beppe2672 - Jazz blue 1.8T

[jv]

[beppe2672]

Cheers jv!

[beppe2672]

Right, where do I start? After having to sell my Edition 30 due to some complicated tax issues I thought I'd go for another mk4. Anyway a friend of mine was selling one cheap so I thought what the hell, there cant be much wrong with it. Gave it a quick one over and parted with my cash. Once I got it back the the workshop and gave it a proper going over I realized its gonna need some work, here's a list of what I've had to fix/replace so far:
Cam belt
Aux belt
Fuel cap solenoid
Both front door modules (dodgy solder)
Throttle body
Filters/spark plugs/oil/coolant
Rear ash tray
Front top mounts
Blowing exhaust
Rocker cover gasket
Central locking
Battery
Seized rear brake caliper
Snapped turbo downpipe stud
all brake pads and discs
Reverse light switch

After getting the car running better it was time to start tearing off all the chavtastic bits the previous owner seemed keen on. The car looked like it had been covered in glue then driven through halfords! So I replaced the front grill with a standard item, removed all the blue led's inside and out, swapped the god awful blue hella magic color tail lights for some smoke ones. Slapped on a set of audi rs4 alloys and some decent tires. Which got me to this stage. 

I know it needs a wash!

[beppe2672]

Finaly got to the stage where everything was working the way it should and nothing is broken! (for now). It was time to start upping the performance of my AGU lump. So the airbox was modded, I smoothed it and plastic welded a 75mm intake duct in place of the standard ducting, plumbed it up to some 75mm flexible aluminium tubing and a velocity stack behind the front bumper, fitted a pipercross panel filter and forge 007p. Then it was off to JKM Portsmouth for a stage one remap. Also did a few cosmetic mods, Painted the front grill black, fitted a black VW badge front and rear, DIY anni headlights (absolute pain in the arse), here's the results





Managed to pick up a pretty damn cheap K03s turbo this weekend, saving it for a hybrid project and supporting mods. And I'm waiting on some center caps for my alloys before I get them refurbed. Torn between gloss black, anthracite or shadow chrome for the wheels. My wish list is getting pretty expensive now.

On a side note I'm looking forward to not having the car in my work 90% of the time!

[beppe2672]

Little update, started gathering the bits for a K04-001/K04-02x hybrid this week, picked up a knackered K04-001 yesterday and got that stripped, exhaust housing was fine, which is all that matters, hopefully should be picking up the K04-02x cold side I need this weekend. Just gotta slip the metalsmiths on my barracks a crate of beer to tig weld the K03 charge pipe onto the K04-02x housing and send it all of to get balanced, oh and a forge K04 actuator Should have a pretty nice turbo for around £350! Also picked up a 3" TIP I need to accept the larger K04-02x intake.

Just spent a whole lot of my day e-mailing companies to try and find a billet 2275E compressor wheel.

[beppe2672]

Just a little update, got my modified K04-02x compressor housing chopped up and ready for welding on monday


Forgot for much I hated draw filing, chopped up an old k03 actuator bracket I had to use as a bit of a jig, held up to a normal k03 housing everything seems to line up perfectly! Also ground out the inside of the K03 bit to the same internal diameter as the K04 side to make sure there was no step or ridge inside.

[beppe2672]

Mini update on the diy hybrid build, got all the bits I need either on its way or on my workbench, the spec I settled for is as follows:
-K04-001 ported turbine housing
-K04-001 turbine
-K04-020 compressor housing (modified to fit K03 outlet)
-K04-049 compressor wheel (2277 ETT from a vxr, I wanted something different)
-Forge K03 actuator with a blue spring (rio persuaded me)
and a full rebuild kit with stepped seals and an uprated thrust bearing

[beppe2672]

Home made hybrid is ready for balancing! I've just test fit everything, looks like it's gonna work. Here's a few pics of the internals compared to standard K03s stuff.

2277 wheel on the right, K03s on the left.


K04-001 turbine on the left, K03s on the right


And here's the modified compressor housing, still needs a couple of bits shaving of the outside to stop the casing fouling on the block.


Boxing up all the moving parts to be sent off to get balanced hopefully later this week!

[beppe2672]

Had an mot yesterday, failed epically! Offside front lower ball joint, blowing exhaust, near side rear tyre worn and I need a new front number plate! Luckily I had a brand new Pirelli p zero sat in my boot. Jkm let me have the car back to do the work myself. So I popped down to eurocarparts and came back with a bag of goodies, gonna replace both lower ball joints, anti roll bar bushes, new exhaust hangars and clamps. It's gonna be a busy day!

[beppe2672]

After spending a grand total of £60 on parts, the car passed its mot re-test! Road worthy for another year! But after spending the last 2 days poking around under the golf I've realised the suspension needs a bit of love, so the hybrid project is going on hold till I can get it all sorted!