux for £1200  :grin:

so its MOT, tax and then drive it around and sort all the expected niggles (suspension height, tracking, and anything else that pops up!  :laugh:
Title: Re: Golfyste's road legal mk4 "project track car" *cage is done!*
Post by: golfyste on 04 August 2013, 15:12
Anyway a little update from yesterday!

Seen as soon I will have the car on the road I thought I best get it ready!

I started by dropping the car on its wheels for the first time in about 6 months!

Once it was down I tightened the hub nuts and top mounts.

I then Set about setting the suspension height up, i got the wishbones about level but its not perfect as my drive is t completely level but will do ti I can get it set up on a ramp.

I then set about trying to clean 8 months of dirt and grime off of the car!

A before shot...
(http://i1197.photobucket.com/albums/aa433/golfyste/DSC03097.jpg)

After washing but before polish...
(http://i1197.photobucket.com/albums/aa433/golfyste/DSC03099.jpg)

Me and Ryan then proceeded to clay bar, polish and wax her!

And this was the end result! Which is pretty good considering it was all done by hand!

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC03101.jpg)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC03102.jpg)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC03106.jpg)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC03107.jpg)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC03108.jpg)
Title: Re: Golfyste's road legal mk4 "project track car" *Ready for the MOT*
Post by: golfyste on 05 August 2013, 22:52
Ok bit of a problem  :undecided:

Managed to run the car around the block a couple of times to try make sure it was running ok for the mot.
Majority seemed ok
Car is driving nicely but.....

I warmed the car up before I ran it around and after the 4th time around the block the car started plopping of masses of white smoke!!

I slowly got it home and gave it a little rev at the bottom of the drive and another big ploom came out!
I got out a have it a sniff and it smells abit like fuel  :huh:

I don't think it's the head gasket as it seemed one before I fitted all the engine mods and it is white and doesn't smell like oil so in disregarding them.
I managed to do a very small log and the afr on acceleration was around 11-12
But when I let off the acceleraor lambda reading shot up to about 1.9 Witch equals around 24:1! Is this right?

I'm think/hoping its just over fueling but don't hve a clue why as all the same mods off my old car are on this one.
I know all engines are different but could it make that much difference??

Cheers for any help lads
Title: Re: Golfyste's road legal mk4 "project track car" *Ready for the MOT*
Post by: Diamond Hell on 06 August 2013, 09:12
Start with basics - compression check, then possibly check the injector spray patterns to make sure there's not one locked open or anything stupid.

Could the turbo seals have started leaking? Possible wallop on the shaft somewhere along the line?

Was everything up to temp, or still cold?  Certainly going to struggle with MOT if it's issuing smoke  :undecided:.
Title: Re: Golfyste's road legal mk4 "project track car" *Ready for the MOT*
Post by: golfyste on 06 August 2013, 09:19
Will be looking Into ASAP
Plan was to try a compression check to start with.
How would i go about checking the injectors?
Jut remove and turn the car over?

I don't think it could be turbo related as its only 16 month old and is a genuine Borgwarner unit. And it seemed to spin nicely when It was out.

Car was warned up as I had it running to bleed the power steering and while I set the laptop up.
Not to worries about mot as I have a friend ha
But I'm more worries about some sort of damage or causing a accident everytime it puffs a cloud of smoke out!
Title: Re: Golfyste's road legal mk4 "project track car" *Ready for the MOT*
Post by: Granta Gti on 06 August 2013, 13:19
Could be valve stem oil seals or turbo. Usually white smoke for oil and blue/black for fuel.
Title: Re: Golfyste's road legal mk4 "project track car" *Ready for the MOT*
Post by: golfyste on 06 August 2013, 19:26
Hoping its not the turbo as its only 16 month old  :undecided:

I've had the car running again and it seems the smoke is a little more blue then i first thought  :sad:

Managed to get a few videos and upload them to youtube.

First video shows the engine running with the coolant about 60 degrees so not completely cold, the smell is quite strange but i cant decided wether it smells like fuel or oily

http://youtu.be/R2xrMtyYkWU

http://www.youtube.com/watch?v=R2xrMtyYkWU&feature=c4-overview&list=UUB6MCVgSFOdqE7CX7jeGzRA



Second video shows the lambda on vcds. does it look about right?

http://youtu.be/Xs3pA_xZh50

http://www.youtube.com/watch?v=Xs3pA_xZh50&feature=c4-overview&list=UUB6MCVgSFOdqE7CX7jeGzRA



third video again shows lambda but also the coilpacks as i was thinking it was maybe not completely burning the fuel although NO misfires were detected

http://youtu.be/H2pjzlfqzSg

http://www.youtube.com/watch?v=H2pjzlfqzSg&feature=c4-overview&list=UUB6MCVgSFOdqE7CX7jeGzRA



I also noticed that after doing all these little tests there was quite abit of liquid inside of the exhaust.

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC03117.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC03117.jpg.html)



I will do a compression test when i have a day off work at with my dad.

i had a little more spare time so decided to do a couple of small mods  :cool:



I decided i wanted to have the wheel sit slightly closer to me so i needed a spacer and though it was a good excuse to get one of these!

A B&G quick release wheel hub

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC03109.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC03109.jpg.html)



And fitted

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC03110.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC03110.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC03111.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC03111.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC03112.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC03112.jpg.html)



Also got around to polybushing my ths engine mounts which involed cutting away as much of the old softer poly to replace with the harder poly i purchased

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC03053.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC03053.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC03054.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC03054.jpg.html)



And finished

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC03119.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC03119.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC03118.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC03118.jpg.html)



Also what is peoples opinions on wheel tape??

Yes or No?

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC03120.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC03120.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC03121.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC03121.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC03122.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC03122.jpg.html)



Cheers for any help lads!  :cool:
Title: Re: Golfyste's road legal mk4 "project track car" *Ready for the MOT*
Post by: Diamond Hell on 07 August 2013, 09:04
Sorry bud, that says turbo seals to me.  :sad:

Is there anything on that engine that could be loose and allowing oil to leak?

Is the tick-over lumpy?

Is the smoke worse on start-up?  If yes then it *could* be valve stem seals, but I think that's unlikely because that sort of smoke normally clears pretty quickly after start-up.
Title: Re: Golfyste's road legal mk4 "project track car" *Ready for the MOT*
Post by: golfyste on 08 August 2013, 19:36
Ok this mornin i got around to testing the compression and also the coolant system.

Compression was ok with three cylinders at 135 psi and one at 145 psi

The coolant system also held pressure which has ruled out both the headgasket and the rings.

Also my dad id borrowing the chem tester from work to test the coolant for gasses tomorrow morning

I noticed that when i removed the spark plug out of cylinder three there was a little blue gas coming out of the hole

After i had put it all back to get i started it and there wasn't really much smoke.

http://www.youtube.com/watch?v=avTusTM09Jc



I drove it around the block again and after about three times around and giving it a little it started plooming smoke again mainly when i give it some and then let off at a junction and then when i accelerate it smokes quite a bit.

i then go it back down the drive and it was smoking a little

http://www.youtube.com/watch?v=YrADC3ttJ3g

i'm thinking it might be the valve stem seals and hopefully not the turbo as i bought it new not too long ago.



i then had to go out to my brother to help him fit some windows but when i got back i decided to order some mats i had bought due to getting into the car twice when it was raining last week and the floor being a complete mess and slippy when it was wet some im thinking mats for road driving and some drip tape underneath for track  :cool:

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC03126.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC03126.jpg.html)
Title: Re: Golfyste's road legal mk4 "project track car" *Ready for the MOT*
Post by: golfyste on 10 August 2013, 22:50
Ok small update but sadly no pictures

i removed my tip and found small amounts of oil inside the turbo which i believe may be normal?? but no side to side movement in the shaft so im asuming its not the turbo??

i also fitted a sunstrip i bought off of ebay but have found its a bit small so i may need to get another one!

Done alot of tidying in the garage as its a pure mess but also spent a while fitting the some coilovers onto ryans car  :cool:

Don't know the next step really, im going to see how bad it is and if its liveable im going to try hang on for a few weeks while i rebuild my spare engine and hopefully that will sort the problem if not i will have to order some gaskets and a valve tool so i can remove the head and replace the valve stems!
Title: Re: Golfyste's road legal mk4 "project track car" *Ready for the MOT*
Post by: golfyste on 13 August 2013, 01:53
Another update with good and bad news!!

The car is now MOT'd, taxed and on the road!

just trying to solve a few little niggles, the car was misfiring under boost which then turned into a constant misfire, found to be a faulty coilpack....

i had a spare so that is on for the moment while i ring up vw  to see if it is under recall.

the car is still smoking but only seems to do it if i put my toe down and then when i slow and set off again it puffs out a big cloud...

i also think i may have a dodgy lambda or the conversion isn't working properly... im getting a lambda reading and the lambda control is moving but normally in the - down to about -25 (and i have to note the lambda doesn't seem to read or move for the first minute of start up

one of the things that is confusing me is both adaption blocks for the lambda are reading 0%. i read somewhere that this means the sensor is bad??

 

and last but not least it seems the standard clutch doesnt seem to like 310 lbft as it has started slipping under load after only a few miles of driving so it looks like i will be having the box off this weekend and fitting the vr6 unit i had fitted to the old car.

 

All good fun!!  :rolleyes:
Title: Re: Golfyste's road legal mk4 "project track car" *She's on the road!*
Post by: golfyste on 13 August 2013, 02:18
More good news!

Currently working some night shifts and took the advantage to put the car on the weighbridge.....

With half a tank of fuel it's giving a reading of 1160kg to the nearest 20! so it's between 1150-1170kg  :evil:

My old 5 door weighed 1340kg

so the 3 door is about 1310kg so I've managed to strip around 150kg which I'm pretty happy about considering it now has a roll cage!  :grin:
Title: Re: Golfyste's road legal mk4 "project track car" *She's on the road!*
Post by: Diamond Hell on 13 August 2013, 14:58
Good effort.

See if the smoke clears up when you've got the clutch swapped over and you've taken it out for a bloody good spank.

Please spend some time motivating Dave, if possible. :grin:
Title: Re: Golfyste's road legal mk4 "project track car" *She's on the road!*
Post by: golfyste on 13 August 2013, 19:28
Cheers dude

Yeah havin to drive it very gently  :laugh:

Got a slight misfire on cylinder 2, rang VW but its not on recall so gonna have to purchase all new coils before mapping.

What's he been doing?
Was looking forward to a update but it never happened haha
I will get bugging him  :grin:
Title: Re: Golfyste's road legal mk4 "project track car" *She's on the road!*
Post by: golfyste on 13 August 2013, 19:29
O yeah!
On another note the way this thing sticks to the road is crazy  :laugh: :laugh: :laugh:

Love it!
Title: Re: Golfyste's road legal mk4 "project track car" *She's on the road!*
Post by: golfyste on 17 August 2013, 14:02
Ok quick dinner time update!

Decided to set about changing the standard clutch for the vr6 unit i have!

few pics of where i am upto!

Just starting.....(you can also see my sunstrip which i may think be too big but havent driven it much yet so will see)

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC03161.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC03161.jpg.html)

Stripping it down

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC03162.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC03162.jpg.html)



And the box out!

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC03163.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC03163.jpg.html)



And the old clutch covered in dust!

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC03165.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC03165.jpg.html)



Vr6 unit fitted!

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC03166.jpg) (http://s1197.photobucket.com/user/golfyste/media/DSC03166.jpg.html)



just need to get it all back together also with the polybushed engine mounts  :cool:



will update later!  :grin:
Title: Re: Golfyste's road legal mk4 "project track car" *She's on the road!*
Post by: golfyste on 18 August 2013, 18:18
Ok update from yesterday!

Got the box back on and also fitted the poly filled engine mounts!

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC03168.jpg)

http://youtu.be/IVpITVC9YKc

And got it all back together!

(http://i1197.photobucket.com/albums/aa433/golfyste/DSC03170.jpg)



engine is solid with both poly'd mounts!

quick vid of Ryan trying to move the engine! Haha

http://youtu.be/AOaZqILDdyM



The clutch is now holding nicely with no slipping!

But I had a misfire oon cylinder 2 under load so I switched the coilpack for a spare and it was still missin so I switched it with another spare which was ok for a short while and then started misfiring again

i then fitted a fairly new coil which made it better then it had been before but by the time we got around the block it started feeling a tad like it was starting to miss again but I couldn't check as the laptop had run out of battery....



sooooo the car is eating coilpacks on cylinder two haha

first protocol tomorrow is to check the plugs are tight and check the condition/gap. They were ok when I fitted them but need to eliminate them as the problem

Anyone have any other ideas what might be causing the problem?

Cheers lads



oh 1 mmore thing when it's was running right it was pulling like a train!! Just new the map to be tweeked  :evil:
Title: Re: Golfyste's road legal mk4 "project track car" *She's on the road!*
Post by: golfyste on 31 August 2013, 01:00
Ok I thinks it about time for a update!!

Sorry but I have minimum pictures as I haven't done many big jobs!



I replaced the coilpack with a we unit and upto now it's been fine so I'm hoping I just a a bunch of spares that were naff haha



i the. Started gettin a over boosting issue and a code was coming up with map sensor signal too high I have since replaced it with a new one from tps and all is good!



Me and the lass ha a bungee jump in Manchester and with that drive included I have currently got 170 miles to half a tank so pretty impressed! Haha



A few negative points to mention  :cry:

The blue smoke I have been getting I think is from the turbo oil seals!

When I pulled my map sensor out I got some oil dripping from the hole so I removed the lower boost pipe and there was a nice sized puddle of oil  :sad:

It's annoyed me quite a bit as I bought the k04-001 from backdraft about 16 months ago with a hefty price tag and its always been taken car of.

i contacted backdraft but apparently Borgwarner don't give it a warrenty as its a upgrade part and not a standard part

So I'm a bit stuck on what to do about it as I was thinking of geti a bigger turbo an jut using this one to run in the engine when it's built but obviate I don't want to be burning loads f oil in the new engine!



A couple of other things is the rear heated window doesn't work (going to check all the wirin and fuses) and I get red hot air coming through the vents even when it's on cold and no fans running haha



i also did some logs with showed good afr etc

I also logged the maf and got a peak of 196gs which works out at roughly 245bhp using the /0.8 method.



And ideas/advice etc throw it at me  :cool:
Title: Re: Golfyste's road legal mk4 "project track car" *She's on the road!*
Post by: Wazzzer on 31 August 2013, 12:49
I'd stick a Chinese turbo on mate...
Title: Re: Golfyste's road legal mk4 "project track car" *She's on the road!*
Post by: golfyste on 31 August 2013, 17:26
Just found a company called xspower from the USA who do a k04-001 delivered for £280 so might do that while I run the engine in and sort a bigger turbo!  :grin:
Title: Re: Golfyste's road legal mk4 "project track car" *She's on the road!*
Post by: golfyste on 27 September 2013, 20:11
Ok so it's seems like I haven't done anything in ages!

BUT my holidays are over and I arrived home to this!

(http://i1197.photobucket.com/albums/aa433/golfyste/null_zpse47ea26e.jpg)

It's the k04-001 I ordered from Xs- power
It's pretty much the same as the Chinese turbos but I hve been told the compressor is bigger then the usual 001! I have asked them to email me the full spec sheet but I have taken a quick (rough ruler) measurement of the inlet I.d which measured 43.5mm

I will be fitting it tomorrow as well as maybe a few other small jobs and then I will be checking it over with vcds (afr etc) to make sure it's safe to run and then hopefully pop down to the r-tech charity day on Sunday!!  :grin:

A few more pictures...

(http://i1197.photobucket.com/albums/aa433/golfyste/null_zps9926ed53.jpg)

Vs a k03s
(http://i1197.photobucket.com/albums/aa433/golfyste/null_zpsb33c1bdb.jpg)

And gasket set
(http://i1197.photobucket.com/albums/aa433/golfyste/null_zps7e8438eb.jpg)


And I also forgot to mention I bought I new wide angle rear view mirror  :cool:

(http://i1197.photobucket.com/albums/aa433/golfyste/null_zps485bc3a7.jpg)
Title: Re: Golfyste's road legal mk4 "project track car" *She's on the road!*
Post by: golfyste on 27 September 2013, 21:35
Ok been thinking for a while that I want a afr gauge!

Been looking at the aem kit available...

http://m.aemeurope.co.uk/product_article.php?name=Digital-Wideband-Air-/-Fuel-Gauge&model=30-4100&prod=AEM-0158



The only problem is I don't really want to disassemble the downpipe to weld a new boss for the sensor.

my question is! Does the me7.5 Ecu actually need the rear lambda (post cat)?? Or is it purely to check that the car is working?

I thought is seen as I don't have a cat coil I just fob off the rear lambda and use that port for the afr gauge??



I'm looking forward to getting the running properly so I can get on a track day or too before the engine swap!
Title: Re: Golfyste's road legal mk4 "project track car" *She's on the road!*
Post by: Wazzzer on 27 September 2013, 22:26
that's a K03 you're comparing it to, not a K03s :wink:

Does look good though. I think one of the problems the cheap turbos can suffer with is the wastegate not sealing properly due to a poor surface finish; might be worth checking it out while it's off the car
Title: Re: Golfyste's road legal mk4 "project track car" *She's on the road!*
Post by: golfyste on 27 September 2013, 22:28
Yeah it is sorry  :laugh:
Didn't even look at it just assumed k03s but forgot the track car with a k03  :laugh:

Will try get a photo of the wastegate now!
Title: Re: Golfyste's road legal mk4 "project track car" *She's on the road!*
Post by: golfyste on 27 September 2013, 22:38
Ok pictures of the wastegate!

Looks quite good in my eyes.
Surfaces are nice and smooth!

(http://i1197.photobucket.com/albums/aa433/golfyste/null_zps9c907cbf.jpg)

(http://i1197.photobucket.com/albums/aa433/golfyste/null_zps8d394810.jpg)

(http://i1197.photobucket.com/albums/aa433/golfyste/null_zps04a25569.jpg)

Hopefully it will be £280 well spent  :laugh:
Title: Re: Golfyste's road legal mk4 "project track car" *She's on the road!*
Post by: Wazzzer on 27 September 2013, 22:55
sound mate :afro:

We'll all be watching how this turbo fairs :grin:
Title: Re: Golfyste's road legal mk4 "project track car" *She's on the road!*
Post by: golfyste on 27 September 2013, 22:58
 :grin:

The plan is too hopefully get it to r-tech on Sunday an get a dyno print out and maybe get a devils own kit installed and do a few trackdays before winter sets in!

Then maybe buy a 4x4 for winter and take the golf off the road for the engine build/swap and maybe a few other little mods  :rolleyes:

And then run the engine in and get it tweeked to see what I can push the turbo to!
Title: Re: Golfyste's road legal mk4 "project track car" *She's on the road!*
Post by: golfyste on 28 September 2013, 22:59
Ok its been a long day which to be honest hasn't been the smoothest....

Started pretty early so start with a few quite jobs  :laugh:
removed the front bumper so i could remove the boost pipes and empty them of oil....

(http://i1197.photobucket.com/albums/aa433/golfyste/null_zps28db8a17.jpg) (http://s1197.photobucket.com/user/golfyste/media/null_zps28db8a17.jpg.html)

very nice  :sick:

(http://i1197.photobucket.com/albums/aa433/golfyste/null_zps1c9083a9.jpg) (http://s1197.photobucket.com/user/golfyste/media/null_zps1c9083a9.jpg.html)

Got on with removing the turbo....
(http://i1197.photobucket.com/albums/aa433/golfyste/null_zps944c5055.jpg) (http://s1197.photobucket.com/user/golfyste/media/null_zps944c5055.jpg.html)

Once i got the turbo removed i got slightly confused as i found there it pretty much no side to side play in the shaft  :huh:
So i spent a while getting annoyed and wondering what else it could be and all i could think was that the breathers are letting oil into the tip....which is possible but then also remembered i have been having to top the oil up just under every 2 weeks so surely it cant be that??

Anyway i decided to carry on with fitting the new turbo....
I slacked with the photos during reassembly as the turbo was being a real PITA to line up with the manifold!

random photo haha
(http://i1197.photobucket.com/albums/aa433/golfyste/null_zps427309be.jpg) (http://s1197.photobucket.com/user/golfyste/media/null_zps427309be.jpg.html)


I eventually managed to get it all sorted and changed over! as well as removed the plugs to clean of oil and check the gaps.

i then got it on the road and did a few logs
On actuator pressure...

(http://i1197.photobucket.com/albums/aa433/golfyste/logc-actuator.png) (http://s1197.photobucket.com/user/golfyste/media/logc-actuator.png.html)

As you can see the fueling on actuator seems good varying between 11.7 and 12.5 under hard acceleration

I then logged fueling and CF's with the n75 plugged in.

(http://i1197.photobucket.com/albums/aa433/golfyste/loga.png) (http://s1197.photobucket.com/user/golfyste/media/loga.png.html)

As you can see i have marked in yellow where the main acceleration is and that the fueling is safe.
But you can also see that my cf's are hitting 6 repeatedly!
correct me is i'm wrong but i read on rosstech that cf's of 5 or over are considered quite bad and need to be investigated further! is this right??

I was also experiencing a cut off boost and jerking while accelerating so i logged the boost and as you can see it seems to over boost a little and then it cuts it down to actuator and lets it build again...

(http://i1197.photobucket.com/albums/aa433/golfyste/logb.png) (http://s1197.photobucket.com/user/golfyste/media/logb.png.html)


What do people think?? All down to the map not being suited to the turbo or something more sinister?

A update on the smoking issue too!
I'm no longer getting smoke while driving which i was getting alot of before but i am still getting smoke on start up  :undecided:

So think i may have to remove the pcv system next and install a catch can.


Sadly i don't think i will be able to run it on the rollers at r-tech tomorrow but i may cruise down on actuator pressure just for the sake of charity.

Any help advice is highly appreciated as always!

Cheers lads
Title: Re: Golfyste's road legal mk4 "project track car" *She's on the road!*
Post by: jamie16v on 29 September 2013, 21:41
hey ste, its the exact same turbo i have but at the time i bought mine, xs power were trading from wales. :tongue:
i had very simular problems to you to begin with, overboosting like mad and retarding quite a lot too.
i didn`t use the standard actuator, i fitted a forge with a yellow spring but found the diaphragm to be leaking which meant the wastegate was being held shut. i fixed that and found it was still having a massive boost spike (25 psi settled down to about 15) at low rpm / high load and found that this was due to either the map or the n75 being unable to control the wastegate. i fixed this by temporarily fitting a bleed type 3 port MBC and set it to about 18psi (ive had it at a solid 20psi and it pulls crazy  :evil:).
i was still having timing retard, mainly on cyl3 and found that this was because i still had the standard cat fitted due to putting it through the MOT. i fitted the decat and walla! running sweet.
i plan to fit a 2 port valve in parallel  with the n75 next to smooth things out as it is a little jerky when letting off boost.
on a side note, the turbo has been fitted a while now and still pulls strong and no issues so far.
oh, and from what i can work out, it has both k04 turbine and compressor wheels, so basically, a k04 in a k03s shell.
here, have a read http://www.golfgtiforum.co.uk/index.php?topic=118677.20
Title: Re: Golfyste's road legal mk4 "project track car" *She's on the road!*
Post by: golfyste on 29 September 2013, 22:54
Wow! Haha cheers for the info dude!
Good to know the turbo is still going strong I was considering changin it back but I may have to fit a mbc for the time being u till I can get the map tweeked and keep this turbo.

How do you go about fitting the mbc to work with the n75?

I currently have the standard actuator fitted as the holes in the bracket for my forge one didn't line up!  :undecided:

Hmmm k04 internals mean potential higher 200's maybe  :evil:

Title: Re: Golfyste's road legal mk4 "project track car" *She's on the road!*
Post by: jamie16v on 29 September 2013, 23:06

How do you go about fitting the mbc to work with the n75?
http://uk-mkivs.net/forums/p/383118/2704970.aspx



Hmmm k04 internals mean potential higher 200's maybe  :evil:
indeed  :grin: as long as you have the fuel supply to cope, i.e bigger injectors, fuel pump/new filter and maf.
I currently have the standard actuator fitted as the holes in the bracket for my forge one didn't line up!  :undecided:
contact forge, im sure theyll send you a bracket. luckily mine was a straight fit. there are three types apparently. the bracket didnt fit my old k03s.
or, just modify your current bracket to accept the forge actuator, all it takes is two holes drilling or notches grinded.
Title: Re: Golfyste's road legal mk4 "project track car" *She's on the road!*
Post by: golfyste on 29 September 2013, 23:25
Big thanks!
Think I may have to do that or the time being then!

Well I have bam injectors and pump all I'm missing is a bam maf but tbf when I get it tweeked I'm not lookin for max power as that will what I'm after with te tfsi k04. For now its just a safe power I can use for runnin I'm the new engine once it's done!

I could modify (or more be bothered/have tome) the bracket as it needed bending and completely reshaping not just redrilling etc otherwise I would have!  :laugh:
Title: Re: Golfyste's road legal mk4 "project track car" *She's on the road!*
Post by: golfyste on 29 September 2013, 23:27
A quick update from today!  :cool:

 I spent the day at the R-Tech charity event and it was a awesome day at that!

Sadly i didn't get the car on the rollers due to it not running very well but there were some awesome displays of power from the other cars and r-tech managed to raise about £2,200 for charity so all in all it was a successful day!

A few pictures from the day, some of you may recognize a few of the cars!



(http://i1197.photobucket.com/albums/aa433/golfyste/GOPR0196.jpg) (http://s1197.photobucket.com/user/golfyste/media/GOPR0196.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/GOPR0198.jpg) (http://s1197.photobucket.com/user/golfyste/media/GOPR0198.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/GOPR0200.jpg) (http://s1197.photobucket.com/user/golfyste/media/GOPR0200.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/GOPR0202.jpg) (http://s1197.photobucket.com/user/golfyste/media/GOPR0202.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/GOPR0204.jpg) (http://s1197.photobucket.com/user/golfyste/media/GOPR0204.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/GOPR0206.jpg) (http://s1197.photobucket.com/user/golfyste/media/GOPR0206.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/GOPR0208.jpg) (http://s1197.photobucket.com/user/golfyste/media/GOPR0208.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/GOPR0209.jpg) (http://s1197.photobucket.com/user/golfyste/media/GOPR0209.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/GOPR0210.jpg) (http://s1197.photobucket.com/user/golfyste/media/GOPR0210.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/GOPR0211.jpg) (http://s1197.photobucket.com/user/golfyste/media/GOPR0211.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/GOPR0211.jpg) (http://s1197.photobucket.com/user/golfyste/media/GOPR0211.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/Untitled4.png) (http://s1197.photobucket.com/user/golfyste/media/Untitled4.png.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/Untitled2.png) (http://s1197.photobucket.com/user/golfyste/media/Untitled2.png.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/Untitled3.png) (http://s1197.photobucket.com/user/golfyste/media/Untitled3.png.html)
Title: Re: Golfyste's road legal mk4 "project track car" *She's on the road!*
Post by: Dave_IOW on 29 September 2013, 23:41
My AGU with K03s was also knocking back to 5psi when I was at full chat in 3rd, 4th and 5th, although I did have that peaking at 22psi, Forge actuator, yellow spring.

So what do we think is doing this? N75 not being able to adapt far enough for the increased boost on a map not designed for it? Mine has a stage1 k03 map on it.
Title: Re: Golfyste's road legal mk4 "project track car" *She's on the road!*
Post by: golfyste on 29 September 2013, 23:46
Yeah I'm guessing that's what is causing it!

The bigger comp wheel is just throwing a lot more air and pressure into the system then the n75 has been set up To handle and in turn is causing I to spike!
Title: Re: Golfyste's road legal mk4 "project track car" *She's on the road!*
Post by: jamie16v on 29 September 2013, 23:47
That's my opinion dave! Though not sure why yours is dropping to 5psi.
Do you get any codes? Do you have logs?
Title: Re: Golfyste's road legal mk4 "project track car" *She's on the road!*
Post by: golfyste on 29 September 2013, 23:49
Well when it drops the pressure isn't that dropping it to actuator pressure?

So surely that means Dave actuator is knacked?
Title: Re: Golfyste's road legal mk4 "project track car" *She's on the road!*
Post by: jamie16v on 30 September 2013, 00:21
Could just be the n75 map IMO. The actuator sounds like it's doing its jobs as it reaches 22 psi and then opens the wastegate. A vac test will tell for sure.
Title: Re: Golfyste's road legal mk4 "project track car" *She's on the road!*
Post by: golfyste on 30 September 2013, 00:24
Ahh ok then.

Anyway I just order a bunch of parts included hose and related bits to fit my catch can and also a mbc  :cool:
Title: Re: Golfyste's road legal mk4 "project track car" *She's on the road!*
Post by: jamie16v on 30 September 2013, 00:37
You know it makes sense  :wink:
Title: Re: Golfyste's road legal mk4 "project track car" *She's on the road!*
Post by: Wazzzer on 30 September 2013, 22:13
Dave that is boost based limp mode...
Title: Re: Golfyste's road legal mk4 "project track car" *She's on the road!*
Post by: jamie16v on 30 September 2013, 23:08
Doesn't limp mode hold in until the ignition switch is reset?
Title: Re: Golfyste's road legal mk4 "project track car" *She's on the road!*
Post by: Dave_IOW on 30 September 2013, 23:36
Mine didn't, I could lay off the throttle, wait a couple of secs, nail it again and would be back up to where I started? Once I hit whatever limit it was, back down to 5psi.

Could do this an unlimited amount of times without switching engine off?

Was kind of hoping it was because the Cambelt was a tooth and a half out :grin:
Title: Re: Golfyste's road legal mk4 "project track car" *She's on the road!*
Post by: Wazzzer on 02 October 2013, 22:11
No not on the AGU Jamie, like I say it's just boost limp mode. The N75 is just opening the wastegate fully to save the engine. It's the only form of protection the AGU has and it works well TBH
Title: Re: Golfyste's road legal mk4 "project track car" *She's on the road!*
Post by: golfyste on 02 October 2013, 22:15
I got a email today from Xs-power containing the specs of the turbo!
The image shows it is indeed a k04 inside a k03 housing!

(http://i1197.photobucket.com/albums/aa433/golfyste/null_zps0485f749.gif)
Title: Re: Golfyste's road legal mk4 "project track car" *She's on the road!*
Post by: golfyste on 03 October 2013, 20:58
Ok time for another update!

This lot arrived yesterday!

(http://i1197.photobucket.com/albums/aa433/golfyste/null_zps898abef4.jpg)

So I set about fitting it all to try and sort my problems!
I made a little braket for the catch can and fitted all the pipe work!

(http://i1197.photobucket.com/albums/aa433/golfyste/null_zps18c8e9dc.jpg)

Breather filter and in position

(http://i1197.photobucket.com/albums/aa433/golfyste/null_zps56799e37.jpg)

(http://i1197.photobucket.com/albums/aa433/golfyste/null_zps627dc9cc.jpg)

I also fitted the mbc in parallel with the n75.
It's not the neatest thing in the world but its works! (Don't mind the temporary bung haha I replaced it today with a proper bung I ordered)

(http://i1197.photobucket.com/albums/aa433/golfyste/null_zpseff9aa9f.jpg)

I've managed to set the mbc I 19 psi and its pulling nice and smoothly and fitting he oil catch can has eliminated my smoking issues!!  :grin:
The "puck valve" was full of oil and wasn't closing under vacuum (on boost) so was sucking oil through it!

So all that is good now but of course more problems has appeared  :angry:
I have a oil leak but am struggling to find where it's coming from! There was quite a bit of oil about but it's also been raining all day so hard to tell here its coming from.

While I was trying to find it I was getting annoyed by the plate with the n112 valve etc so I ripped it all out and planked the vacuum lines and fed a new one to my 007p haha

I also found that my ns drive shaft is a bit worn and is knocking a little so I need to look at replacing it!

Title: Re: Golfyste's road legal mk4 "project track car" *She's on the road!*
Post by: golfyste on 05 October 2013, 23:07
Ok so got a bad exhaust blow this morning!
So after work and some tea I got the car jacked up and had a good look around!

(http://i1197.photobucket.com/albums/aa433/golfyste/null_zps4d7f2be9.jpg)

I found that the turbo bolts had actually started coming loose! So I nipped them up tightly and will be keeping my eyes on them!

Also I saw a bit of oil leaking from the turbo oil return so I removed it and fitted a new gasket.
Just gotta keep my eye out it some more drips.

I also emptied the catch can and after only a couple of days I got all this!!

 (http://i1197.photobucket.com/albums/aa433/golfyste/null_zps81d3608a.jpg)


Surely this isn't right?
On my old car it would take maybe 2 week to get this much!
Anybody any idea What can cause this excess oil vapour?

Also went around and checked everything was tight and found the top mounts a tad loose so nipped them up which will hopefully solve the slight knocking I had!


Just gonna try keep my eye out for anything wrong to make sure it's running nice before I plan anything else!
Title: Re: Golfyste's road legal mk4 "project track car" *She's on the road!*
Post by: golfyste on 18 October 2013, 13:45
Last week I put my fan on high to try demist the windscreen and it stopped working and there was a very nice burning smell  :sad:

So I set about trying to find the problem!

I found that I was pretty lucky really as the fuse for the fan had melted! And also put a nice hole in the fuse box!! But luckily it had only taken out that one connection and not all the surrounding ones.

A few pictures if the damage...

You can see how the fuse is melted and it had actually fused in place and it took a good pull to get it out!

(http://i1197.photobucket.com/albums/aa433/golfyste/null_zps3d3c2478.jpg)

The fuse it's self!

(http://i1197.photobucket.com/albums/aa433/golfyste/null_zps82ef0ee5.jpg)

And the rear heated screen fuse below it

(http://i1197.photobucket.com/albums/aa433/golfyste/null_zpsed878c45.jpg)



and you can see inside how it has melted the fuse connection

(http://i1197.photobucket.com/albums/aa433/golfyste/null_zps6176534c.jpg)

(http://i1197.photobucket.com/albums/aa433/golfyste/null_zps3bf0a80c.jpg)



I removed all the lower dash and spent the afternoon tryin to find what had caused the fuse to melt.

I removed all the controls test resistances across all the wires and components, tested the resistor block and also test the fan and everything is perfectly fine so I'm assuming that it was the fuse had maybe work loose and gone faulty and caused it to arch across causing the damage.

(http://i1197.photobucket.com/albums/aa433/golfyste/null_zps6e5acf22.jpg)

I then wired in a external fuses off the switch live in the fuse box to the controls when the normal wire went and now everything works fine!

(http://i1197.photobucket.com/albums/aa433/golfyste/null_zpsf8bd4552.jpg)



Another little mini project I've got on the go started with a delivery of these  :grin:

An r32 replica bumper...

(http://i1197.photobucket.com/albums/aa433/golfyste/null_zps9ecbc81a.jpg)

(http://i1197.photobucket.com/albums/aa433/golfyste/null_zpsdf3ee99d.jpg)

And a polyurethane bmw m3 trunk spoiler

(http://i1197.photobucket.com/albums/aa433/golfyste/null_zps3d19d207.jpg)



Basically I needed a r32 bumper as I'm going to be fitting a wellycooler but as known they don't fit behind the standard mk4 bumper so I needed the extra space you get behind the r32 bumper.

I was wanting a gen bumper but I couldn't justify £350-£400 on a bumper and then painting it to maybe smash it up on track and also I have other I need to spend the money on! so I opted for a £120 rep bumper haha

The plan with the m3 spoiler arrived a week or two ago when I found a r32 spoiler in my shed that I had forgot about which I had bought for my previous golf but never fitted! And I thought about how I could make the r32 spoiler an actually effective spoiler that creates downforce as with no weight in the back of the car the back end is a little light at speed!

I just wanted a cheap DIY mid and I was thinking about making a lip out of fibreglass and the idea just spring to mind so I bought a m3 lip on eBay haha

As you can see the m3 lip is a nice scooped shape and should produce at least a little downforce

(http://i1197.photobucket.com/albums/aa433/golfyste/null_zps8d153f67.jpg)

i was thinking something like this

(http://i1197.photobucket.com/albums/aa433/golfyste/null_zps7f9f0079.jpg)

I cut the spoiler to length and managed to file and shape the end quite well

(http://i1197.photobucket.com/albums/aa433/golfyste/null_zpsb7b2d375.jpg)

With the lip the right length

(http://i1197.photobucket.com/albums/aa433/golfyste/null_zps95a563f2.jpg)

I've been forming the lip into a bend to match the profile of the spoiler for the last few days and it holds its shape so I just have to set about sticking it to the spoiler next!

(http://i1197.photobucket.com/albums/aa433/golfyste/null_zpsc08e7355.jpg)



I've also been messing with the bumper as I knew it wouldn't fit perfectly haha

I managed to get it to fit quite well on the arches unlike most replicas but it's a bit tight around the headlights! You sort of have to force it into position!

You can't really tell in the pictures that it's not perfect but it's good enough for what I need although I wouldn't recommend it for someone with more of a "scene" car as you can tell it doesn't fit perfect.

(http://i1197.photobucket.com/albums/aa433/golfyste/null_zps811e3947.jpg)

(http://i1197.photobucket.com/albums/aa433/golfyste/null_zps5fa63e23.jpg)

It also makes my ths cooler look small haha

(http://i1197.photobucket.com/albums/aa433/golfyste/null_zps1c688c1a.jpg)



And the final little edition!.....a case for my iphone attached to the shifter platform as I was fed up of having to jam my phone between my leg and my seat while it's plugged into the head unit haha

(http://i1197.photobucket.com/albums/aa433/golfyste/null_zps0acfce0a.jpg)



next step is get the spoiler fitted and then get that and the bumper painted fitted and then get a wellycooler fitted!

I'm also on the lookout for some brembos and 256mm rear brake setup!



And comments etc welcome!  :cool:
Title: Re: Golfyste's road legal mk4 "project track car" *She's on the road!*
Post by: Dave_IOW on 18 October 2013, 17:00
Good work mate, R32 front makes a massive difference for room doesn't it!

I'd love a wellycooler, but there's NO way I can fit one unless I strap it on the outside of the front bumper :laugh:
Title: Re: Golfyste's road legal mk4 "project track car" *She's on the road!*
Post by: Wazzzer on 18 October 2013, 17:14
The technical term for what you are creating on the spoiler is a gurney flap  :wink:
Title: Re: Golfyste's road legal mk4 "project track car" *She's on the road!*
Post by: golfyste on 18 October 2013, 18:38
Good work mate, R32 front makes a massive difference for room doesn't it!

I'd love a wellycooler, but there's NO way I can fit one unless I strap it on the outside of the front bumper :laugh:

Yeah it does! The ths cooler look big behind the standard bumper and you have to cut quite a bit away but tiny behind the r32 bumper there's loads of room!

Yeah a big problem with puttin the 1.8t in the mk2


Cheer a wazzer  :laugh:
Title: Re: Golfyste's road legal mk4 "project track car" *She's on the road!*
Post by: golfyste on 20 October 2013, 20:30
A little update!

I ordered a toyosports type b cooler (wellycooler) so that should be coming this week!

I've also done a little work on the spoiler.

I started by cleaning up the surface on the spoiler that the lip would be stuck too and marked up the center points on boththe spoiler and the lip.

(http://i1197.photobucket.com/albums/aa433/golfyste/null_zps7cdf7d50.jpg)



I also decided that I was going to stick the lip on using the supplied adhesive tape and some tiger seal Inbetween. So I roughed up the surface Inbetween the tape with some emery.

I then applied a small bead of tiger seal and stuck the lip in the desired position and although it felt very solid as soon as it stuck I tightly wrapped some electrical tape around it just in case.

(http://i1197.photobucket.com/albums/aa433/golfyste/null_zps14727589.jpg)

(http://i1197.photobucket.com/albums/aa433/golfyste/null_zpsd7aacc95.jpg)

(http://i1197.photobucket.com/albums/aa433/golfyste/null_zps1b6e9a69.jpg)



I'm going to let it all set over night and then just go around the edges with some tiger seal to stop any water ingress and help hold it that little bit better!

Once that's all sorted I can send both the spoiler and the bumper to be painted!  :grin:
Title: Re: Golfyste's road legal mk4 "project track car" *She's on the road!*
Post by: golfyste on 21 October 2013, 20:54
Wellycooler arrived today  :grin:



(http://i1197.photobucket.com/albums/aa433/golfyste/null_zpsc9729f0e.jpg)
Title: Re: Golfyste's road legal mk4 "project track car" *She's on the road!*
Post by: Dave_IOW on 22 October 2013, 18:10
Did you go for 3" or 2.5"?

Mine should be here soon :grin:
Title: Re: Golfyste's road legal mk4 "project track car" *She's on the road!*
Post by: golfyste on 22 October 2013, 18:53
Went for the bigger core with 3" inlets for maximum effect!  :evil:
The photo doesn't do it justice  :sad:
Title: Re: Golfyste's road legal mk4 "project track car" *She's on the road!*
Post by: Dave_IOW on 22 October 2013, 19:36
Think cores are same size mate, 600 x 300 x 75   :kiss:

Just no need for reducers each side  :tongue:
Title: Re: Golfyste's road legal mk4 "project track car" *She's on the road!*
Post by: Dave_IOW on 22 October 2013, 19:37
The photo doesn't do it justice  :sad:

There's a picture on SCN against a 42" TV, that gives you the idea of these beasts :wink:
Title: Re: Golfyste's road legal mk4 "project track car" *She's on the road!*
Post by: golfyste on 22 October 2013, 19:44
You seem to be correct  :grin:
I had only seen the 2.5" inlets version which was smaller but you can get the big core with 2.5 too haha   :laugh:

Never miiiiiind doesn't really make much difference I'll still make it fit  :grin:
Title: Re: Golfyste's road legal mk4 "project track car" *She's on the road!*
Post by: Dave_IOW on 22 October 2013, 22:54
You seem to be correct  :grin:
I had only seen the 2.5" inlets version which was smaller but you can get the big core with 2.5 too haha   :laugh:

Never miiiiiind doesn't really make much difference I'll still make it fit  :grin:

Yeah, most 2.5" ones have got the 64mm core too, I know what you mean!

Just got the problem of making mine fit now, you should be alright though mate, when you aiming to fit it? Have you test fitted behind your bumper yet? If so, what's the room like? You going for 3 or 2.5 pipework?
Title: Re: Golfyste's road legal mk4 "project track car" *She's on the road!*
Post by: golfyste on 23 October 2013, 16:03
Yeah I imagine your gonna have quite a job on!  :laugh:
No haven't test fitted it yet!
There's plenty of room behind the r32 bumper is I'm not worried  :cool:
Going for 2.5" dude, what you going for?
Title: Re: Golfyste's road legal mk4 "project track car" *She's on the road!*
Post by: Dave_IOW on 23 October 2013, 17:45
I'm going for 2.5" mate, why I opted for that sized inlets so I didn't have to use any reducers.

Going to try and hard pipe the whole lot later on when it's up and running, eliminate any potential leaks :cool:
Title: Re: Golfyste's road legal mk4 "project track car" *She's on the road!*
Post by: golfyste on 23 October 2013, 22:01
Sweet, will be awesome in the mk2!
I'm not gonna hard pipe it yet as I'm planning on going tfsi turbo which will completely change the routing!
Title: Re: Golfyste's road legal mk4 "project track car" *She's on the road!*
Post by: golfyste on 05 November 2013, 03:06
Ok not much to update I'm afraid...

motovation has been slacking and weather has been crap!

First of all I had to help myate Ryan change his sump as he decided to attack a speedbump with his! Creating a nice big crack in it! So I stripped te sump of my spare engine and took the necessary tools to his!



(http://i1197.photobucket.com/albums/aa433/golfyste/null_zpse0d14eb5.jpg)

(http://i1197.photobucket.com/albums/aa433/golfyste/null_zps55cc25f4.jpg)



ive also been doing a little work ok the spoiler out of the weather!

I decided I was going to smooth the lip in a little more so lots of messing with filler and sanding and filler and sanding then priming and more filler ect ect



(http://i1197.photobucket.com/albums/aa433/golfyste/null_zpsf5a1f8a3.jpg)

(http://i1197.photobucket.com/albums/aa433/golfyste/null_zpsf1c3ab2b.jpg)

(http://i1197.photobucket.com/albums/aa433/golfyste/null_zps1a3e2d9a.jpg)

(http://i1197.photobucket.com/albums/aa433/golfyste/null_zps70fb565b.jpg)

(http://i1197.photobucket.com/albums/aa433/golfyste/null_zps45c2b965.jpg)

(http://i1197.photobucket.com/albums/aa433/golfyste/null_zpse6cb0df2.jpg)

(http://i1197.photobucket.com/albums/aa433/golfyste/null_zps57564334.jpg)

(http://i1197.photobucket.com/albums/aa433/golfyste/null_zpsdba34eb2.jpg)



It's getting there! Haha



I also discovered some bad news...it's seems my crankcase is getting pressurised as I looked under the bonnet and the oil cap had been blown off and had sprayed oil everywhere!!

So it looks like I will be taking the golf off the road for the winter to do the engine build/swap soon then I had hoped!

But never mind I've gone and bought myself a winter car haha which is coming tomorrow so I will update with a few photos! Haha




Title: Re: Golfyste's road legal mk4 "project track car" *She's on the road!*
Post by: Dave_IOW on 05 November 2013, 07:42
Winter car? :huh: :laugh:
Title: Re: Golfyste's road legal mk4 "project track car" *She's on the road!*
Post by: golfyste on 05 November 2013, 12:00
Yeah seen as the golf is coming back off the road to strip the bay and swap the engine I thought I would buy myself something that won't get stuck in the snow as easily as the golf did last year  :laugh:
Title: Re: Golfyste's road legal mk4 "project track car" *She's on the road!*
Post by: Rylarr on 05 November 2013, 20:56
THE WINTER CAR IS SOOOOO SICK  :laugh:

and that speed bump jumped out on me  :whistle:
Title: Re: Golfyste's road legal mk4 "project track car" *She's on the road!*
Post by: golfyste on 06 November 2013, 21:25
Ok ok

I said winter car but it's more of a mini monster trust  :laugh:

(http://i1197.photobucket.com/albums/aa433/golfyste/null_zpsccac95da.jpg)

(http://i1197.photobucket.com/albums/aa433/golfyste/null_zps1512e01b.jpg)

(http://i1197.photobucket.com/albums/aa433/golfyste/null_zpsdabe635b.jpg)

(http://i1197.photobucket.com/albums/aa433/golfyste/null_zps4f16bea8.jpg)

I'm not gettin stuck as easy as I did last year! Haha

I see this winter being quite fun!
Title: Re: Golfyste's road legal mk4 "project track car" *She's on the road!*
Post by: Dave_IOW on 06 November 2013, 22:19
Haha that looks fun mate :laugh:
Title: Re: Golfyste's road legal mk4 "project track car" *She's on the road!*
Post by: Diamond Hell on 06 November 2013, 22:31
Find a 4x4 Club.  Go trialing.  Then you'll have fun.

If you go off-road you're going to need to let those huge balloons down to about 10PSI to make them grip properly.

And read up on winching before you start playing with that drum on the front - lots of dos and don'ts and ways to get seriously hurt.
Title: Re: Golfyste's road legal mk4 "project track car" *She's on the road!*
Post by: golfyste on 08 November 2013, 01:14
Yeah I'll definitely be goin laning! I know quite a few around me due to going out on the ktm!

Yeah I'm gonna get a decent tyre compressor so I can hangs the pressures at will.  :cool:

And I've already read up a bit on winching and I also do quite a bit of rigging and slinging at work and will probably only be doing simple straight pulls but thanks for the concern  :smiley:

Have open ears if you have any tip  :smiley:

Currently working on the disco this week to get it through the kit and serviced etc so I can get it on the road then it will be back to working on the golf  :cool:
Title: Re: Golfyste's road legal mk4 "project track car" *She's on the road!*
Post by: smithyvr6 on 09 November 2013, 22:25
What bike is that you have in you garage??
Title: Re: Golfyste's road legal mk4 "project track car" *She's on the road!*
Post by: golfyste on 10 November 2013, 00:00
Ktm 400exc dude  :cool:
If you go back to page 12 I posted a few photos of it as I had to remove the engine!
Title: Re: Golfyste's road legal mk4 "project track car" *She's on the road!*
Post by: Wazzzer on 10 November 2013, 11:40
So does this mean the K04 wasn't at fault?
Title: Re: Golfyste's road legal mk4 "project track car" *She's on the road!*
Post by: golfyste on 10 November 2013, 11:43
Yeah I think the original 001 was ok as it was the catch can and venting the breather to atmosphere that solved the problem!

Now stuck as to weather I fit the original 001 to the rebuilt engine as the Ecu already has a decent map in it and will be better for running the engine in ir do I fit the bigger new 001 and run on actuator pressure to run the engine in until I get it mapped!?!?  :huh: :undecided:
Title: Re: Golfyste's road legal mk4 "project track car" *She's on the road!*
Post by: smithyvr6 on 10 November 2013, 15:49
Just had a look at page 12 mate...that was lucky  :shocked: ive got a 2009 yzf 250 and a 1998 rm 250.
Title: Re: Golfyste's road legal mk4 "project track car" *She's on the road!*
Post by: golfyste on 10 November 2013, 15:51
Just had a look at page 12 mate...that was lucky  :shocked: ive got a 2009 yzf 250 and a 1998 rm 250.
[/quote/]

Just abit!!  :laugh:
Very nice! I need to get out on mine a but more often I think haha
Title: Re: Golfyste's road legal mk4 "project track car" *She's on the road!*
Post by: Wazzzer on 10 November 2013, 16:59
bit of a dilemma then bud. Personally I'd stick with the newer one...
Title: Re: Golfyste's road legal mk4 "project track car" *She's on the road!*
Post by: Diamond Hell on 11 November 2013, 08:47
Do the breathers on these engines block at all?  Worth having a poke around before you rip the motor out and get all heavy on it.

The risk with your Discovery is that you'll get further from safety before it beaches itself.  :grin:

Also you have a winch on the front, which is handy if you need to recover someone else, but rubbish if you've driven into something you want to get out of cos your only option is further forwards.  :wink:
Title: Re: Golfyste's road legal mk4 "project track car" *She's on the road!*
Post by: golfyste on 31 December 2013, 18:23
Ok I've not updated this I'm ages!
Mainly because I've been crazy busy with work and family etc and also been working on/fixing the disco
....but that's another story 
BUT! It's time to get back on this!

Just started work on the engine

Got it in the garage

(http://i1197.photobucket.com/albums/aa433/golfyste/AF506474-6AF2-4B93-AE80-0CCDAD2DD216.jpg) (http://"http://s1197.photobucket.com/user/golfyste/media/AF506474-6AF2-4B93-AE80-0CCDAD2DD216.jpg.html")

Stripped the loom off and tagged everything up

(http://i1197.photobucket.com/albums/aa433/golfyste/CEBD862D-D1F9-4D3A-8FD9-7DDD20DBF789.jpg) (http://"http://s1197.photobucket.com/user/golfyste/media/CEBD862D-D1F9-4D3A-8FD9-7DDD20DBF789.jpg.html")

Removed the egr and hard pipes that won't be needed and started attaching my home made engine stand bracket

(http://i1197.photobucket.com/albums/aa433/golfyste/D68D66D8-2DAF-420B-B117-20BFF015EA5B.jpg) (http://"http://s1197.photobucket.com/user/golfyste/media/D68D66D8-2DAF-420B-B117-20BFF015EA5B.jpg.html")


Just need to make another bracket for the stand attachment and then I can start stripping it down!

bit of a dilemma then bud. Personally I'd stick with the newer one...

Yeah I think ok going to dude just gonna drive it on actuator pressure until it's mapped!


DH - the breathers do block up but mine were clear but either way I already had £600 worth of rods and other bits for he rebuild so it's being done anyway haha
Title: Re: Golfyste's road legal mk4 "project track car" *Lets start the engine build!*
Post by: golfyste on 19 January 2014, 22:36
Ok update time!

I've finally had some time to do some work on the engine!

Got it all up onto the home made stand...

(http://i1197.photobucket.com/albums/aa433/golfyste/F3A80B03-D702-44A6-A87B-24ABEF791D92.jpg) (http://s1197.photobucket.com/user/golfyste/media/F3A80B03-D702-44A6-A87B-24ABEF791D92.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/CF875BCF-AEE2-4CA9-86DC-F447274F6E73.jpg) (http://s1197.photobucket.com/user/golfyste/media/CF875BCF-AEE2-4CA9-86DC-F447274F6E73.jpg.html)


Started the strip down process which included removing all the water lines, fuel rail and injectors, oil cooler etc etc

(http://i1197.photobucket.com/albums/aa433/golfyste/53EB61C8-33CC-414B-92E4-A5F77036F879.jpg) (http://s1197.photobucket.com/user/golfyste/media/53EB61C8-33CC-414B-92E4-A5F77036F879.jpg.html)

I bagged and tagged everything as I removed it just to make things easier

(http://i1197.photobucket.com/albums/aa433/golfyste/8EF03951-E4BF-4FB8-8089-4F7F622CFB84.jpg) (http://s1197.photobucket.com/user/golfyste/media/8EF03951-E4BF-4FB8-8089-4F7F622CFB84.jpg.html)


I got to this point and got stuck as I needed the VW ribe tool for the headbolts which I had ordered and I also couldn't (and still can't as the compressor has packed up!) remove the crankshaft pulley bolt!

(http://i1197.photobucket.com/albums/aa433/golfyste/BD771E41-88BF-4C4F-A7C8-01AE0143DA7B.jpg) (http://s1197.photobucket.com/user/golfyste/media/BD771E41-88BF-4C4F-A7C8-01AE0143DA7B.jpg.html)


A few pics of a couple of bits I ordered...

(http://i1197.photobucket.com/albums/aa433/golfyste/3D9F7088-F86D-4660-8302-1ACB402D2B9E.jpg) (http://s1197.photobucket.com/user/golfyste/media/3D9F7088-F86D-4660-8302-1ACB402D2B9E.jpg.html)

I then set around removing and stripping the head down!

(http://i1197.photobucket.com/albums/aa433/golfyste/0D2159F4-F243-475F-AF54-BCA7B1A1BFEB.jpg) (http://s1197.photobucket.com/user/golfyste/media/0D2159F4-F243-475F-AF54-BCA7B1A1BFEB.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/B89E734A-F632-4FF3-820A-9DA54C62FF61.jpg) (http://s1197.photobucket.com/user/golfyste/media/B89E734A-F632-4FF3-820A-9DA54C62FF61.jpg.html)

The pistons look pretty horrible! Good job a have some more haha

(http://i1197.photobucket.com/albums/aa433/golfyste/B446B558-1537-4279-829F-361EF7B0DC12.jpg) (http://s1197.photobucket.com/user/golfyste/media/B446B558-1537-4279-829F-361EF7B0DC12.jpg.html)


My little set up

(http://i1197.photobucket.com/albums/aa433/golfyste/E8487BE8-31BA-40F7-A3E7-292A0142C326.jpg) (http://s1197.photobucket.com/user/golfyste/media/E8487BE8-31BA-40F7-A3E7-292A0142C326.jpg.html)

And stripping the large port head....

(http://i1197.photobucket.com/albums/aa433/golfyste/11B4D51D-FC70-404A-8FF9-9232137024EA.jpg) (http://s1197.photobucket.com/user/golfyste/media/11B4D51D-FC70-404A-8FF9-9232137024EA.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/C7AA3B4A-CF65-4402-B628-340DF4E06C7B.jpg) (http://s1197.photobucket.com/user/golfyste/media/C7AA3B4A-CF65-4402-B628-340DF4E06C7B.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/2437E092-B466-4647-BFF3-D94F4BD4A0E0.jpg) (http://s1197.photobucket.com/user/golfyste/media/2437E092-B466-4647-BFF3-D94F4BD4A0E0.jpg.html)

All bagged up

(http://i1197.photobucket.com/albums/aa433/golfyste/3DA3E612-C51D-4E0B-876E-47D8642077D0.jpg) (http://s1197.photobucket.com/user/golfyste/media/3DA3E612-C51D-4E0B-876E-47D8642077D0.jpg.html)


Removing the valves

(http://i1197.photobucket.com/albums/aa433/golfyste/3386B563-6B4C-496C-81F4-18F0064BDCD2.jpg) (http://s1197.photobucket.com/user/golfyste/media/3386B563-6B4C-496C-81F4-18F0064BDCD2.jpg.html)

All removed and cleaned up!

(http://i1197.photobucket.com/albums/aa433/golfyste/D0C2FE9D-DC6E-478E-A410-8D3275F40D0C.jpg) (http://s1197.photobucket.com/user/golfyste/media/D0C2FE9D-DC6E-478E-A410-8D3275F40D0C.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/A38EF95A-19F2-4344-90E4-D64CC6108A0E.jpg) (http://s1197.photobucket.com/user/golfyste/media/A38EF95A-19F2-4344-90E4-D64CC6108A0E.jpg.html)


The next step for the head is to try find somewhere to acid dip it to get it back like new and also get rid if all the carbon build up!

I also need to move onto the lower block and try get the crankshaft bolt out so I can strip the pistons and rods out and then clean up and paint the block and also hone it before starting to build it back up!

Any suggestions or anything are welcome
Cheers
Title: Re: Golfyste's road legal mk4 "project track car" *Lets start the engine build!*
Post by: Diamond Hell on 20 January 2014, 20:29
Send it to JNL Racing to be properly breathed on.  :cool:
Title: Re: Golfyste's road legal mk4 "project track car" *Lets start the engine build!*
Post by: golfyste on 20 January 2014, 20:31
I have heard of jnl!

What would you suggest I get them to do?
Also I have no idea on the cost of head work! Haha  :laugh:
Title: Re: Golfyste's road legal mk4 "project track car" *Lets start the engine build!*
Post by: golfyste on 20 January 2014, 22:30
If I get the guides replaced will I also need to get the valves replaced?

Don't really want to buy new valves as the plan is to uprate the valves and stuff next winter!

Could do with it dipping and cleaning up properly though!

Also unsure wether to do any porting or not   :undecided:

Original plan was to just get it rebuilt standard and get it all running and mapped and then look at some headwork next winter!
Title: Re: Golfyste's road legal mk4 "project track car" *Lets start the engine build!*
Post by: Dave_IOW on 21 January 2014, 07:28
Wouldn't have thought unless your putting super tech valves in now, there's not much point doing anything much to it yet.
Title: Re: Golfyste's road legal mk4 "project track car" *Lets start the engine build!*
Post by: Diamond Hell on 21 January 2014, 10:42
If you're staying standard get it tidied up by a local machine shop - skim, guides and dip-clean shouldn't be too much.  You can put your existing valves back in, no worries.  They should be fine to lap your valves back in for you as well - might be worthwhile getting it done.... depends on costs.

Unfortunately head work ain't cheap.... but it's probably the area where you're mostly likely to see big gains, after the rotary silencer.
Title: Re: Golfyste's road legal mk4 "project track car" *Lets start the engine build!*
Post by: golfyste on 21 January 2014, 13:31
That's what I wanted to hear!  :cool:
So I'll get the guides done and get it all cleaned up etc
Found a local machine shop who do headwork but can't for the life of me find anywhere to buy the guides???
Only ones I can find are updated super tech guides but can't find oem ones.
Vw don't sell then  :undecided:
Title: Re: Golfyste's road legal mk4 "project track car" *Lets start the engine build!*
Post by: Diamond Hell on 21 January 2014, 20:12
You should have the guides as part of the head gasket kit - that's certainly how they're normally flogged.
Title: Re: Golfyste's road legal mk4 "project track car" *Lets start the engine build!*
Post by: golfyste on 21 January 2014, 20:14
Naaa no guides only seals!
Apparently VW  don't make them and not many other people do either!

I've ordered some anyway and also ordered a few other bits and bobs so will update when they arrive!
Title: Re: Golfyste's road legal mk4 "project track car" *Lets start the engine build!*
Post by: golfyste on 26 January 2014, 21:18
Ok so a quick update!  :cool:

New compressor came! Which meant I could remove the seized crankshaft bolt using the BIG 1" drive impact gun!

(http://i1197.photobucket.com/albums/aa433/golfyste/481C43ED-AE2A-45BA-8282-1FF6CFDF0D81.jpg) (http://s1197.photobucket.com/user/golfyste/media/481C43ED-AE2A-45BA-8282-1FF6CFDF0D81.jpg.html)

 (http://i1197.photobucket.com/albums/aa433/golfyste/B29B21C7-3D39-497A-9F65-FFD2EE5D3428.jpg) (http://s1197.photobucket.com/user/golfyste/media/B29B21C7-3D39-497A-9F65-FFD2EE5D3428.jpg.html)


This then allowed me to strip the rest of the lower block.
Including removing the oil pump and chain, belt side crankshaft oil seal plate, clutch side oil seal flange, big end bearing caps, main bearing caps

(http://i1197.photobucket.com/albums/aa433/golfyste/D682C84E-9D8B-4388-9E9D-A768C5A8BD9A.jpg) (http://s1197.photobucket.com/user/golfyste/media/D682C84E-9D8B-4388-9E9D-A768C5A8BD9A.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/E0B54432-13B9-4146-8FC9-7E751DD44685.jpg) (http://s1197.photobucket.com/user/golfyste/media/E0B54432-13B9-4146-8FC9-7E751DD44685.jpg.html)


I then proceeded to remove the piston oil squirters and pistons

(http://i1197.photobucket.com/albums/aa433/golfyste/146D709B-69C3-4248-8E9D-5B8D3ABB84E2.jpg) (http://s1197.photobucket.com/user/golfyste/media/146D709B-69C3-4248-8E9D-5B8D3ABB84E2.jpg.html)

And then decided to compare the old piston and rod setup to the new one!

(http://i1197.photobucket.com/albums/aa433/golfyste/2AFCFAFA-2149-438E-91E0-63736D68AA3E.jpg) (http://s1197.photobucket.com/user/golfyste/media/2AFCFAFA-2149-438E-91E0-63736D68AA3E.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/044A7574-12DF-42A1-B1C2-D738FA387149.jpg) (http://s1197.photobucket.com/user/golfyste/media/044A7574-12DF-42A1-B1C2-D738FA387149.jpg.html)


I then started cleaning the block off all the thick crap and flaking bits of paint using a scraper and also started cleaning it with degreaser/acid and a stiff brush but haven't got any photos!


Also a few more bits arrived!

New revised piston for the 007p

(http://i1197.photobucket.com/albums/aa433/golfyste/205C8A43-A5AE-4873-8D02-0E9C192BE676.jpg) (http://s1197.photobucket.com/user/golfyste/media/205C8A43-A5AE-4873-8D02-0E9C192BE676.jpg.html)

New braided lines and fluid

(http://i1197.photobucket.com/albums/aa433/golfyste/73437696-D4C9-45AE-B220-271FEC14F35A.jpg) (http://s1197.photobucket.com/user/golfyste/media/73437696-D4C9-45AE-B220-271FEC14F35A.jpg.html)

And also a low range torque wrench and some redline assembly lube  :grin:

(http://i1197.photobucket.com/albums/aa433/golfyste/0F242011-12F3-442D-ACE0-052F815E9AA1.jpg) (http://s1197.photobucket.com/user/golfyste/media/0F242011-12F3-442D-ACE0-052F815E9AA1.jpg.html)

That's it for now!
Just ordered some paint for the block etc and some rear discs and pads!
Title: Re: Golfyste's road legal mk4 "project track car" *Lets start the engine build!*
Post by: golfyste on 31 January 2014, 00:09
Ok managed to pull the engine out and give it a good clean, scrub and have masked it up ready for painting!

Also a few more bits have arrived!
Rear 256mm callipers and carriers (haven't got any photos yet) they look in good condition but I think I may refurb them before fitting!

Also new 256mm rear discs and pads!

(http://i1197.photobucket.com/albums/aa433/golfyste/689A8E3F-3B87-4725-A1CB-79517911FD3C_1.jpg) (http://s1197.photobucket.com/user/golfyste/media/689A8E3F-3B87-4725-A1CB-79517911FD3C_1.jpg.html)

New febi oil pump!

(http://i1197.photobucket.com/albums/aa433/golfyste/E950189A-9821-4FEB-A527-72A47E93B494_1.jpg) (http://s1197.photobucket.com/user/golfyste/media/E950189A-9821-4FEB-A527-72A47E93B494_1.jpg.html)

And also the first parts for my oil cooler set up which include a 16 row cooler and a mocal sandwich plate with integrated 80deg thermostat.

(http://i1197.photobucket.com/albums/aa433/golfyste/CC8B18D0-E38B-4A58-AF68-4E4B0379872D.jpg) (http://s1197.photobucket.com/user/golfyste/media/CC8B18D0-E38B-4A58-AF68-4E4B0379872D.jpg.html)
Title: Re: Golfyste's road legal mk4 "project track car" *Lets start the engine build!*
Post by: golfyste on 05 February 2014, 19:14
Got a little bit done today!

Finished cleaning up and masking the lower block and started to paint it.

Black etch primer (just what I had in the garage) and then started spraying it with the xht red.

(http://i1197.photobucket.com/albums/aa433/golfyste/B9E97C99-4E92-4C3A-B670-30823FF8AB2A.jpg) (http://s1197.photobucket.com/user/golfyste/media/B9E97C99-4E92-4C3A-B670-30823FF8AB2A.jpg.html)

A couple of coats later, each dried using the propane heater and it was done!

(http://i1197.photobucket.com/albums/aa433/golfyste/4CB6F3C2-98AE-442C-A416-A788AEBE84CA.jpg) (http://s1197.photobucket.com/user/golfyste/media/4CB6F3C2-98AE-442C-A416-A788AEBE84CA.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/0595702A-2D1B-4667-A39B-CFD18D9B469F.jpg) (http://s1197.photobucket.com/user/golfyste/media/0595702A-2D1B-4667-A39B-CFD18D9B469F.jpg.html)

It's far from perfect as it could have done with being shot blasted! But it's not a
Show car so ok not bothered haha.

Also moved onto cleaning up the Cupra r rear calipers and carriers.
A lick of etch primer and xht paint.

(http://i1197.photobucket.com/albums/aa433/golfyste/2684748C-5EA8-4512-BA09-4570FFC1BF4E.jpg) (http://s1197.photobucket.com/user/golfyste/media/2684748C-5EA8-4512-BA09-4570FFC1BF4E.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/332669C3-EC1D-4A3F-98DE-B79A3C177FF5.jpg) (http://s1197.photobucket.com/user/golfyste/media/332669C3-EC1D-4A3F-98DE-B79A3C177FF5.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/C12E961B-EE18-43C9-8FE4-6ECB5BE72FC0.jpg) (http://s1197.photobucket.com/user/golfyste/media/C12E961B-EE18-43C9-8FE4-6ECB5BE72FC0.jpg.html)

I was gonna refurb the calipers with new seals and pistons but they are nice and free so I'm gonna concentrate on some other things first and look Into later in the year.

Need to buy some main bearing shells and bolts and then I can look at building up the lower block and fitting the rings!

Any advice or comments welcome!  :cool:
Title: Re: Golfyste's road legal mk4 "project track car" *Lets start the engine build!*
Post by: golfyste on 07 February 2014, 20:54
Ok so another little update!

Did a little fiddling with the loom yesterday and removed the sai wiring as it's not wanted!

(http://i1197.photobucket.com/albums/aa433/golfyste/B508FAFE-D536-4A83-ADC6-1DD84C3F73D3.jpg) (http://s1197.photobucket.com/user/golfyste/media/B508FAFE-D536-4A83-ADC6-1DD84C3F73D3.jpg.html)


Also been to tps today and collected all this lot today!!

(http://i1197.photobucket.com/albums/aa433/golfyste/6948E29C-69A7-4C1E-B2F1-EBF3E00E5E24.jpg) (http://s1197.photobucket.com/user/golfyste/media/6948E29C-69A7-4C1E-B2F1-EBF3E00E5E24.jpg.html)

40l of quantum platinum (was on offer! Haha)
5 oil filters
Tensioner
Hydraulic damper
Non a/c aux belt
Crank seals
Oil pick up
Agu injector seats
Banjo washers
Injectors o-rings
Dipstick tubes
New main bolts which were suprisingly cheap!!
Couple of gaskets
And main shell bearings but only half a set as instead of giving me 5 pairs they have me 5 halves!

I also missed the delivery of my flexhone tool so gotta try get to the post office and get it!
Title: Re: Golfyste's road legal mk4 "project track car" *Lets start the engine build!*
Post by: golfyste on 15 February 2014, 21:37
Ok time for another little update!

I managed to pick my flex hone tool up from the post office!

(http://i1197.photobucket.com/albums/aa433/golfyste/9C9B42B5-AA87-479A-B405-B5A4D9349748_1.jpg) (http://s1197.photobucket.com/user/golfyste/media/9C9B42B5-AA87-479A-B405-B5A4D9349748_1.jpg.html)

So I set about honing the bores, got it ok for a first attempt but after some advice from jnl I managed to get the angle of the crosshatch a bit more like 45 degrees

(http://i1197.photobucket.com/albums/aa433/golfyste/C8AB814C-D78F-4EC4-9D71-F994F6723F0B_1.jpg) (http://s1197.photobucket.com/user/golfyste/media/C8AB814C-D78F-4EC4-9D71-F994F6723F0B_1.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/73301D97-26B2-4F88-A7FD-1742DC5141E6.jpg) (http://s1197.photobucket.com/user/golfyste/media/73301D97-26B2-4F88-A7FD-1742DC5141E6.jpg.html)


And then a few more parts arrived!
Baffled sump from forge! And also piston rings and crankshaft thrust washers.

(http://i1197.photobucket.com/albums/aa433/golfyste/3E3E1B96-5676-4D3F-83AF-AB70538FF080.jpg) (http://s1197.photobucket.com/user/golfyste/media/3E3E1B96-5676-4D3F-83AF-AB70538FF080.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/75E38DA2-0A87-40F5-B6BC-D33CA0F54416_1.jpg) (http://s1197.photobucket.com/user/golfyste/media/75E38DA2-0A87-40F5-B6BC-D33CA0F54416_1.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/02FFCBD4-CBFE-4708-8CC1-B490F7184480_1.jpg) (http://s1197.photobucket.com/user/golfyste/media/02FFCBD4-CBFE-4708-8CC1-B490F7184480_1.jpg.html)


I then set about gapping all the rings. After some online research I went for:
0.018" top
0.016" middle
0.018" oil ring

After the gapping I marked up the pistons 1-4 and fitted all the rings ready for install!

(http://i1197.photobucket.com/albums/aa433/golfyste/4F8F84BF-889A-4B48-8A4D-B3BE0A90E88B.jpg) (http://s1197.photobucket.com/user/golfyste/media/4F8F84BF-889A-4B48-8A4D-B3BE0A90E88B.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/F030907F-69E0-41C2-A675-8775D01A4F9E_1.jpg) (http://s1197.photobucket.com/user/golfyste/media/F030907F-69E0-41C2-A675-8775D01A4F9E_1.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/B729F845-3783-4715-B99D-C2E67E6649EB.jpg) (http://s1197.photobucket.com/user/golfyste/media/B729F845-3783-4715-B99D-C2E67E6649EB.jpg.html)


I then started install the rods onto the pistons remembering to use the redline assembly lube.
I got 2 done but found that fitting the gudgin pin retaining clips is a pain and ran out of time! I have also lost 3 of the clips so either have to buy some new ones or try remove the ones on my standard rods!

(http://i1197.photobucket.com/albums/aa433/golfyste/D4912A6E-CC45-430F-9A3E-16D847CB8ADB_1.jpg) (http://s1197.photobucket.com/user/golfyste/media/D4912A6E-CC45-430F-9A3E-16D847CB8ADB_1.jpg.html)

Just need to finish putting the rods/pistons together and then I can drop them in along with the crankshaft and move on from there!
Title: Re: Golfyste's road legal mk4 "project track car" *Lets start the engine build!*
Post by: dom on 16 February 2014, 09:26
This is going to be crazy when it's finished! :cool:
Title: Re: Golfyste's road legal mk4 "project track car" *Lets start the engine build!*
Post by: golfyste on 24 February 2014, 12:17
This is going to be crazy when it's finished! :cool:

Yeah I actually can't wait!

Everything has been going slow lately due to my landy getting stolen but gonna try get back to it ASAP!
Title: Re: Golfyste's road legal mk4 "project track car" *Lets start the engine build!*
Post by: Dave_IOW on 07 March 2014, 23:20
Certainly heading in the right direction mate  :smiley:
Title: Re: Golfyste's road legal mk4 "project track car" *Lets start the engine build!*
Post by: Diamond Hell on 10 March 2014, 12:59
If you could give Dave some pointers on the 'right direction' that would be great.  :whistle:
Title: Re: Golfyste's road legal mk4 "project track car" *Lets start the engine build!*
Post by: golfyste on 17 April 2014, 17:23
Ok I have to apologise for the lack of updates!!
Just been really busy lately and tbh when the landrover got stolen a lost a load of motivation!
BUT! Work has been restarted!

I'll start by saying the project for put to the side for a couple of weeks as I bought a new car to replace the landy and spent a little time doing a few small fixes and services etc!
Some may disapprove but to be honest it's an awesome car! Haha
Got myself a little 1.8 mx5 mk2! Haha

(http://i1197.photobucket.com/albums/aa433/golfyste/4F0F0667-5BBF-4D84-85A9-FF536E9C8D78.jpg) (http://s1197.photobucket.com/user/golfyste/media/4F0F0667-5BBF-4D84-85A9-FF536E9C8D78.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/5FB22796-E82B-41B3-83C8-E5B4181CDF49.jpg) (http://s1197.photobucket.com/user/golfyste/media/5FB22796-E82B-41B3-83C8-E5B4181CDF49.jpg.html)

It's a tidy little car and is loads of fun due to it handling like a gokart! Haha
Can't complain for a grand! Haha


Anyway back to the golf!
I got the piston retainer clips and finished installing the pistons onto the rods.

(http://i1197.photobucket.com/albums/aa433/golfyste/8024E9D3-C3C8-4571-A164-76089A49779C.jpg) (http://s1197.photobucket.com/user/golfyste/media/8024E9D3-C3C8-4571-A164-76089A49779C.jpg.html)

I then found sometime to pull the bottom end out of the garage and give it it's final clean before assembly!

(http://i1197.photobucket.com/albums/aa433/golfyste/FA9848EC-9D79-4F59-846D-C3D6246864D6.jpg) (http://s1197.photobucket.com/user/golfyste/media/FA9848EC-9D79-4F59-846D-C3D6246864D6.jpg.html)

I then installed the crank and piston oil squirters.
Also applying the redline assembly lube to all bearing surfaces etc

(http://i1197.photobucket.com/albums/aa433/golfyste/2D9A508D-8A56-43AD-9A2E-C85A23ECE62F.jpg) (http://s1197.photobucket.com/user/golfyste/media/2D9A508D-8A56-43AD-9A2E-C85A23ECE62F.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/6AD5E9F7-7C8C-4D49-800E-C35638F49A50.jpg) (http://s1197.photobucket.com/user/golfyste/media/6AD5E9F7-7C8C-4D49-800E-C35638F49A50.jpg.html)

I then started installing the pistons and rods with the calio coated bearings!

(http://i1197.photobucket.com/albums/aa433/golfyste/27999474-E5A3-456B-A2CC-3B5227D76DFA.jpg) (http://s1197.photobucket.com/user/golfyste/media/27999474-E5A3-456B-A2CC-3B5227D76DFA.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/CF29A2C4-A206-44E5-ACD9-683284EC3195.jpg) (http://s1197.photobucket.com/user/golfyste/media/CF29A2C4-A206-44E5-ACD9-683284EC3195.jpg.html)


I then had quite a big break from work but the next job was ensuring everything was ok before torquing everything up and then installing the oil pump, chain and tensioner and then the crank seals.

(http://i1197.photobucket.com/albums/aa433/golfyste/D80A8297-53FF-4730-8D46-6AEEDF966463.jpg) (http://s1197.photobucket.com/user/golfyste/media/D80A8297-53FF-4730-8D46-6AEEDF966463.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/341DB6D6-8E36-4FB9-BCC4-043545C676C1.jpg) (http://s1197.photobucket.com/user/golfyste/media/341DB6D6-8E36-4FB9-BCC4-043545C676C1.jpg.html)

I then installed the forge baffled sump! And that pretty much finished off the bottom end!!

(http://i1197.photobucket.com/albums/aa433/golfyste/A4FBC9B9-DB23-425A-963C-2062035FDB47.jpg) (http://s1197.photobucket.com/user/golfyste/media/A4FBC9B9-DB23-425A-963C-2062035FDB47.jpg.html)

I then arranged to meet Royce to buy the already build head he had for sale (big thanks for driving to meet me by the way!)
Ok the meantime I set about ripping out all the aircon and ac tad and installing the wellycooler core!

(http://i1197.photobucket.com/albums/aa433/golfyste/0FD0EB93-D32B-4C53-8BFA-DBBE7B01C9D7.jpg) (http://s1197.photobucket.com/user/golfyste/media/0FD0EB93-D32B-4C53-8BFA-DBBE7B01C9D7.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/9C06D39A-0736-487A-8650-5B99565E34AC.jpg) (http://s1197.photobucket.com/user/golfyste/media/9C06D39A-0736-487A-8650-5B99565E34AC.jpg.html)

The wellycooler!

(http://i1197.photobucket.com/albums/aa433/golfyste/CC80D023-A427-4511-8610-65A9976A75D1.png) (http://s1197.photobucket.com/user/golfyste/media/CC80D023-A427-4511-8610-65A9976A75D1.png.html)

And test fitting the r32 rep!

(http://i1197.photobucket.com/albums/aa433/golfyste/51CF557E-6BB2-48DB-8713-2F59CEE81DBC.jpg) (http://s1197.photobucket.com/user/golfyste/media/51CF557E-6BB2-48DB-8713-2F59CEE81DBC.jpg.html)

I then went to pick up the head from Royce!

(http://i1197.photobucket.com/albums/aa433/golfyste/B7E1B06A-C2E0-41AC-8670-3CB58B346512.jpg) (http://s1197.photobucket.com/user/golfyste/media/B7E1B06A-C2E0-41AC-8670-3CB58B346512.jpg.html)

When I got home I set about rebuild the head I had already stopped and then I switched the vvt tensioner from the aum head I had into the new agu head!

(http://i1197.photobucket.com/albums/aa433/golfyste/0A7015F8-3AE0-42C6-A606-5156E1041F3F.jpg) (http://s1197.photobucket.com/user/golfyste/media/0A7015F8-3AE0-42C6-A606-5156E1041F3F.jpg.html)


And that pretty much brings is to the present!!
The next plans are to clean and paint the head and rocker cover and then I can finish assembling the engine with cambelt and ancils ect ect and then strip out the current engine ready for a bay tidy up!!

I'll try and keep abit more ontop of it from now on! Haha
Title: Re: Golfyste's road legal mk4 "project track car" *Lets start the engine build!*
Post by: golfyste on 19 April 2014, 21:12
So time for another update!

Started this morning by cleaning up the head I bought from Royce. Got rid of any oil, grime and dirt and then masked it up and started to paint it!

(http://i1197.photobucket.com/albums/aa433/golfyste/3BCA3849-8A35-4DE4-A56F-12FFD312687E.jpg) (http://s1197.photobucket.com/user/golfyste/media/3BCA3849-8A35-4DE4-A56F-12FFD312687E.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/47046B39-679B-4B7C-B520-01833EA3C69E.jpg) (http://s1197.photobucket.com/user/golfyste/media/47046B39-679B-4B7C-B520-01833EA3C69E.jpg.html)

I then painted the rocker cover in red to match the block....came out quite well :)

(http://i1197.photobucket.com/albums/aa433/golfyste/836C38CB-60A4-4D43-90B5-C7659765C98C.jpg) (http://s1197.photobucket.com/user/golfyste/media/836C38CB-60A4-4D43-90B5-C7659765C98C.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/5863AE7C-625A-408E-A5A5-65EC37CBC61F.jpg) (http://s1197.photobucket.com/user/golfyste/media/5863AE7C-625A-408E-A5A5-65EC37CBC61F.jpg.html)

Fitted the headgasket and then got the head in position.

(http://i1197.photobucket.com/albums/aa433/golfyste/D2F8401F-5322-432F-99BE-00AB7DD93A88.jpg) (http://s1197.photobucket.com/user/golfyste/media/D2F8401F-5322-432F-99BE-00AB7DD93A88.jpg.html)

Timing belt and thermostat installed.

(http://i1197.photobucket.com/albums/aa433/golfyste/9E72AB58-AB95-48F4-95B5-4CA7C2F6BB90.jpg) (http://s1197.photobucket.com/user/golfyste/media/9E72AB58-AB95-48F4-95B5-4CA7C2F6BB90.jpg.html)

I then painted the cambelt covers and oil cap in vht wrinkle black...didn't come out as wrinkly as I would have liked but It's ok! :)

(http://i1197.photobucket.com/albums/aa433/golfyste/56910CA6-EC83-4AD2-ACEF-2E57B65983D7.jpg) (http://s1197.photobucket.com/user/golfyste/media/56910CA6-EC83-4AD2-ACEF-2E57B65983D7.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/4B813173-851B-4DDC-8B59-8509BD085169.jpg) (http://s1197.photobucket.com/user/golfyste/media/4B813173-851B-4DDC-8B59-8509BD085169.jpg.html)

Covers installed and few pics at the end if the day!

(http://i1197.photobucket.com/albums/aa433/golfyste/70C67F4E-0C19-4EF6-8886-D2AB24A1D8EC.jpg) (http://s1197.photobucket.com/user/golfyste/media/70C67F4E-0C19-4EF6-8886-D2AB24A1D8EC.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/8E082627-055A-47D6-8C21-D612D2BDE269.jpg) (http://s1197.photobucket.com/user/golfyste/media/8E082627-055A-47D6-8C21-D612D2BDE269.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/70A3EBB2-FF91-4828-BC87-03719B20CAB8.jpg) (http://s1197.photobucket.com/user/golfyste/media/70A3EBB2-FF91-4828-BC87-03719B20CAB8.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/9F92CACE-1A60-41F8-83B0-ECF9C8627F6F.jpg) (http://s1197.photobucket.com/user/golfyste/media/9F92CACE-1A60-41F8-83B0-ECF9C8627F6F.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/C3814BF8-228C-4D7C-8512-C0A43DC561CB.jpg) (http://s1197.photobucket.com/user/golfyste/media/C3814BF8-228C-4D7C-8512-C0A43DC561CB.jpg.html)

Main engine is pretty much done now...just need to clean and paint any ancillaries, and then get around to ripping the old engine out! 
Title: Re: Golfyste's road legal mk4 "project track car" *The engine is built!*
Post by: Scott-R on 19 April 2014, 21:37
Great effort!
Title: Re: Golfyste's road legal mk4 "project track car" *The engine is built!*
Post by: Rhyso on 19 April 2014, 21:49
Nice colour scheme. Do love that wrinkle paint  :smiley:
Title: Re: Golfyste's road legal mk4 "project track car" *The engine is built!*
Post by: golfyste on 19 April 2014, 21:55
Cheers lads! Yeah I'm pretty happy with it upto now! Happy with the colours aswell!
May have to do the rest of the highlights in the bay graphite but we will see!  :wink:
Title: Re: Golfyste's road legal mk4 "project track car" *The engine is built!*
Post by: murraymint on 19 April 2014, 22:13
That looks awesome!  :cool:
Title: Re: Golfyste's road legal mk4 "project track car" *The engine is built!*
Post by: dom on 19 April 2014, 22:45
Looks great :cool:

When do you reckon you'll be swapping the engines?
Title: Re: Golfyste's road legal mk4 "project track car" *The engine is built!*
Post by: scarr89 on 20 April 2014, 20:25
Great work. Keep it up! :afro:
Title: Re: Golfyste's road legal mk4 "project track car" *The engine is built!*
Post by: golfyste on 24 April 2014, 04:09
Big thanks lads!  :cool:
Hopefully be pulling the current engine
Out and switching them throughout June!
Title: Re: Golfyste's road legal mk4 "project track car" *The engine is built!*
Post by: golfyste on 25 May 2014, 00:14

Ok another little update!
Again I've failed at keeping upto date so it's actually another fairly large one! Haha

I decided to sort of my manifold as the bam injectors my Ecu is mapped for don't normally fit in a agu manifold....
I had to trim 12mm off of the manifold to allow the rail to sit lower so the injectors were flush inside.

(http://i1197.photobucket.com/albums/aa433/golfyste/1A0C8C5A-D927-4FB5-968C-8CA17B6A55CC.jpg) (http://s1197.photobucket.com/user/golfyste/media/1A0C8C5A-D927-4FB5-968C-8CA17B6A55CC.jpg.html)
(http://i1197.photobucket.com/albums/aa433/golfyste/3EB15288-D483-4EBF-92FE-D2DD21C081E6.jpg) (http://s1197.photobucket.com/user/golfyste/media/3EB15288-D483-4EBF-92FE-D2DD21C081E6.jpg.html)

I then painted the manifold on graphite and test fitted it just to see how it looked!

(http://i1197.photobucket.com/albums/aa433/golfyste/413E9A7A-145E-4B81-AE4D-F94997341239.jpg) (http://s1197.photobucket.com/user/golfyste/media/413E9A7A-145E-4B81-AE4D-F94997341239.jpg.html)
(http://i1197.photobucket.com/albums/aa433/golfyste/77DD2AB6-C08C-4F79-9570-1964E76B62F9.jpg) (http://s1197.photobucket.com/user/golfyste/media/77DD2AB6-C08C-4F79-9570-1964E76B62F9.jpg.html)

I then had a day of fitting my old intercooler and a vr6/g60 kit from darkside to my mates car.
We sort of had a little golf meet going off!

(http://i1197.photobucket.com/albums/aa433/golfyste/9BF5BE68-650D-43C8-8D7D-294D3C35CF5B.jpg) (http://s1197.photobucket.com/user/golfyste/media/9BF5BE68-650D-43C8-8D7D-294D3C35CF5B.jpg.html)
(http://i1197.photobucket.com/albums/aa433/golfyste/435FA42D-7A58-4FB7-BFCE-9B85FD0EC353.jpg) (http://s1197.photobucket.com/user/golfyste/media/435FA42D-7A58-4FB7-BFCE-9B85FD0EC353.jpg.html)
(http://i1197.photobucket.com/albums/aa433/golfyste/9BA9097E-1BBA-4DB8-B7F8-0A5A58399B45.jpg) (http://s1197.photobucket.com/user/golfyste/media/9BA9097E-1BBA-4DB8-B7F8-0A5A58399B45.jpg.html)

Another day another job.
I set about modifying the bam injectors to fit in the agu seats as the shoulders catch and stop them going all the way in.

(http://i1197.photobucket.com/albums/aa433/golfyste/A9A5AFE4-B098-46F4-9F16-144B181A6212.jpg) (http://s1197.photobucket.com/user/golfyste/media/A9A5AFE4-B098-46F4-9F16-144B181A6212.jpg.html)

Better

(http://i1197.photobucket.com/albums/aa433/golfyste/DFAC74CE-CB19-4918-91ED-8B6D8D16D78F.jpg) (http://s1197.photobucket.com/user/golfyste/media/DFAC74CE-CB19-4918-91ED-8B6D8D16D78F.jpg.html)

I was then going to fit my new seats and get them all fitted but when I opened the box I found tps had given me aum seats instead of agu ones doh!
So I got bored and slightly polished my fuel rail haha.

Next step was ting the crash bar for the intercooler and then also test fitting the bumper and making any adjustments and marking where I need to cut for the pipework to run!

(http://i1197.photobucket.com/albums/aa433/golfyste/123BF9F3-9C2A-4788-9B8C-D8BFD9F2690F.jpg) (http://s1197.photobucket.com/user/golfyste/media/123BF9F3-9C2A-4788-9B8C-D8BFD9F2690F.jpg.html)
(http://i1197.photobucket.com/albums/aa433/golfyste/5575FAF7-A378-453F-AF96-2B324460E12F.jpg) (http://s1197.photobucket.com/user/golfyste/media/5575FAF7-A378-453F-AF96-2B324460E12F.jpg.html)
(http://i1197.photobucket.com/albums/aa433/golfyste/A2B06506-5ADE-4F46-8A73-EBDBBFFF0281.jpg) (http://s1197.photobucket.com/user/golfyste/media/A2B06506-5ADE-4F46-8A73-EBDBBFFF0281.jpg.html)
(http://i1197.photobucket.com/albums/aa433/golfyste/533683D7-7DBF-447D-A5A5-B4D0FE5FDF30.jpg) (http://s1197.photobucket.com/user/golfyste/media/533683D7-7DBF-447D-A5A5-B4D0FE5FDF30.jpg.html)
(http://i1197.photobucket.com/albums/aa433/golfyste/356445B9-475D-4C1E-9264-1B72DDA29CE5.jpg) (http://s1197.photobucket.com/user/golfyste/media/356445B9-475D-4C1E-9264-1B72DDA29CE5.jpg.html)

That then brings is to today!
Got my new injector seats and then got busy!
Fitted the injectors and fuel rail.

(http://i1197.photobucket.com/albums/aa433/golfyste/E6A658BC-9E42-41D0-9515-0F3CF2B7BE45.jpg) (http://s1197.photobucket.com/user/golfyste/media/E6A658BC-9E42-41D0-9515-0F3CF2B7BE45.jpg.html)

Painted a few more bits including the fpr, brackets, coolant pipe etc.


(http://i1197.photobucket.com/albums/aa433/golfyste/CC3C30DB-6785-4361-9F50-779595B56CD5.jpg) (http://s1197.photobucket.com/user/golfyste/media/CC3C30DB-6785-4361-9F50-779595B56CD5.jpg.html)

Painted and fitted then throttle body.

(http://i1197.photobucket.com/albums/aa433/golfyste/8FED3466-79E5-4A91-8D2E-A10963481157.jpg) (http://s1197.photobucket.com/user/golfyste/media/8FED3466-79E5-4A91-8D2E-A10963481157.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/621E1C2C-9129-4917-918D-5898C8329315.jpg) (http://s1197.photobucket.com/user/golfyste/media/621E1C2C-9129-4917-918D-5898C8329315.jpg.html)

Stripped the alternator, power steering pump and mount off my old engine.

(http://i1197.photobucket.com/albums/aa433/golfyste/91BE507F-8E08-4579-B21B-B1B906DDCA44.jpg) (http://s1197.photobucket.com/user/golfyste/media/91BE507F-8E08-4579-B21B-B1B906DDCA44.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/8F61FD95-5DC2-49B8-B5BF-7A9EF13B9AFF.jpg) (http://s1197.photobucket.com/user/golfyste/media/8F61FD95-5DC2-49B8-B5BF-7A9EF13B9AFF.jpg.html)

Fitted my mocal sandwich plate...

(http://i1197.photobucket.com/albums/aa433/golfyste/816A4936-FB03-4CE4-B6E1-33BF6F3CF4B7.jpg) (http://s1197.photobucket.com/user/golfyste/media/816A4936-FB03-4CE4-B6E1-33BF6F3CF4B7.jpg.html)

Painted the power steering pump, alternator, tensioner and them fitted them with the new non a/c belt.

(http://i1197.photobucket.com/albums/aa433/golfyste/9F1EA710-43D3-4003-B8C5-E94492CBC9B5.jpg) (http://s1197.photobucket.com/user/golfyste/media/9F1EA710-43D3-4003-B8C5-E94492CBC9B5.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/FAB6EA51-3002-4B76-95DA-EC69690BBA0F.jpg) (http://s1197.photobucket.com/user/golfyste/media/FAB6EA51-3002-4B76-95DA-EC69690BBA0F.jpg.html)

That's it for now!
Not really a plan for what next just gonna get out there and think of what to do ok the spot haha.
Title: Re: Golfyste's road legal mk4 "project track car" *The engine is built!*
Post by: Chris. on 25 May 2014, 01:01
Interesting you had to modify the injectors.  Mine went in no issue, just used 'hats' to space them up over.

What coils you running on the me7.5 stuff?
Title: Re: Golfyste's road legal mk4 "project track car" *The engine is built!*
Post by: golfyste on 25 May 2014, 10:16
Did the sit flush with the seat inside?
I had to trip them as I cut the manifold to allow them to sit lower  :smiley:
Title: Re: Golfyste's road legal mk4 "project track car" *The engine is built!*
Post by: dom on 25 May 2014, 10:52
Engine is looking good :afro:

Do you have anything to remove/fit the injector seats or did you just leave yours in place?
Title: Re: Golfyste's road legal mk4 "project track car" *The engine is built!*
Post by: golfyste on 25 May 2014, 10:59
Cheers dom!
Yeah I've got a gearbox plug tool that fits!
I've got a spare set of aum seats if you need some?
Title: Re: Golfyste's road legal mk4 "project track car" *The engine is built!*
Post by: dom on 25 May 2014, 11:06
Cheers dom!
Yeah I've got a gearbox plug tool that fits!
I've got a spare set of aum seats if you need some?

Cheers for the offer but I've already got new seats, just no way of screwing them into the manifold properly. I might have to pop over sometime and use it if that's ok?
Title: Re: Golfyste's road legal mk4 "project track car" *The engine is built!*
Post by: golfyste on 25 May 2014, 11:14
Yeah sure thing man!  :cool:
Title: Re: Golfyste's road legal mk4 "project track car" *The engine is built!*
Post by: dom on 25 May 2014, 11:16
Yeah sure thing man!  :cool:

Sweet, you around tomorrow?
Title: Re: Golfyste's road legal mk4 "project track car" *The engine is built!*
Post by: golfyste on 25 May 2014, 11:17
Can be dude :).
Message me on Facebook  :smiley:
Title: Re: Golfyste's road legal mk4 "project track car" *The engine is built!*
Post by: dom on 25 May 2014, 11:23
Can be dude :).
Message me on Facebook  :smiley:

Will do :afro:
Title: Re: Golfyste's road legal mk4 "project track car" *The engine is built!*
Post by: Chris. on 25 May 2014, 13:35
fairly sure they did.  Certainly no leaks from them.
Title: Re: Golfyste's road legal mk4 "project track car" *The engine is built!*
Post by: golfyste on 25 May 2014, 15:07
Hmmm strange. Mine went in far enough to seal the o-ring but the end of the nozzle was sat in a bit so I wanted then further in so they sat flush but the shoulder was in the way.  :smiley:
Title: Re: Golfyste's road legal mk4 "project track car" *The engine is built!*
Post by: golfyste on 05 September 2014, 09:09
Ok once again I failed at keepin upto date! Haha
So it's gonna be another reasonably sized one!
I'm not going to lie I've been slacking quite abit over the last 2 months. Mainly due to falling I'll a good few times and also having a couple of holidays while the weather was nice!

But the ball is rolling again :)

Started by getting a cheeky picture of how the bay stood with the old engine in.

(http://i1197.photobucket.com/albums/aa433/golfyste/E82FCC05-36D7-4B9A-99EF-0B06A95795D8.jpg) (http://s1197.photobucket.com/user/golfyste/media/E82FCC05-36D7-4B9A-99EF-0B06A95795D8.jpg.html)

Set about trimming the front r32 bumper for the boost pipes.

(http://i1197.photobucket.com/albums/aa433/golfyste/2FD54A02-81B4-4B43-ADC0-9D973373A2C5.jpg) (http://s1197.photobucket.com/user/golfyste/media/2FD54A02-81B4-4B43-ADC0-9D973373A2C5.jpg.html)

Then the old engine came out!

(http://i1197.photobucket.com/albums/aa433/golfyste/FAAF5DD5-BB98-40E4-927D-C167BED87990.jpg) (http://s1197.photobucket.com/user/golfyste/media/FAAF5DD5-BB98-40E4-927D-C167BED87990.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/241715B8-2986-4EAB-AA14-182A9075A8A8.jpg) (http://s1197.photobucket.com/user/golfyste/media/241715B8-2986-4EAB-AA14-182A9075A8A8.jpg.html)

I had a service kit with the revised piston arrive for my 007p so fitted that.

(http://i1197.photobucket.com/albums/aa433/golfyste/F80C45B9-A7F6-4018-A660-A28A6B4DAAF4.jpg) (http://s1197.photobucket.com/user/golfyste/media/F80C45B9-A7F6-4018-A660-A28A6B4DAAF4.jpg.html)

Also had a set of 2.0l tfsi coilpack adaptors arrive but I got sent the wrong ones! But I complained and got the correct set for free :) So I have a set for for sale to fit aum/auq style rocker covers haha.

(http://i1197.photobucket.com/albums/aa433/golfyste/BA219177-9203-4856-A70E-DA7EB909FB5A.jpg) (http://s1197.photobucket.com/user/golfyste/media/BA219177-9203-4856-A70E-DA7EB909FB5A.jpg.html)

And the correct ones

(http://i1197.photobucket.com/albums/aa433/golfyste/D4E788F4-9027-4C7B-A934-75E0C0428214.jpg) (http://s1197.photobucket.com/user/golfyste/media/D4E788F4-9027-4C7B-A934-75E0C0428214.jpg.html)

I set about ripping out all the aircon pipes!

(http://i1197.photobucket.com/albums/aa433/golfyste/4526E50B-5042-4167-8188-A14939E46602.jpg) (http://s1197.photobucket.com/user/golfyste/media/4526E50B-5042-4167-8188-A14939E46602.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/5971D655-EEA1-4092-9735-95B0946847C8.jpg) (http://s1197.photobucket.com/user/golfyste/media/5971D655-EEA1-4092-9735-95B0946847C8.jpg.html)

I painted my poly filled engine mounts.

(http://i1197.photobucket.com/albums/aa433/golfyste/C048F353-9163-4042-B923-BB227F2DE6E1.jpg) (http://s1197.photobucket.com/user/golfyste/media/C048F353-9163-4042-B923-BB227F2DE6E1.jpg.html)

Did a bit more wiring work! Removed a few things that Weren't needed such as aircon etc and wires in my new oem coilpack harness.

 (http://i1197.photobucket.com/albums/aa433/golfyste/B2C664D1-916B-44AD-8CD2-9BEF63B2594C.jpg) (http://s1197.photobucket.com/user/golfyste/media/B2C664D1-916B-44AD-8CD2-9BEF63B2594C.jpg.html)

Also Ripped out my carbon canister and put a resistor on the plug.

(http://i1197.photobucket.com/albums/aa433/golfyste/CE504827-AA36-43D8-8901-5846E708A9E0.jpg) (http://s1197.photobucket.com/user/golfyste/media/CE504827-AA36-43D8-8901-5846E708A9E0.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/B2FE0FCF-F4AB-4EFC-AE3C-A3A595538A0C.jpg) (http://s1197.photobucket.com/user/golfyste/media/B2FE0FCF-F4AB-4EFC-AE3C-A3A595538A0C.jpg.html)

I sent my bumper and modified spoiler to a mate to be painted and they turned out really well!

(http://i1197.photobucket.com/albums/aa433/golfyste/07706B5B-3FF7-471F-90B7-AC8473FEDD7C.jpg) (http://s1197.photobucket.com/user/golfyste/media/07706B5B-3FF7-471F-90B7-AC8473FEDD7C.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/D86958CF-CA6B-48A1-8CB3-19FE1E470F7F.jpg) (http://s1197.photobucket.com/user/golfyste/media/D86958CF-CA6B-48A1-8CB3-19FE1E470F7F.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/E0F61363-7A8C-4871-89E6-3959E4F48C2D.jpg) (http://s1197.photobucket.com/user/golfyste/media/E0F61363-7A8C-4871-89E6-3959E4F48C2D.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/A9629999-F678-4D3F-96D9-DFBF507B7DC4.jpg) (http://s1197.photobucket.com/user/golfyste/media/A9629999-F678-4D3F-96D9-DFBF507B7DC4.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/D816BBC3-CE1A-4366-BB22-F7368AB9457E.jpg) (http://s1197.photobucket.com/user/golfyste/media/D816BBC3-CE1A-4366-BB22-F7368AB9457E.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/29EA050B-3041-4B76-99A2-E383961AF9F1.jpg) (http://s1197.photobucket.com/user/golfyste/media/29EA050B-3041-4B76-99A2-E383961AF9F1.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/8B4D069F-BC61-44EC-A719-00CF3D6306DC.jpg) (http://s1197.photobucket.com/user/golfyste/media/8B4D069F-BC61-44EC-A719-00CF3D6306DC.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/FFB508AD-8A21-4A74-991E-50C573151077.jpg) (http://s1197.photobucket.com/user/golfyste/media/FFB508AD-8A21-4A74-991E-50C573151077.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/FF05C39F-3A14-4C1E-A844-40F0875F8524.jpg) (http://s1197.photobucket.com/user/golfyste/media/FF05C39F-3A14-4C1E-A844-40F0875F8524.jpg.html)


I then saw a carbon fibre bonnet with lacquer peal come up for sale cheap so I snatched it up and it's currently being sorted by my mate.

(http://i1197.photobucket.com/albums/aa433/golfyste/ACE2AE31-1AB9-4354-840C-4DA4E12E77AC.jpg) (http://s1197.photobucket.com/user/golfyste/media/ACE2AE31-1AB9-4354-840C-4DA4E12E77AC.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/EA5612CF-3BDD-420D-A646-B71F31A37A4A.jpg) (http://s1197.photobucket.com/user/golfyste/media/EA5612CF-3BDD-420D-A646-B71F31A37A4A.jpg.html)

I also fitted some braided fuel line, new brake boosted pipe as my old one was split and new coolant line to the top of the bottle.

(http://i1197.photobucket.com/albums/aa433/golfyste/58A5B156-8C08-43D8-90F0-BA8D5868E959.jpg) (http://s1197.photobucket.com/user/golfyste/media/58A5B156-8C08-43D8-90F0-BA8D5868E959.jpg.html)

I then went nearly 2 months without doing anything which brings is to yesterday!
Had a decent 12 hour session in the garage and got quite a bit done!

I started by removing and porting the the old manifold some more. I then fitted the mani and turbo to the new engine

(http://i1197.photobucket.com/albums/aa433/golfyste/0598677A-9690-4AC7-B127-C8E1ECCD7195.jpg) (http://s1197.photobucket.com/user/golfyste/media/0598677A-9690-4AC7-B127-C8E1ECCD7195.jpg.html)

I then cleaned the gearbox abit, switch the clutch over from the old engine, painted the gearbox mount and shifter arm and then fitted the box to the engine.

(http://i1197.photobucket.com/albums/aa433/golfyste/2C7E8141-329A-4063-B0A6-0220F0255459.jpg) (http://s1197.photobucket.com/user/golfyste/media/2C7E8141-329A-4063-B0A6-0220F0255459.jpg.html)

Got the engine in!!

(http://i1197.photobucket.com/albums/aa433/golfyste/EAEAAADD-152E-49CA-9725-E46B2A338132.jpg) (http://s1197.photobucket.com/user/golfyste/media/EAEAAADD-152E-49CA-9725-E46B2A338132.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/3F87A090-ADDF-46C3-A4E4-22F602D687FD.jpg) (http://s1197.photobucket.com/user/golfyste/media/3F87A090-ADDF-46C3-A4E4-22F602D687FD.jpg.html)

Then spent hours sorting all the wiring, also fitting the dogbone, coilpacks fuel lines, coolant pipes, etc


(http://i1197.photobucket.com/albums/aa433/golfyste/344FBE60-543D-4FA6-8DF3-2F4D53B5C9AD_1.jpg) (http://s1197.photobucket.com/user/golfyste/media/344FBE60-543D-4FA6-8DF3-2F4D53B5C9AD_1.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/C8A2930E-76B2-49FB-A468-149AE6F890C0.jpg) (http://s1197.photobucket.com/user/golfyste/media/C8A2930E-76B2-49FB-A468-149AE6F890C0.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/A25A45B5-BB1F-43B8-B065-44C7C72AECED.jpg) (http://s1197.photobucket.com/user/golfyste/media/A25A45B5-BB1F-43B8-B065-44C7C72AECED.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/BA957080-D537-4A33-96FB-CB1BF7154CA1.jpg) (http://s1197.photobucket.com/user/golfyste/media/BA957080-D537-4A33-96FB-CB1BF7154CA1.jpg.html)

I then figured out my boost pipe route and ordered some parts.
I also set about modifying my heatshield to make it fully enclosed. Just needs welding up.

(http://i1197.photobucket.com/albums/aa433/golfyste/8A4461B4-B3EA-4583-8CB8-C964FFC79AAA.jpg) (http://s1197.photobucket.com/user/golfyste/media/8A4461B4-B3EA-4583-8CB8-C964FFC79AAA.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/5681C7C5-3F1B-451F-9C66-E4B92709CE6D.jpg) (http://s1197.photobucket.com/user/golfyste/media/5681C7C5-3F1B-451F-9C66-E4B92709CE6D.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/90E49D26-F2F4-43DA-AF39-C23004FD5F15.jpg) (http://s1197.photobucket.com/user/golfyste/media/90E49D26-F2F4-43DA-AF39-C23004FD5F15.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/93D6C5B5-6E10-4497-9A8F-11117E39C345.jpg) (http://s1197.photobucket.com/user/golfyste/media/93D6C5B5-6E10-4497-9A8F-11117E39C345.jpg.html)

I then took a couple of night shots at the end of the night before I came in!

(http://i1197.photobucket.com/albums/aa433/golfyste/731075C4-E99A-4705-957E-DB1F96355436.jpg) (http://s1197.photobucket.com/user/golfyste/media/731075C4-E99A-4705-957E-DB1F96355436.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/9903CF1A-A008-4792-9D03-873AAA630F17.jpg) (http://s1197.photobucket.com/user/golfyste/media/9903CF1A-A008-4792-9D03-873AAA630F17.jpg.html)

Next jobs on the list are to finish the heatshield, make up the fmic pipework, fit the oil cooler and then fit brembos and a couple of other small things and then it should be on the road!! :).

Cheers for reading lads!
Title: Re: Golfyste's road legal mk4 "project track car" *The engine is in!!!*
Post by: Wazzzer on 06 September 2014, 21:26
Nice update, looks like it's really coming together now!
Title: Re: Golfyste's road legal mk4 "project track car" *The engine is in!!!*
Post by: golfyste on 07 September 2014, 18:57
Cheers dude!
Yeah hopefully won't be long until it's up and running now!
Title: Re: Golfyste's road legal mk4 "project track car" *The engine is in!!!*
Post by: SI74 on 10 September 2014, 13:58
Really like that red.
Title: Re: Golfyste's road legal mk4 "project track car" *The engine is in!!!*
Post by: golfyste on 12 September 2014, 09:26
Cheers dude  :smiley:
Title: Re: Golfyste's road legal mk4 "project track car" *The engine is in!!!*
Post by: golfyste on 19 October 2014, 02:29

Ok time for another overdue update!
I went a couple of weeks not doing anything due i getting a new car.....again! Haha.
I got a 06 ibiza pd130 as part of a swap deal with my mx5. I mainly got it as I'm regularly driving down to London and need the mpg!
It was in a bit of a mess When I got it - horrible inside, messy wiring, broken bits bodged intercooler, no bumper grills etc etc. here's a few pics including before and after of the the intercooler.

(http://i1197.photobucket.com/albums/aa433/golfyste/A4D5CCDB-A00C-448C-A90D-494E7DFEF076.jpg) (http://s1197.photobucket.com/user/golfyste/media/A4D5CCDB-A00C-448C-A90D-494E7DFEF076.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/9FBCC41F-6708-49DA-AE50-9F1300EDB537_2.jpg) (http://s1197.photobucket.com/user/golfyste/media/9FBCC41F-6708-49DA-AE50-9F1300EDB537_2.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/B1788879-357F-4D81-A2B6-88BB46B69A6C.jpg) (http://s1197.photobucket.com/user/golfyste/media/B1788879-357F-4D81-A2B6-88BB46B69A6C.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/31A5FD27-B8FC-40A2-94BA-594F7C7F3583.jpg) (http://s1197.photobucket.com/user/golfyste/media/31A5FD27-B8FC-40A2-94BA-594F7C7F3583.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/BC095B9C-C8E5-401F-837A-7BAB01C8AF17.jpg) (http://s1197.photobucket.com/user/golfyste/media/BC095B9C-C8E5-401F-837A-7BAB01C8AF17.jpg.html)

It's a decent car now and only has 65k on the clock and is running 180 bhp and get 65mpg on the motorway  :).

ANYWAY!! Back to the golf! :).
I didn't do to well at taking photos to start with haha.
I finished the heatshield, including raising it my 20mm so it sealed against the body, painted it etc. I haven't got any photos but you. Can see it in photos later on :).

My bbt supersize tip arrived :).
(http://i1197.photobucket.com/albums/aa433/golfyste/509FDF7F-34C4-4E04-BACB-341530A4A0B0.jpg) (http://s1197.photobucket.com/user/golfyste/media/509FDF7F-34C4-4E04-BACB-341530A4A0B0.jpg.html)

I decided I was going to mount my catchcan where the aircon used to be so I painted it (graphite of corse) and then made up some brackets :).

(http://i1197.photobucket.com/albums/aa433/golfyste/87A77F29-5A4D-47A1-9BA9-35FAAF1104E6.jpg) (http://s1197.photobucket.com/user/golfyste/media/87A77F29-5A4D-47A1-9BA9-35FAAF1104E6.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/9778D3E7-B9C1-4B64-8353-296E4725387C.jpg) (http://s1197.photobucket.com/user/golfyste/media/9778D3E7-B9C1-4B64-8353-296E4725387C.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/9778D3E7-B9C1-4B64-8353-296E4725387C.jpg) (http://s1197.photobucket.com/user/golfyste/media/9778D3E7-B9C1-4B64-8353-296E4725387C.jpg.html)

I ordered several parts including intercooler pipework, a silicone throttle body pipe, some connectors for the breather pipework etc.
couple of pics showing TB pipe, heatshield, silicone 45 and alloy 45 for fmic pipes and tip

(http://i1197.photobucket.com/albums/aa433/golfyste/47D80DBD-3D2B-4357-9940-35CFD380B8E4.jpg) (http://s1197.photobucket.com/user/golfyste/media/47D80DBD-3D2B-4357-9940-35CFD380B8E4.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/7FAE11A5-881A-4970-8FED-2AA8CA4AEC5D.jpg) (http://s1197.photobucket.com/user/golfyste/media/7FAE11A5-881A-4970-8FED-2AA8CA4AEC5D.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/16EBA3FC-CBBF-42BE-933B-446C414DEF36.jpg) (http://s1197.photobucket.com/user/golfyste/media/16EBA3FC-CBBF-42BE-933B-446C414DEF36.jpg.html)

Catch can piped up.

(http://i1197.photobucket.com/albums/aa433/golfyste/5D19F718-1C0C-4E7B-9A0A-CF5E915FAC22.jpg) (http://s1197.photobucket.com/user/golfyste/media/5D19F718-1C0C-4E7B-9A0A-CF5E915FAC22.jpg.html)

Got the front end back on ready to mock up the intercooler pipes......discovered my heatshield is in the way of the headlight so had to mod it haha.

(http://i1197.photobucket.com/albums/aa433/golfyste/522A4756-106B-4AE8-A1ED-D0B211D8D927.jpg) (http://s1197.photobucket.com/user/golfyste/media/522A4756-106B-4AE8-A1ED-D0B211D8D927.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/D7B4C0BF-3E93-4A34-8B0E-C0C43739BEEF.jpg) (http://s1197.photobucket.com/user/golfyste/media/D7B4C0BF-3E93-4A34-8B0E-C0C43739BEEF.jpg.html)

Another pic of the catch can pipework. I also had to extend the metal coolant pipe that runs past the tip as I had cut it back and bent it so the supersize tip fitted easily so just used some spare coolant pipe to extend it :).

(http://i1197.photobucket.com/albums/aa433/golfyste/78E7F8A9-AA8E-495C-A94D-3A09ECF2C566.jpg) (http://s1197.photobucket.com/user/golfyste/media/78E7F8A9-AA8E-495C-A94D-3A09ECF2C566.jpg.html)

I was still waiting for the rest of my intercooler pipes to arrive so I set about mounting the oil cooler :).

(http://i1197.photobucket.com/albums/aa433/golfyste/B9465958-9ED9-4148-B708-B2FB20498BD0.jpg) (http://s1197.photobucket.com/user/golfyste/media/B9465958-9ED9-4148-B708-B2FB20498BD0.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/F25AAAA5-5716-4FEC-9D5A-29B64A8E7731.jpg) (http://s1197.photobucket.com/user/golfyste/media/F25AAAA5-5716-4FEC-9D5A-29B64A8E7731.jpg.html)

I then cut some slits in the arch lines to allow airflow through the cooler and then put some mesh over to protect it :).

(http://i1197.photobucket.com/albums/aa433/golfyste/7F9C3DFF-1AA8-4397-9912-962313EBB749.jpg) (http://s1197.photobucket.com/user/golfyste/media/7F9C3DFF-1AA8-4397-9912-962313EBB749.jpg.html)

Then my intercooler pipes came!

Random fmic shot :).

(http://i1197.photobucket.com/albums/aa433/golfyste/887B2E7A-FA81-4B73-ABBD-F4AC40AEBA02.jpg) (http://s1197.photobucket.com/user/golfyste/media/887B2E7A-FA81-4B73-ABBD-F4AC40AEBA02.jpg.html)

Drivers side mocked up.

(http://i1197.photobucket.com/albums/aa433/golfyste/4641AE3E-2078-4571-94DA-A91E3DA872C7.jpg) (http://s1197.photobucket.com/user/golfyste/media/4641AE3E-2078-4571-94DA-A91E3DA872C7.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/FF938A95-BA76-4525-B4F2-23BAA1713A2D.jpg) (http://s1197.photobucket.com/user/golfyste/media/FF938A95-BA76-4525-B4F2-23BAA1713A2D.jpg.html)

And the rest :).

(http://i1197.photobucket.com/albums/aa433/golfyste/9E758BEF-668A-4C25-8B8B-FA8A3AD6A461.jpg) (http://s1197.photobucket.com/user/golfyste/media/9E758BEF-668A-4C25-8B8B-FA8A3AD6A461.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/A90CF080-A148-482F-808E-FC1D6BCB08BD.jpg) (http://s1197.photobucket.com/user/golfyste/media/A90CF080-A148-482F-808E-FC1D6BCB08BD.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/2F5A5E9D-460B-41EB-94DE-F06197832B28.jpg) (http://s1197.photobucket.com/user/golfyste/media/2F5A5E9D-460B-41EB-94DE-F06197832B28.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/BE130741-FC45-4E5C-A06E-A44EDB8C804A.jpg) (http://s1197.photobucket.com/user/golfyste/media/BE130741-FC45-4E5C-A06E-A44EDB8C804A.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/F40411F4-6912-4FC5-82D0-220FEAE87416.jpg) (http://s1197.photobucket.com/user/golfyste/media/F40411F4-6912-4FC5-82D0-220FEAE87416.jpg.html)

Then I drilled the hoses for recirc, n75 and map sensor

(http://i1197.photobucket.com/albums/aa433/golfyste/188EF832-72FA-41BE-BF44-61F4BA9A7464.jpg) (http://s1197.photobucket.com/user/golfyste/media/188EF832-72FA-41BE-BF44-61F4BA9A7464.jpg.html)

And that pretty much brings us upto date!
I also bolted the driveshafts on, and cleaned up the hubs, wishbones, droplinks etc and repainted ten as they started going rusty! But no pics!
I've taken the intercooler pipes to get welded and should be done this week :).

And couple of negative points.....I found a puddle in the rear wheel well! I think it may be the door-roof deal so have bought another which should be arriving shortly so will see if that sorts it.
I also got some bad new from my mate sorting my carbon bonnet!
He managed to sort it and get it looking great! Apart from in a few places he said where it was pealing was because it had been attacked by paint stripper and has damaged the fibres!
BUT! He said he can sort it and relacquer it again and should be ok!
Couple of pics to show what I mean!

It does look awesome!

 (http://i1197.photobucket.com/albums/aa433/golfyste/AC41E757-EDA9-45F4-B1A8-06D6F71074A8.jpg) (http://s1197.photobucket.com/user/golfyste/media/AC41E757-EDA9-45F4-B1A8-06D6F71074A8.jpg.html)

Can just see the little dots on this photo. I said it would be ok but he has too much pride in his work to let me fit it like this so is redoing it haha.

(http://i1197.photobucket.com/albums/aa433/golfyste/C0581A60-85F4-4BBD-8747-074959B213FE.jpg) (http://s1197.photobucket.com/user/golfyste/media/C0581A60-85F4-4BBD-8747-074959B213FE.jpg.html)

So now it for fmic pipes. Get oil cooler pipes up. Bolt exhaust onto the turbo and fit the  brakes and then we are pretty much sorted!! :)

Cheers for reading guys and any comments are welcome :).
Title: Re: Golfyste's road legal mk4 "project track car" *The engine is in!!!*
Post by: golfyste on 21 October 2014, 18:51
so I visited CNtuning today and I picked this lot up!!

(http://i1197.photobucket.com/albums/aa433/golfyste/C5F2B293-8363-474C-BB3D-A42E63F60ED5.jpg) (http://s1197.photobucket.com/user/golfyste/media/C5F2B293-8363-474C-BB3D-A42E63F60ED5.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/34602A69-04D7-45C3-A808-DB0BCDD14280.jpg) (http://s1197.photobucket.com/user/golfyste/media/34602A69-04D7-45C3-A808-DB0BCDD14280.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/9DDDEC8A-EA99-4ACF-90EF-0CE9B558C653.jpg) (http://s1197.photobucket.com/user/golfyste/media/9DDDEC8A-EA99-4ACF-90EF-0CE9B558C653.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/D198EE0A-047B-4DF0-8FE8-4C0D73B34C7A.jpg) (http://s1197.photobucket.com/user/golfyste/media/D198EE0A-047B-4DF0-8FE8-4C0D73B34C7A.jpg.html)

I got a 1 off k300s which has been heavily ported by jnl and fitted with a 15psi actuator, ceramic coated relentless manifold with a egt probe that has been port matched to the turbo.
550cc injectors
Big air filter with s3 Maf
A fully rebuilt 6 speed box with new syncro arp bolts. Also fitted with a Mfactory Limited slip diff!
Shafts, cables, slave line, starter motor etc.  and also 2 A048 tyres

Got it all for a bargain aswell!
Can't wait to get it all fitted!!! :D
Title: Re: Golfyste's road legal mk4 "project track car" *The engine is in!!!*
Post by: Chris. on 22 October 2014, 03:02
naughty update hahaha
Title: Re: Golfyste's road legal mk4 "project track car" *The engine is in!!!*
Post by: golfyste on 22 October 2014, 12:05
Haha it's all coming together now  :evil:
I was thinking about mapping it myself but seen as I'm going to be running a test unit for bbt I will let niki map it haha.
Title: Re: Golfyste's road legal mk4 "project track car" *The engine is in!!!*
Post by: Rylarr on 24 October 2014, 21:08
that ibiza front mount hahahaha
its a nice car tho man... after we cleaned it!  :grin:
Dirty man!!!
Title: Re: Golfyste's road legal mk4 "project track car" *The engine is in!!!*
Post by: golfyste on 27 October 2014, 20:36
Haha I know dude was such a bodge. And was sooooo disgusting inside! Haha

Ok so I got back home from a week away so I though I would compare the BBT k300 to a normal k03.
You can see how much bigger the compressor housing is with it using a k04 housing.

(http://i1197.photobucket.com/albums/aa433/golfyste/8AC1D733-7926-47E8-8334-C0D4DBEDBA1D.jpg) (http://s1197.photobucket.com/user/golfyste/media/8AC1D733-7926-47E8-8334-C0D4DBEDBA1D.jpg.html)

I picked my welded fmic pipes up today. They were all good and they have made a pretty decent job of them. Ok for £60 for the lot :).

(http://i1197.photobucket.com/albums/aa433/golfyste/5ED51D60-83D2-4438-8411-A99EB2049330.jpg) (http://s1197.photobucket.com/user/golfyste/media/5ED51D60-83D2-4438-8411-A99EB2049330.jpg.html)

Ok so today I set about getting some stuff fitted!
I fitted the fmic pipes, the new HUGE air filter. The vacuum lines to the fpr, recirc and boost gauge. And also the brake booster hose.
Does anybody know if the brake booster 'needs' 2 check valves as I only have 1 :/.
I also properly fitted the tip, recirc, n75 and map sensor :).
It's now ready for the bumper to go on :).
Next step is pipe the oil cooler up and I need to modify the catch can as Clive from CNtuning ha told me if I'm running it it too atmosphere I need larger pipework to deduce the back pressure as I won't have the auction from the intake.

A few picture of today's work :).

(http://i1197.photobucket.com/albums/aa433/golfyste/1AAB7AD2-FD5C-4E78-9161-1C0FB9EFEDE9_1.jpg) (http://s1197.photobucket.com/user/golfyste/media/1AAB7AD2-FD5C-4E78-9161-1C0FB9EFEDE9_1.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/475E7A7A-550D-4E54-9F76-1A0A37FCF329_1.jpg) (http://s1197.photobucket.com/user/golfyste/media/475E7A7A-550D-4E54-9F76-1A0A37FCF329_1.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/81CA6940-B292-45EE-BD6F-F05650BD9FBD_1.jpg) (http://s1197.photobucket.com/user/golfyste/media/81CA6940-B292-45EE-BD6F-F05650BD9FBD_1.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/91CFF30A-1A15-4FFE-8D84-1196A759F469_1.jpg) (http://s1197.photobucket.com/user/golfyste/media/91CFF30A-1A15-4FFE-8D84-1196A759F469_1.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/A9C81A13-D553-411C-A92D-259701F4C092_1.jpg) (http://s1197.photobucket.com/user/golfyste/media/A9C81A13-D553-411C-A92D-259701F4C092_1.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/31DE70A5-2FA6-4CF3-A718-84D8FF438817_1.jpg) (http://s1197.photobucket.com/user/golfyste/media/31DE70A5-2FA6-4CF3-A718-84D8FF438817_1.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/FD969010-52BE-44D6-9345-A71439B55242_1.jpg) (http://s1197.photobucket.com/user/golfyste/media/FD969010-52BE-44D6-9345-A71439B55242_1.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/161C5245-6AD0-4407-BD29-632D2E353320_1.jpg) (http://s1197.photobucket.com/user/golfyste/media/161C5245-6AD0-4407-BD29-632D2E353320_1.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/C9E2AE28-D3CE-4462-8A41-0B1B67A33C50_1.jpg) (http://s1197.photobucket.com/user/golfyste/media/C9E2AE28-D3CE-4462-8A41-0B1B67A33C50_1.jpg.html)
Title: Re: Golfyste's road legal mk4 "project track car" *The engine is in!!!*
Post by: golfyste on 29 October 2014, 18:07
Another little update.
I decided how I'm going to pipe up my oil cooler and also how UK going to modify my catch can using Clive from cntunings advice.

(http://i1197.photobucket.com/albums/aa433/golfyste/CCA53A4D-4132-406E-9446-5B809AE14274.jpg) (http://"http://s1197.photobucket.com/user/golfyste/media/CCA53A4D-4132-406E-9446-5B809AE14274.jpg.html")

I fitted a new door seal as there was a puddle in the rear footwell so have mopped it up and will check it again after a bit of rain.
I also go around to fitting my custom r32 spoiler....I may have gone overboard with the tape but it's better to be safe then sorry!

(http://i1197.photobucket.com/albums/aa433/golfyste/CD6E30D9-EE82-4BB3-A78F-86EE3B4C79E7_2.jpg) (http://"http://s1197.photobucket.com/user/golfyste/media/CD6E30D9-EE82-4BB3-A78F-86EE3B4C79E7_2.jpg.html")

I then set about cleaning up and fitting my Brembos so I whipped the grinder out gave them a scrub and then fitted them on the car :).

(http://i1197.photobucket.com/albums/aa433/golfyste/15F7E5E9-4896-42FE-BAAD-9E77A9283FA4.jpg) (http://"http://s1197.photobucket.com/user/golfyste/media/15F7E5E9-4896-42FE-BAAD-9E77A9283FA4.jpg.html")

I just need to get the oil pipes made up and connect them. Fill it with fluids and it can be started! :).
Title: Re: Golfyste's road legal mk4 "project track car" *The engine is in!!!*
Post by: Wazzzer on 29 October 2014, 18:43
Nice one mate, makes me want to fit my Brembos lol
Title: Re: Golfyste's road legal mk4 "project track car" *The engine is in!!!*
Post by: golfyste on 29 October 2014, 22:25
Cheers dude!  :cool:
Yeah get them fitted should make a massive difference!
Title: Re: Golfyste's road legal mk4 "project track car" *The engine is in!!!*
Post by: golfyste on 11 November 2014, 03:53
Ok another little update!
I got my oil cooler pipes made up.

(http://i1197.photobucket.com/albums/aa433/golfyste/BA9EB9A7-185E-4DBD-95BA-D95151D373FC.jpg) (http://s1197.photobucket.com/user/golfyste/media/BA9EB9A7-185E-4DBD-95BA-D95151D373FC.jpg.html)

The parts came that I needed to modify my catch can. Going to run the outlet to the tip use the vacuum to keep the crankcase pressure down instead of having to modify the can itself and use bigger pipework.

(http://i1197.photobucket.com/albums/aa433/golfyste/5BDE2AE8-D63C-4C0C-A34D-3AB4F0DDFF7F.jpg) (http://s1197.photobucket.com/user/golfyste/media/5BDE2AE8-D63C-4C0C-A34D-3AB4F0DDFF7F.jpg.html)


Oil cooler pipes fitted

(http://i1197.photobucket.com/albums/aa433/golfyste/7EEBA890-C485-4ACB-A070-925C7A576D6F_1.jpg) (http://s1197.photobucket.com/user/golfyste/media/7EEBA890-C485-4ACB-A070-925C7A576D6F_1.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/F1C0238B-9E4E-4E60-BDBD-71FA42D3C51F.jpg) (http://s1197.photobucket.com/user/golfyste/media/F1C0238B-9E4E-4E60-BDBD-71FA42D3C51F.jpg.html)

And also modifying the catch can pipework

(http://i1197.photobucket.com/albums/aa433/golfyste/5B9B8E44-C5B0-4E12-8AEC-56505AAC83A0.jpg) (http://s1197.photobucket.com/user/golfyste/media/5B9B8E44-C5B0-4E12-8AEC-56505AAC83A0.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/3CE460A1-B569-48E6-8E78-506232BA9CB1.jpg) (http://s1197.photobucket.com/user/golfyste/media/3CE460A1-B569-48E6-8E78-506232BA9CB1.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/4EFD33F3-2D05-4910-A622-7230BF142B1E.jpg) (http://s1197.photobucket.com/user/golfyste/media/4EFD33F3-2D05-4910-A622-7230BF142B1E.jpg.html)

I also got the heatshield and air filter back in and got my other headlight fitted.

(http://i1197.photobucket.com/albums/aa433/golfyste/BC1501BF-5FDB-4B55-A9CB-61BCDE411077.jpg) (http://s1197.photobucket.com/user/golfyste/media/BC1501BF-5FDB-4B55-A9CB-61BCDE411077.jpg.html)

And today I bolted the downpipe on, ordered a magnetic sump plug and oil filter magnets. I just need to refit the rear section of the exhaust as
It decided to fall off when I was twisting the exhaust so I need a better clamp! And then it can started!
Getting very close now!!

Also on another note. I still have water coming into the rear passenger footwell after changing the door seal so I'm going to remove the inner door panel and try resealing it to make sure it's not that!
Title: Re: Golfyste's road legal mk4 "project track car" *The engine is in!!!*
Post by: golfyste on 12 November 2014, 22:16
Killing the little updates lately :).

Magnetic plug and filter plugs came so threw them on :).

(http://i1197.photobucket.com/albums/aa433/golfyste/5FDF03D1-1847-4D0D-A3BD-769F83ECCEB8.jpg) (http://s1197.photobucket.com/user/golfyste/media/5FDF03D1-1847-4D0D-A3BD-769F83ECCEB8.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/99479FE0-2D07-46FA-8CA5-2633F15A1BDB.jpg) (http://s1197.photobucket.com/user/golfyste/media/99479FE0-2D07-46FA-8CA5-2633F15A1BDB.jpg.html)


Got her on all fours for the first time in months and months.

(http://i1197.photobucket.com/albums/aa433/golfyste/EE5CEA3A-A347-4AF5-98A5-13B09893C5FF.jpg) (http://s1197.photobucket.com/user/golfyste/media/EE5CEA3A-A347-4AF5-98A5-13B09893C5FF.jpg.html)

And also I managed to get a bargain on ebay!!
Direnza high flow radiator for £56 :).

(http://i1197.photobucket.com/albums/aa433/golfyste/C6E3E3B9-1E71-4B5A-A207-24D8758CCADE.jpg) (http://s1197.photobucket.com/user/golfyste/media/C6E3E3B9-1E71-4B5A-A207-24D8758CCADE.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/57A7FD0C-4985-4053-9F5F-330DFC6AA5D6.jpg) (http://s1197.photobucket.com/user/golfyste/media/57A7FD0C-4985-4053-9F5F-330DFC6AA5D6.jpg.html)
Title: Re: Golfyste's road legal mk4 "project track car" *The engine is in!!!*
Post by: Wazzzer on 15 November 2014, 21:39
front end is coming off again then lol
Title: Re: Golfyste's road legal mk4 "project track car" *The engine is in!!!*
Post by: golfyste on 15 November 2014, 22:28
Haha yeah I will do it when I fit the k300 and gearbox :).
Now everything is done it's only a half an hour job to get the front end off :).
Title: Re: Golfyste's road legal mk4 "project track car"
Post by: golfyste on 14 March 2015, 23:04
Ok it's been aaages since I updated this!
The main reason it's been so long is because this happened!

(http://i1197.photobucket.com/albums/aa433/golfyste/79D4A93E-9834-4811-ACCC-2F5A9EEAC120.jpg) (http://"http://s1197.photobucket.com/user/golfyste/media/79D4A93E-9834-4811-ACCC-2F5A9EEAC120.jpg.html")

I went and bought myself a house. Been quite busy working on it and doing bits and with me living on my own it's took a lot of my time!

I did a lot but the relevant bits include painting the garage door, making myself a bench and a wheel rack! Haha

(http://i1197.photobucket.com/albums/aa433/golfyste/2AB229C3-66CB-4585-96EC-80F32E9E757C.jpg) (http://"http://s1197.photobucket.com/user/golfyste/media/2AB229C3-66CB-4585-96EC-80F32E9E757C.jpg.html")
(http://i1197.photobucket.com/albums/aa433/golfyste/F13540C9-4E2C-4C5B-8BA8-CCD4EB669BE7.jpg) (http://"http://s1197.photobucket.com/user/golfyste/media/F13540C9-4E2C-4C5B-8BA8-CCD4EB669BE7.jpg.html")
(http://i1197.photobucket.com/albums/aa433/golfyste/185CB0F7-7F6D-4CB3-8B32-EA6E9DCE6EC7.jpg) (http://"http://s1197.photobucket.com/user/golfyste/media/185CB0F7-7F6D-4CB3-8B32-EA6E9DCE6EC7.jpg.html")

Ok back to the car!
It's been a bit of a long and confusing process but that will make more sense when I get to the end of this!

One of the next things I did was get the car started!
It started quite nicely and I warmed it up and then drained the oil.
(http://i1197.photobucket.com/albums/aa433/golfyste/B16A57E4-1FE6-4A24-92F4-7A4FAF5AC447.jpg) (http://"http://s1197.photobucket.com/user/golfyste/media/B16A57E4-1FE6-4A24-92F4-7A4FAF5AC447.jpg.html")

The next job was changing/upgrading the rear brake callipers, discs and lines. I got most of it done but doing so I broke one te old solid lines! So I decided I had to make new lines and then some custom braided lines for the ends which took a couple of weeks.

(http://i1197.photobucket.com/albums/aa433/golfyste/583A34C6-DFB7-4683-96C2-B7753B839401.jpg) (http://"http://s1197.photobucket.com/user/golfyste/media/583A34C6-DFB7-4683-96C2-B7753B839401.jpg.html")
(http://i1197.photobucket.com/albums/aa433/golfyste/499BD05E-BC40-4274-A8DD-93AF2DDE3FCC.jpg) (http://"http://s1197.photobucket.com/user/golfyste/media/499BD05E-BC40-4274-A8DD-93AF2DDE3FCC.jpg.html")

I then modified my fmic outlet pipe to make fitting the bumper easier :).

(http://i1197.photobucket.com/albums/aa433/golfyste/BD29C4B6-6BDF-4811-9C2E-3E256CB53FAD.jpg) (http://"http://s1197.photobucket.com/user/golfyste/media/BD29C4B6-6BDF-4811-9C2E-3E256CB53FAD.jpg.html")
(http://i1197.photobucket.com/albums/aa433/golfyste/E3C4C9A9-A6A9-426D-81D8-CCB46E6A67DB.jpg) (http://"http://s1197.photobucket.com/user/golfyste/media/E3C4C9A9-A6A9-426D-81D8-CCB46E6A67DB.jpg.html")
(http://i1197.photobucket.com/albums/aa433/golfyste/C5F69F9C-2684-422D-9215-05F3ED93D558.jpg) (http://"http://s1197.photobucket.com/user/golfyste/media/C5F69F9C-2684-422D-9215-05F3ED93D558.jpg.html")

I then got the bumper fitted :). Fits quite well for a rep!
(http://i1197.photobucket.com/albums/aa433/golfyste/E2F4177E-FA8D-43BC-BCB2-0D1844057167.jpg) (http://"http://s1197.photobucket.com/user/golfyste/media/E2F4177E-FA8D-43BC-BCB2-0D1844057167.jpg.html")

Also made some black mesh grills and got them fitted
(http://i1197.photobucket.com/albums/aa433/golfyste/EB2AB6CA-91B4-458E-BD99-4CD0D1F01FD4.jpg) (http://"http://s1197.photobucket.com/user/golfyste/media/EB2AB6CA-91B4-458E-BD99-4CD0D1F01FD4.jpg.html")

Next thing was my mate brought around my finished carbon bonnet!  :).

(http://i1197.photobucket.com/albums/aa433/golfyste/5A3E6150-31E8-43DD-B6EF-D121C7ABF977.jpg) (http://"http://s1197.photobucket.com/user/golfyste/media/5A3E6150-31E8-43DD-B6EF-D121C7ABF977.jpg.html")

I got the latch fitted and adjusted and also had to cut holes for the washers jets etc.

Sadly the bonnet doesn't line up 100% (sits a little proud in the middle) but function over form! I may fit some bonnet raiser to make it look like it supposed to be like that haha

(http://i1197.photobucket.com/albums/aa433/golfyste/CED3C19B-A8D4-499F-9576-D10B2EB76CEE.jpg) (http://"http://s1197.photobucket.com/user/golfyste/media/CED3C19B-A8D4-499F-9576-D10B2EB76CEE.jpg.html")

(http://i1197.photobucket.com/albums/aa433/golfyste/3E3F9437-1B2B-4402-B054-94DB6CCFF179.jpg) (http://"http://s1197.photobucket.com/user/golfyste/media/3E3F9437-1B2B-4402-B054-94DB6CCFF179.jpg.html")

Lines up if pushed

(http://i1197.photobucket.com/albums/aa433/golfyste/41FA2C18-567B-4C4D-8362-C3B04369E77D.jpg) (http://"http://s1197.photobucket.com/user/golfyste/media/41FA2C18-567B-4C4D-8362-C3B04369E77D.jpg.html")

We all love carbon :).

(http://i1197.photobucket.com/albums/aa433/golfyste/28CE68A3-277F-464B-A0C3-F4481F538B5D.jpg) (http://"http://s1197.photobucket.com/user/golfyste/media/28CE68A3-277F-464B-A0C3-F4481F538B5D.jpg.html")

Next up finished the read brake lines.

(http://i1197.photobucket.com/albums/aa433/golfyste/7255B9A2-81FA-4922-A6D4-718B268A939E.jpg) (http://"http://s1197.photobucket.com/user/golfyste/media/7255B9A2-81FA-4922-A6D4-718B268A939E.jpg.html")

Then I bled the system and the abs pump.

(http://i1197.photobucket.com/albums/aa433/golfyste/288B9A1F-0D8A-4BCE-A188-29A4C770646F.jpg) (http://"http://s1197.photobucket.com/user/golfyste/media/288B9A1F-0D8A-4BCE-A188-29A4C770646F.jpg.html")

(http://i1197.photobucket.com/albums/aa433/golfyste/0DC84C73-925E-4464-9663-70E25B750578.jpg) (http://"http://s1197.photobucket.com/user/golfyste/media/0DC84C73-925E-4464-9663-70E25B750578.jpg.html")
(http://i1197.photobucket.com/albums/aa433/golfyste/F3342994-72EB-439B-B0AC-1C99C21920BC.jpg) (http://"http://s1197.photobucket.com/user/golfyste/media/F3342994-72EB-439B-B0AC-1C99C21920BC.jpg.html")
(http://i1197.photobucket.com/albums/aa433/golfyste/E19139FC-5CB8-4D5A-9B97-9F1257D214A2.jpg) (http://"http://s1197.photobucket.com/user/golfyste/media/E19139FC-5CB8-4D5A-9B97-9F1257D214A2.jpg.html")

I also bought a new battery!
Which are apparently the bees knees so hoping it copes well :).
(http://i1197.photobucket.com/albums/aa433/golfyste/3E58FA3E-A1B4-4E9E-8A0B-D926B105364D.jpg) (http://"http://s1197.photobucket.com/user/golfyste/media/3E58FA3E-A1B4-4E9E-8A0B-D926B105364D.jpg.html")

Also gave it a clean.
(http://i1197.photobucket.com/albums/aa433/golfyste/2908FD5F-A23C-450C-A5A0-C21E140525F3.jpg) (http://"http://s1197.photobucket.com/user/golfyste/media/2908FD5F-A23C-450C-A5A0-C21E140525F3.jpg.html")
(http://i1197.photobucket.com/albums/aa433/golfyste/74184B7E-EF8E-415D-A3EE-C24BD18DE395.jpg) (http://"http://s1197.photobucket.com/user/golfyste/media/74184B7E-EF8E-415D-A3EE-C24BD18DE395.jpg.html")

I've also done quite a few other little bits but nothing important really.

Now this is where the complicated stuff starts!

1 step forward. 10 steps

Burning loads of oil. Chucks puffs out while driving but ploomes it out on tickover.
Done compressions tests.
Only have 115psi on C1
Adding oil makes no difference
135 on C2&3, 150 with a little oil.
145 on cylinder 4

When driving the oil buring got so bad it started killing plugs and misfiring as soon as I did a little slow driving. No misfiring if I kept the revs up while bedding it in hard between 2k and 4k
Removed the plugs 1,2&3 and they are black as hell but dry. No 4 was soaking wet. Looking into C4 I can literally see it swimming in oil.

I dunno where I stand really i dunno why the rings aren't sealing or are them compressions right on a non bed in engine? Although 1 is substantially low compared to the others.

Wondering if the bored are oval'd or something. I've no idea.

After speaking to the lads on Facebook I'm gonna start stripping the begone tomorrow and take loads of pics and send them to JP. I have a feeling the block is knackered and needs boring out.

We will see.
Hopefully I can get it sorted soonish!
I'll try keep this up to date from now on.
I left it a whole as I didn't k is what was happening with the smoke!
Title: Re: Golfyste's road legal mk4 "project track car"
Post by: golfyste on 16 March 2015, 00:55
 Ok little update
I was pretty depressed last night but managed to find a new wave of motivation today!

Stripped the head off
(http://i1197.photobucket.com/albums/aa433/golfyste/759FB694-3C44-4B24-A137-9802B50A13ED.jpg) (http://"http://s1197.photobucket.com/user/golfyste/media/759FB694-3C44-4B24-A137-9802B50A13ED.jpg.html")

Cylinder 1 has corroded while it's been stood. Which is causing the low compression on there. Others haven't bed in very well and then bore washed due lack of compression causing it to run rich.
It's gonna need machining etc.
I'm trying to keep my chin up.
The engine was going to come back out anyway to fit the 6 speed box, k300 and relentless mani so I'll just have to do that now and bed it in with the k300 fitted.

Cylinder is knackered
(http://i1197.photobucket.com/albums/aa433/golfyste/F074B860-7BDF-470F-B4F7-9BB061AE6569.jpg) (http://"http://s1197.photobucket.com/user/golfyste/media/F074B860-7BDF-470F-B4F7-9BB061AE6569.jpg.html")

Cylinder 4 was swimming in so much oil it burnt itself clean. Can't see it here but oil was everywhere
(http://i1197.photobucket.com/albums/aa433/golfyste/582DBE49-8B86-477A-935C-60FC087AE068.jpg) (http://"http://s1197.photobucket.com/user/golfyste/media/582DBE49-8B86-477A-935C-60FC087AE068.jpg.html")

Lots of overfueling due to lack of compression.
(http://i1197.photobucket.com/albums/aa433/golfyste/4838FC6F-7CF5-4C58-9B07-2F08CF0FDB25.jpg) (http://"http://s1197.photobucket.com/user/golfyste/media/4838FC6F-7CF5-4C58-9B07-2F08CF0FDB25.jpg.html")


I think I'm going to strip the block down and take the block to jp.
I either need to get this bored out and fit some 83mm Pistons or get another block and just get him to home it for the standard Pistons.

On a lighter note. A pic of my rsr's haha
(http://i1197.photobucket.com/albums/aa433/golfyste/5DE0F686-7A57-4B15-A5F3-40816754DEBF.jpg) (http://"http://s1197.photobucket.com/user/golfyste/media/5DE0F686-7A57-4B15-A5F3-40816754DEBF.jpg.html")
Title: Re: Golfyste's road legal mk4 "project track car"
Post by: Wazzzer on 26 March 2015, 18:54
Ah not good news mate, although that was the only real thing it could have been...

At least you can get on with the other stuff as well, also I'll send you a PM in a bit
Title: Re: Golfyste's road legal mk4 "project track car"
Post by: golfyste on 26 March 2015, 19:35
Yeah plans have been made.
Gonna take the block to jp at jnl to get honed and checked over.
Already got it in bits. And also got other things I need to for so gonna try get it all done at once and have it ready for mapping when I next refit the engine so it's just a case of running it in :).

Probably won't update about the engine untill it's all in and started though haha.

I did fit my direnza high flow radiator today though :).

(http://i1197.photobucket.com/albums/aa433/golfyste/32C90428-9003-420E-9FD0-90ED3C52DE7C.jpg) (http://s1197.photobucket.com/user/golfyste/media/32C90428-9003-420E-9FD0-90ED3C52DE7C.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/F05C236D-53E6-42A4-96A0-B1742D635009.jpg) (http://s1197.photobucket.com/user/golfyste/media/F05C236D-53E6-42A4-96A0-B1742D635009.jpg.html)
Title: Re: Golfyste's road legal mk4 "project track car"
Post by: golfyste on 11 April 2015, 00:02
Had a couple of deliveries. Got some more running in oil, relentless mani fittings, oil pressure and yelp gauges with sandwich plate and a s3 front Arb.

(http://i1197.photobucket.com/albums/aa433/golfyste/68544B3F-55E8-4ADD-8CAD-7B1BF593652B.jpg) (http://s1197.photobucket.com/user/golfyste/media/68544B3F-55E8-4ADD-8CAD-7B1BF593652B.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/49BE5153-64F6-4218-BDD8-485996B65545.jpg) (http://s1197.photobucket.com/user/golfyste/media/49BE5153-64F6-4218-BDD8-485996B65545.jpg.html)


Also been busy in the garage.
Everybody loves organised spanners right? Haha

(http://i1197.photobucket.com/albums/aa433/golfyste/4382AA75-5C78-4925-879C-4467836F818E.jpg) (http://s1197.photobucket.com/user/golfyste/media/4382AA75-5C78-4925-879C-4467836F818E.jpg.html)

Made myself a oil catchy can for the bike :).

(http://i1197.photobucket.com/albums/aa433/golfyste/C6A58B1F-B9BC-4466-87D9-A61FA3DAB00E.jpg) (http://s1197.photobucket.com/user/golfyste/media/C6A58B1F-B9BC-4466-87D9-A61FA3DAB00E.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/9D48E2DD-ABB7-4A92-B8FE-0CCD0567C2D1.jpg) (http://s1197.photobucket.com/user/golfyste/media/9D48E2DD-ABB7-4A92-B8FE-0CCD0567C2D1.jpg.html)

(http://i1197.photobucket.com/albums/aa433/golfyste/98154E4F-02A2-4C45-8F2D-C46BFAD3424E.jpg) (http://s1197.photobucket.com/user/golfyste/media/98154E4F-02A2-4C45-8F2D-C46BFAD3424E.jpg.html)

I then completely Stripped the old engine of everything I needed and bagged it all up. Also cleaned a few engine parts in prep for taking them down to jp including the sump [emoji23]

(http://i1197.photobucket.com/albums/aa433/golfyste/A405A175-4294-41C4-9CCB-C6E311E0802D.jpg) (http://"http://s1197.photobucket.com/user/golfyste/media/A405A175-4294-41C4-9CCB-C6E311E0802D.jpg.html")

I then got everything down south and stayed at my girlfriends this week driving to jp's daily and we set about rebuilding my engine.

Some nice new honing ;).

(http://i1197.photobucket.com/albums/aa433/golfyste/6F545147-391B-47B6-8D83-272463F4C82B.jpg) (http://"http://s1197.photobucket.com/user/golfyste/media/6F545147-391B-47B6-8D83-272463F4C82B.jpg.html")

Also found the head was terrible!
15/20 valves didn't seal and a couple of the valve seals on cylinder 4 were shot. So set about stripping it and sorting it out!

(http://i1197.photobucket.com/albums/aa433/golfyste/621C4441-0442-4669-9526-3AF3862BBB33.jpg) (http://"http://s1197.photobucket.com/user/golfyste/media/621C4441-0442-4669-9526-3AF3862BBB33.jpg.html")

After 3 busy days (would have been 2 if it wasn't for a messing up of parts being delivered) the engine was done! :)
Got it home yesterday and back into the garage!

(http://i1197.photobucket.com/albums/aa433/golfyste/6CD0D699-7F53-48F9-BFFE-7E373BCED6EE.jpg) (http://"http://s1197.photobucket.com/user/golfyste/media/6CD0D699-7F53-48F9-BFFE-7E373BCED6EE.jpg.html")

So that a big step complete!

Just need to add a little more paint, paint the gearbox, get a 6 speed clutch and flywheel from aks and I can set about getting it all fitted! :).

Also got another exciting delivery coming shortly which I will update on when it arrives :D
Title: Re: Golfyste's road legal mk4 "project track car"
Post by: golfyste on 28 April 2015, 05:07
Time to bring this up to date!

the exciting delivery arrived!

(http://i1197.photobucket.com/albums/aa433/golfyste/B59CFBBB-A24F-434C-BDDB-B55430770251.jpg) (http://"http://s1197.photobucket.com/user/golfyste/media/B59CFBBB-A24F-434C-BDDB-B55430770251.jpg.html")

(http://i1197.photobucket.com/albums/aa433/golfyste/93D5FE30-775C-402B-9631-3CEA13A59C7A.jpg) (http://"http://s1197.photobucket.com/user/golfyste/media/93D5FE30-775C-402B-9631-3CEA13A59C7A.jpg.html")

Base kit with dual port injection [emoji16]

Did a little more work on the car
Started by doing all the wiring for my new gauges.
Perm live, ign live, Earth, dimmer etc.
Also laid all the wires into the bay.

I then set about making the mounting plate. Removed the centre air vents and measured it all up.
And then cut the plate to size and made it fit nicely.

(http://i1197.photobucket.com/albums/aa433/golfyste/F4166E21-AB44-472B-B2D3-146EBE4BDFBF.jpg) (http://"http://s1197.photobucket.com/user/golfyste/media/F4166E21-AB44-472B-B2D3-146EBE4BDFBF.jpg.html")

Next I did plenty of measuring and marking and started cutting :).

(http://i1197.photobucket.com/albums/aa433/golfyste/ECD39277-007D-467D-A932-E2F824669794.jpg) (http://"http://s1197.photobucket.com/user/golfyste/media/ECD39277-007D-467D-A932-E2F824669794.jpg.html")

Gauges mounted
(http://i1197.photobucket.com/albums/aa433/golfyste/23ECAEA8-7AA8-4C3B-B987-F63E699D9D29.jpg) (http://"http://s1197.photobucket.com/user/golfyste/media/23ECAEA8-7AA8-4C3B-B987-F63E699D9D29.jpg.html")

And in the car
(http://i1197.photobucket.com/albums/aa433/golfyste/BD51B602-DB2C-4EE1-B157-0B038CE7979E.jpg) (http://"http://s1197.photobucket.com/user/golfyste/media/BD51B602-DB2C-4EE1-B157-0B038CE7979E.jpg.html")

It's a nice tight fit and just has one screw to ensure its 100% secured

(http://i1197.photobucket.com/albums/aa433/golfyste/2544CA5B-54D7-4E74-A0B8-8EBA095BEDD3.jpg) (http://"http://s1197.photobucket.com/user/golfyste/media/2544CA5B-54D7-4E74-A0B8-8EBA095BEDD3.jpg.html")

(http://i1197.photobucket.com/albums/aa433/golfyste/F7B65C6B-7033-450A-9C93-1AE494C30E28.jpg) (http://"http://s1197.photobucket.com/user/golfyste/media/F7B65C6B-7033-450A-9C93-1AE494C30E28.jpg.html")

(http://i1197.photobucket.com/albums/aa433/golfyste/53F59170-88E4-41DB-A324-102B83D51816.jpg) (http://"http://s1197.photobucket.com/user/golfyste/media/53F59170-88E4-41DB-A324-102B83D51816.jpg.html")

(http://i1197.photobucket.com/albums/aa433/golfyste/73E8C3CD-1BF2-43DD-9474-823CB1F2B79C.jpg) (http://"http://s1197.photobucket.com/user/golfyste/media/73E8C3CD-1BF2-43DD-9474-823CB1F2B79C.jpg.html")

Title: Re: Golfyste's road legal mk4 "project track car"
Post by: golfyste on 28 April 2015, 05:09
Finished painting the head.
The finished product [emoji16]

(http://i1197.photobucket.com/albums/aa433/golfyste/9CC03509-B4EB-42C5-BD3A-A1841F3F09AC.jpg) (http://"http://s1197.photobucket.com/user/golfyste/media/9CC03509-B4EB-42C5-BD3A-A1841F3F09AC.jpg.html")

Also cleaned and primed the gearbox.

(http://i1197.photobucket.com/albums/aa433/golfyste/DCC34393-70D8-4641-88D3-4D3FF25CEC38.jpg) (http://"http://s1197.photobucket.com/user/golfyste/media/DCC34393-70D8-4641-88D3-4D3FF25CEC38.jpg.html")

Got my self a new work light for when it gets dark [emoji108]

(http://i1197.photobucket.com/albums/aa433/golfyste/392814BB-79C9-4AAD-915F-95424F132BE2.jpg) (http://"http://s1197.photobucket.com/user/golfyste/media/392814BB-79C9-4AAD-915F-95424F132BE2.jpg.html")

(http://i1197.photobucket.com/albums/aa433/golfyste/4036B231-6FF8-4E5A-8FB6-344163D8B340.jpg) (http://"http://s1197.photobucket.com/user/golfyste/media/4036B231-6FF8-4E5A-8FB6-344163D8B340.jpg.html")

(http://i1197.photobucket.com/albums/aa433/golfyste/6CEE695C-4D8D-4E9E-BE80-6B52B8925EAD.jpg) (http://"http://s1197.photobucket.com/user/golfyste/media/6CEE695C-4D8D-4E9E-BE80-6B52B8925EAD.jpg.html")

Also made my mounting brackets for my water meth tank [emoji41]

(http://i1197.photobucket.com/albums/aa433/golfyste/5653DFFA-78E1-4E30-A6F9-8BD46994101F.jpg) (http://"http://s1197.photobucket.com/user/golfyste/media/5653DFFA-78E1-4E30-A6F9-8BD46994101F.jpg.html")

(http://i1197.photobucket.com/albums/aa433/golfyste/307FECE5-8369-42D8-8719-E081E4CAF928.jpg) (http://"http://s1197.photobucket.com/user/golfyste/media/307FECE5-8369-42D8-8719-E081E4CAF928.jpg.html")

(http://i1197.photobucket.com/albums/aa433/golfyste/E1F6D601-12BF-4F03-BD13-DFEF0221AC89.jpg) (http://"http://s1197.photobucket.com/user/golfyste/media/E1F6D601-12BF-4F03-BD13-DFEF0221AC89.jpg.html")

(http://i1197.photobucket.com/albums/aa433/golfyste/95A01E96-748E-4750-A604-069F2ADC9361.jpg) (http://"http://s1197.photobucket.com/user/golfyste/media/95A01E96-748E-4750-A604-069F2ADC9361.jpg.html")

Just need another metric exhaust clamp [emoji4]


Title: Re: Golfyste's road legal mk4 "project track car"
Post by: golfyste on 28 April 2015, 05:15
Fitted the wmi pump.

(http://i1197.photobucket.com/albums/aa433/golfyste/B2DAFAC7-7A57-4466-B91C-7FE713DFDDAD.jpg) (http://"http://s1197.photobucket.com/user/golfyste/media/B2DAFAC7-7A57-4466-B91C-7FE713DFDDAD.jpg.html")

Also removed the tank and fitted the tank tap and the float switch :).

(http://i1197.photobucket.com/albums/aa433/golfyste/EA7F83A3-B0D2-4E2A-992B-E65FC21011A5.jpg) (http://"http://s1197.photobucket.com/user/golfyste/media/EA7F83A3-B0D2-4E2A-992B-E65FC21011A5.jpg.html")

(http://i1197.photobucket.com/albums/aa433/golfyste/CF2340C8-D846-4F95-B8BA-043FA6355B0D.jpg) (http://"http://s1197.photobucket.com/user/golfyste/media/CF2340C8-D846-4F95-B8BA-043FA6355B0D.jpg.html")

Refitted the tank and also made some little strengthening plates as the aluminium was bending around the cage.
Clamped nice and solid now!

(http://i1197.photobucket.com/albums/aa433/golfyste/255162CB-A722-486C-9C81-BAE5B246708B.jpg) (http://"http://s1197.photobucket.com/user/golfyste/media/255162CB-A722-486C-9C81-BAE5B246708B.jpg.html")

Can actually see where it's started bending the steel so I think it's tight enough haha.

(http://i1197.photobucket.com/albums/aa433/golfyste/463F49B5-142C-4B17-9958-9FE077C5CB27.jpg) (http://"http://s1197.photobucket.com/user/golfyste/media/463F49B5-142C-4B17-9958-9FE077C5CB27.jpg.html")


I've also just been figuring out all the wiring for the wmi and started laying all the wires. 
But came in as its a little dark now! [emoji23]


Had a couple of mates round. Not just for working on the car but thought we would have a little play.

Got the wmi wiring done and all ready to be piped up but I'm gonna wait until the old engine is out to do that.

(http://i1197.photobucket.com/albums/aa433/golfyste/A3E6C76F-266E-4237-BE6E-01261DF91681.jpg) (http://"http://s1197.photobucket.com/user/golfyste/media/A3E6C76F-266E-4237-BE6E-01261DF91681.jpg.html")

Managed to tidy up the gauge wiring a little bit as it was a complete birds next!

(http://i1197.photobucket.com/albums/aa433/golfyste/8031EB46-FBE0-4378-BC0F-CA008D479A93.jpg) (http://"http://s1197.photobucket.com/user/golfyste/media/8031EB46-FBE0-4378-BC0F-CA008D479A93.jpg.html")

All the wiring done and led's installed :).

Just need the afr gauge now!

(http://i1197.photobucket.com/albums/aa433/golfyste/5ED39DFE-069D-4483-A551-79BD929A9150.jpg) (http://"http://s1197.photobucket.com/user/golfyste/media/5ED39DFE-069D-4483-A551-79BD929A9150.jpg.html")