GolfGTIforum.co.uk
Model specific boards => Golf mk2 => Golf mk2 gallery => Topic started by: jv on 19 October 2009, 21:38
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:)
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I thought I would put a little build thread together from start to hopefully(!) finish.
Here is the culprit due to have its insides ripped apart for a VR upgrade. It is currently a 2.0 8v running a newman 282cam. Goes well bless it, but I’m bored of it not being very dramatic. It goes like fairly well, but does not have any sort of grunt behind it. I think the real reason for the convertion is just so i can have that roar!!!
(http://img.photobucket.com/albums/v615/madmanluke/IMG_8824-1.jpg)
I have a good idea of what needs to be done, but I am sure if I do get stuck on any thing, I will be all over mk2vr6.com for information like a rash. Some very knowledgeable people that are happy to help if any one needs to know!
I picked this beauty up on saturday. Thanks to Ash from edition who held onto this for me :) . Its a 97 obd2 mk3 with 68k on the clock and I am hoping to use as much of it as possible. So my mk2 will be running wide-track but will unfortunately be sporting those lovely standard BBS until I find some thing I like in 5 stud!
The car actually came with a MINT set of recaro’s all round. And by mint, i really do mean spotless. These are currently for sale so check out the classifieds soon! All the ‘mod cons’, electric windows, mirrors, sunroof etc etc. all of it going to be sold on to recoup the cost of the car.
If I didn't have the mk2 and have that mk2vr fever... id stick with this. Its a joy to drive. Smooth as anything and plenty of power on tap....if a little....boat like.
(http://img.photobucket.com/albums/v615/madmanluke/att_1.jpg)
(http://img.photobucket.com/albums/v615/madmanluke/photo.jpg)
Next step is to get the mess in the garage cleared out so I can wheel the car in and out of it as and when I want to do the work. The garage is just that little bit too small to have the car in there full time, so this will have to do for now.
Hopeing to get the engine out of the MK2 this week end and also have the VR out for a paint up and refresh. So update due soon! :up:
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Here is a small update.
Woke up today with all intentions of getting the old 2.0 8v out.
First port of call was to clean her. I didnt partially want to be working on a car with over 300 miles worth of crap all over it.
(http://img.photobucket.com/albums/v615/madmanluke/IMG_9079.jpg)
(http://img.photobucket.com/albums/v615/madmanluke/IMG_9084.jpg)
Here is how the Old bay used to look:
(http://img.photobucket.com/albums/v615/madmanluke/IMG_9088.jpg)
(http://img.photobucket.com/albums/v615/madmanluke/IMG_9091.jpg)
By the time it I had just finished giving it a once over, its started chucking it down :( Carried on none the less.
(http://img.photobucket.com/albums/v615/madmanluke/IMG_9099.jpg)
And here it is with the bay empty with me inside! Pretty painless removal. It did give me a bit of grief as I had left the manifold and downpipe on but other that. No complaints.
(http://img.photobucket.com/albums/v615/madmanluke/IMG_9106.jpg)
I had soon found oil EVERYWHERE over the subframe, looks like the gearbox really was on its last legs. So thats awaiting to be dumped :)
I then started on the removal of the dash so I could have good and propper access to everything going into the fuse box. PAIN. IN. THE ARSE. everything was undone and not a problem, but it just wouldn't go over the steering column. Needless to say I have scratched the crap out of my stalks, so I will be doing the mk3 stalk upgrade I think... Glad I got the dash out any way, its off to be flocked in about a week or so's time. Plus I have the install a new heater matrix, so must make it a little easier.
(http://img.photobucket.com/albums/v615/madmanluke/IMG_9112.jpg)
Untill next time (probably tomorrow!)
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Well today consisted of getting the VT out of the donor. All went fine bar one stubbern nut/bolt on the down pipe to exhaust.
(http://img.photobucket.com/albums/v615/madmanluke/IMG_9130.jpg)
(http://img.photobucket.com/albums/v615/madmanluke/IMG_9143.jpg)
(http://img.photobucket.com/albums/v615/madmanluke/IMG_9147.jpg)
And finally
(http://img.photobucket.com/albums/v615/madmanluke/IMG_9150.jpg)
Looking to have the engine sprayed up an the mk2 wiring loom split by next weekend so I can then swap the subframes over.
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Well heres a small update.
I have spent the evening of the last week doing odd bits and bobs whilst I can. At the beggining of the week it consisted of the most important thing. Painting bits. I have managed to get the inlet, gearbox and tensioner so far done. Lots left to do but I will do all of that once it is in and running.
Here is how it was before I started.
(http://img.photobucket.com/albums/v615/madmanluke/IMG_9152.jpg)
And here it is now. Simple but looks better than it did before. its great what a bit of paint and lacquer can do :p
(http://img.photobucket.com/albums/v615/madmanluke/IMG_9163.jpg)
I also spend the time removing both looms. I was pretty glad I could just unplug everything from the mk3 fusebox and leave it as it did not need to be plugged back in any where else. With the mk2 I had to remove the brake servo in order to get the engine loom out! strange, but the servo is being replaced any way....
Took a little more care in taking the mk2 loom out and it looks like I only have to plug in 5 or so connectors from the mk3 loom to get me going? We will soon see...
Yesterday I started on swapping the front subframes over. Went pretty smoothly bar one thing, still need to get back under the car to tighten up all the bolts properly and I also need to bolt up the old mk2 frame to the mk3 so I can have it wheeled off the drive. The one thing is i lost the locking wheel nut to get the wheels off. As I was running out of light i thought smack an 18mm socket on it and whip it off....oh no.
These locking nuts had a loose sleeve round them to stop people doing just that. I noticed that a little too late as now the socket it wrapped around the nut!
Out came the trusty grinder and a chisel. Had to grind the crap out of the socket and split it open with a hammer and chisel.
Here is a few pictures....everyone likes pictures... haha
(http://img.photobucket.com/albums/v615/madmanluke/IMG_9153.jpg)
(http://img.photobucket.com/albums/v615/madmanluke/IMG_9154.jpg)
(http://img.photobucket.com/albums/v615/madmanluke/IMG_9155.jpg)
(http://img.photobucket.com/albums/v615/madmanluke/IMG_9156.jpg)
(http://img.photobucket.com/albums/v615/madmanluke/IMG_9157.jpg)
A working drive hehe
(http://img.photobucket.com/albums/v615/madmanluke/IMG_9161.jpg)
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Mk3 subframe is all bolted up to the mk2 no problems now. Some one suggested it before but you need to have alll bolts very loose and in to start with, then tighten up. Went up no problems after that.
Next thing to tackle is the rear beam at the week end. Hoping to have the VR loom plugged into the fuse box at least at some point this week.
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Well the rear beam is off the donor now. Sods law, I went out and started in blue sky. 10 mins later, it was driving rain! As soon as I got the rear beam off, I gave in as I was soaked through to the bone. But hey, its another major bit done.
My ECU is now packed up and awaiting to be taken to C2 for an immo defeat also.
I am still waiting on my 16v master cylinder and servo and clutch parts. Still plenty to do though.
Here it is sitting on my old sebrings untill I get my mk2 one off.
(http://img.photobucket.com/albums/v615/madmanluke/IMG_9175.jpg)
And mine ready for rear beam removal hopefully at the weekend/ possible an evening during the week.
(http://img.photobucket.com/albums/v615/madmanluke/IMG_9176.jpg)
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Here is an update from today.
Full wide track now complete, and engine is in! Its all coming back out tomorrow.
Things I need. SOLID MK2 CROSSMEMBER FRONT MOUNT- MAJORLY.
Tomorrow it is coming back out so I can do pedal-box, clutch cylinder, rear brake lines, front brake lines, handbrake cables, brake servo and master cylinder.
Heres a few more pictures.
(http://img.photobucket.com/albums/v615/madmanluke/IMG_9181.jpg)
(http://img.photobucket.com/albums/v615/madmanluke/IMG_9182.jpg)
(http://img.photobucket.com/albums/v615/madmanluke/IMG_9187.jpg)
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Another update.
Things that are done:
Engine Loom in and plugged into fusebox
extended wiper loom to reach the motor
put ECU ontop of the fan vent in the passenger foot well
Drivers side CVD boot replaced
Cut down and re-welded exhuast ready to fit again next week
Now have steering again!
Full pedal box complete
Clutch master cylinder in
Brake servo in (still not sure the mk3 vr6 master cylinder will work with this?!?)
Things to buy/do:
New brake copper and unions
get hold of complete rear brake compensator for mk3 beam.
Clip to keep the clutch MC on the clutch pedal
new oring for the dip stick
Throttle cable (not sure what I need - Guys?)
lots and lots of black tape for impending loom split once engine has been started and tested
replace brake flexes for the correct part
go over any air leaks in exhaust with welder again
on order/waiting to arrive:
Raceland 6 branch all heat wrapped up
Flocked dash - due back mid this week
No pictures unfortunatly as it all still looks the same! getting closer to being able to turn that key! :-D
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Well it runs!
I have to sort out a couple of issues. I currently dont have ANY reading to my rev counter at all, not a thing.
Fuel pump seems to be priming all the time... not sure where the fault is with that. Have tried new relays so it may be a wiring issue some where else.
Engine is coming back out again tomorrow to run new front brake lines, rear brake lines, master cylinder.
Then just rebuild the inside again and then itl be finished! il just have to save up again for insurance deposit, mot, tax etc etc, so should be on the road by mid/end of december I think...
Sorry for the poor image quality. - looks like my power steering pump is on its way out as it was doing this before I took the engine out. It just sounds louder now as there is no fluid in it.
(http://img.photobucket.com/albums/v615/madmanluke/th_V1708_21-11-09.jpg) (http://smg.photobucket.com/albums/v615/madmanluke/?action=view¤t=V1708_21-11-09.flv)
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Well the engine came back out today.
I have now tidied up and secured the loom. (I want to run it through the scuttle panel, but I really cant be arsed to, to be fair! The ECU is already plumbed into the passengers side footwell, so I decided against it and just cable tied it up. Il do it when its warmer I think... haha)
I Have also made up complete new brake lines from the servo to front wheels. I am still waiting on this brake compensator valve so i have not replaced the main lines to the rear yet as I do not know what length I will need them. I could go with a manual brake bias valve if this compensator does not turn up.
Thats about it really for this weekend. All thats left to do now, is wait for bits to turn up... Namely, 6 branch, dash, brake compensator. Then the engine will go back in for a final time :) Then it will just be general bolt seats back in, dash in, setup of gear linkages, bleeding brakes etc etc. :clap: During this time, Il be saving my nuts off to get a deposit for insurance together, tax and MOT etc. Slightly skint because of this right now! I really want to have this on the road before the end of december!
(http://img.photobucket.com/albums/v615/madmanluke/IMG_9221.jpg)
(http://img.photobucket.com/albums/v615/madmanluke/IMG_9222.jpg)
(http://img.photobucket.com/albums/v615/madmanluke/IMG_9225.jpg)
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Another update:
My Flocked dash bits turned up the other day. AWESOME. SBP, nothing but good praise for the guys. Very good quality, and I am extremely happy!
It looks a lot better in the flesh, the flash sparkles it up...
(http://img.photobucket.com/albums/v615/madmanluke/IMG_9226.jpg)
(http://img.photobucket.com/albums/v615/madmanluke/IMG_9227.jpg)
(http://img.photobucket.com/albums/v615/madmanluke/IMG_9228.jpg)
(http://img.photobucket.com/albums/v615/madmanluke/IMG_9229.jpg)
(http://img.photobucket.com/albums/v615/madmanluke/IMG_9230.jpg)
My corrado rad and fans also arrived today, so I decided to spend a couple of hours after work tonight doing the car.
First up, engine back in (can get it in and out of the car in under 5 mins now, Its been done so many times!)
(http://img.photobucket.com/albums/v615/madmanluke/photo-3.jpg)
I then rolled the car into the front of garage and proceeded to light up the patio heater! I think this has been the best idea ive had through out the whole of this build!! nice n' toasty :-D
(http://img.photobucket.com/albums/v615/madmanluke/IMG_9231.jpg)
Ah yes, forgot to mention my 6 branch had also arrived, so that was fitted before the engine went in :)
(http://img.photobucket.com/albums/v615/madmanluke/IMG_9238.jpg)
I got everything plugged in, drive shafts bolted up finger tight untill I have the brakes bled, and then started on the radiator.
sits ok, I just need to weld a small plate onto my rad support to support the left hand side of the radiator looking from the front.
(http://img.photobucket.com/albums/v615/madmanluke/IMG_9244.jpg)
The top bolted straight up, :-D
(http://img.photobucket.com/albums/v615/madmanluke/IMG_9243.jpg)
And here she sits now. I also had painted up my standard vr6 wheels in gloss black. The car looks proper murdered. Sort of looks good, sort of doesnt. They will do untill I get hold of some TH lines in 5x100 :)
(http://img.photobucket.com/albums/v615/madmanluke/IMG_9232.jpg)
The only major bit I am now waiting on is a mk3 rear beam support and brake compensator. Untill I get that I cant run the main brake lines to the rear as I do not know what length I need them... Not much left to do!
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Well today I got it started again. Didnt really have the motivation as im slightly sleep deprived at the moment after a uni visit yesterday. lol
Car runs alot lot better than it did before. It used to pop and bang, and generaly run really rough before. I havent changed any thing so Im not quite sure what the issue is. Runs great now none the less!
It sounds awesome out the back also. you can hear it clicking quite a bit in the video, i hadnot done the bolts up that tight at the cat to branch. doesnt do it now though since tightening it up.
I let it run for a while to check the fans came on....nothing....
quick look over the fuse box, I just needed to swap out the old fan loom (strange, it was still plugged into the fusebox, but its not in the engine bay any more!:S) with the vr one into the back. straight away, fans cut in no problem.
(http://img.photobucket.com/albums/v615/madmanluke/th_IMG_1017.jpg) (http://smg.photobucket.com/albums/v615/madmanluke/?action=view¤t=IMG_1017.flv)
Things left to be done. Get hold of brake compensator and mounting plate. This is the only major thing holding me up.
Make mount for the radiator and generally clamp it down better.
Bleed the brakes and clutch.
Find/Buy an original mk2 pump to bottle power steering hose.
Take a look at why the brake lights are on constantly.
Sort out gear linkage. Tidy up wiring by the battery. There is a lot of it and the battery is just sitting ontop of them all at the moment!
plug the dash back in
Sort out the rev counter
Squat the rear down a bit more - ride hight fail currently...
MOT it, Tax it, Insure it. DRIVE IT!
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Well this weekend has been a little slow. Im slowly starting to run out of major things to do, although there are plenty of little bits left. Unfortunatly all electrics which is anoying!
Today I got the power steering working (finaylf ound my mk2 steering hose!) I had to cable tie the bottle to the top of the bottle mount as it sat too low and fuled against the gearbox. Will sort that out properly when I can be bothered, Its secured fine for now.
Found the fault with the left hand side lights not working. The radiator thermo switch and rad power all comes off the same block as the left side head lighting loom. As I have to use my original mk2 light wiring, i will need to cut off the cables from the mk3 block and solder them to the mk2 to hopefully solve that issue.
I also got the front end of the car back on. starting to look like herself again!
(http://img.photobucket.com/albums/v615/madmanluke/IMG_9297.jpg)
(http://img.photobucket.com/albums/v615/madmanluke/IMG_9300.jpg)
lots left to do, but getting ever closer to being on the road, especially as my ATS cups have sold. That will probably be my insurance deposit!
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Probably getting a bit boring for everyone reading, but i like to do this so I can keep track of what I have actualy done!
Today i fixed up the rad fan wiring into the mk2 lighting loom connector, so i now have left side lights and a working fan again. I think the horn runs through this also, as this no longer works?
I have also swapped round the pulls on the heater controls. Note to self. Buy a new heater pannel, all clips are broken and is only being held in place by the controll arms!
I then set to work on trying to get the rev counter working. Soldered eveything up but the rev meter seems to read 500 revs to low. at idle, the counter reads at 200rpm, if i gun the engine to what i think is over 3k rpm, the needle bearly touches over 1000rpm.
I think the guy at maplins may have given me the wrong resistors. I am supposed to use 1k, but i think I may have been given higher.
I have now started to piece back my flocked dash, got the ignition cowling on and speaker grills. I love this stuff so damn much but can see my self cleaning flock out of every hole in the car!
Not much left to do, I need to get to a garage to steal some headed letter paper so i can get the engine down on the log book, so i can MOT and tax this thing asap!
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The car is now rolling under its own power and as it is now, could quite easily be taken out on the road for a blast! Brakes are bled. I had hassle with the rear right caliper being seized. The amount of junk that was pouring out the bleed Peeple was horrifying to be honest. It looked more like foam, than oil when we were bleeding it!
Clutch was pretty easy to bleed, and is 100% times better than any cable driven clutch ive used.
I think I have access to all gears and there is no trouble getting into all of them. Will find out 100% when I drive it to the MOT station.
The short list of things left to do:
make the horn work again (it was working - now doesn't seem to be)
replaced bulbs in front fogs and make sure they work.
get the last bits of the dash together
buy new resistors for rev counter to make that read correct.
bolt down the rear seats
find out why the electric mirrors are not working (not major, Il do that when I can be assed)
hover out 2 months of conversion crap out of the car
Insure it
Fuel it
MOT it
Tax It
and most importantly DRIVE IT. Not long left at all!
Apparently the solid front mounts are ready soon, so I have to have that on before I can really give it some beans when it is on the road. I currently just have my vibra technics squashed into place to hold the engine. :D
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Couple of videos of today:
Just the noise
(http://i97.photobucket.com/albums/l204/shiver85/th_V1547_12-12-09.jpg) (http://s97.photobucket.com/albums/l204/shiver85/?action=view¤t=V1547_12-12-09.flv)
And here it is moving under its own power for the first time off the bricks. Couldnt find the gears very well to start with, all sorted now :
(http://i97.photobucket.com/albums/l204/shiver85/th_V1858_13-12-09.jpg) (http://s97.photobucket.com/albums/l204/shiver85/?action=view¤t=V1858_13-12-09.flv)
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brief update. Many things fixed. Fuel pump now primes only when it should. Note to all - remove relay 32 ;)
removed the front fogs this morning as one had melted in half for some reason :S and i have also raised the car up a little to help get on the ramps at the mot station.
Things left to do:
MOT it - hopefully be done by the end of the week.
get an inspection report for the DVLA. Get that sent off.
Tax it.
I really want to drive her now!!
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Not and hopefully vehicle inspection to change log book over booked in for tomorrow morning.
New fogs should be here today although they will be left off untill MOT is over.
I also have a set of 6k hids on the way :)
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just found out that the VR6 will be in the same tax bracket as my old 2.0 due to the year of my car so providing the car passes its MOT there is every possibility i could be driving it tomorrow!! I can then change the log book over at my own pace :D
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Just had it MOT'd
Failed on one thing!!! Brake flexies had come away from the mounts on the shocks and rubbed on some thing and failed me on that! The guy is getting new flexies for me today hopefully and is going to replace the lines and bleed the brakes ready to have it re tested today possibly or for tomorrow morning.
I cant believe it was only one thing and some thing so easily could have been avoided, but hey. Lets hope it passes later today/tomorrow morning so I can tax it asap!
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All on the road! jeeeezz the noise just makes me wet!
Plenty of usable power haha, upset a few people already with it haha
Think il be out and about with it all tonight, dont care how much petrol I pour through it!
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Just given the car a quick clean and wax before prept this evening. Thought id post some pictures up now of the 'finished' article and how she sits now. No close ups of the engine bay, as its not particularly interesting to be fair!
Ignore the random orange HT lead. Snapped one taking the plastics off just before the car got on the road ^_^
Ran out of light so not the most flattering pictures of it with some hardcore flash all over it!
(http://img.photobucket.com/albums/v615/madmanluke/IMG_9456.jpg)
(http://img.photobucket.com/albums/v615/madmanluke/IMG_9463.jpg)
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Well today, I finally got the windows and mirrors working. It looks like I may have accidentally cut a cable whilst splicing the old loom out, removing the switched live to the relay. Connected it back up, and hey presto, we have windows and mirrors!
Tomorrow Im hoping to remove my window tints as they are peeling badly. May leave it without tints completely for a good while.
During the week, I managed to get beached on a speed bump. Looks like I am now loosing oil :( The drive is covered in spots of oil... Whacked the car up and sure enough, Ive pretty much only got half a sump bolt left!
Im sure some one said some where we can use a ford sump bolt some where? It uses an allen socket rather than a normal one so is not so likely to get ripped to pieces. Any one know what I need?
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the only ford sump plugs i know is the 13mm ones :huh: :huh:
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it may not have been a ford plug, although i know you can change it for some thing else. Just cant remember what!
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it wasnt a ford plug in the end, it was a polo one. Heres the thread I found it from:
but it sounds like you cant buy them?
(http://i74.photobucket.com/albums/i270/GVK34/sumpnuts.jpg)
(http://i74.photobucket.com/albums/i270/GVK34/sumpnuts02.jpg)
VR6 sump sits fairly low in a mk2 and more often than not you find that some of the sump plug gets ground away from being in contact with the road/kerbs etc!
I have found solution, the 9N 12v Polo (3cyl petrol) comes with a shallow sump plug with 6mm allen key fitting as production fit - it's the same thread etc as the regular 19mm hex plug that fits pretty much EVERY watercooled VAG engine.
I don't think you can buy this shallow sump plug as the parts give us the regular 19mm hex plug to replace it with.
So im still not sure what to do. I think il pop into the stealers during the week and see if they can still offer me the plug like above... We'll soon find out..
Window tints are now off. Getting the tints off was no problem. Getting the glue that it left behind though... feck me! My hands are ruined and I still have another window to scrap glue off!! Does look better though. Ive been meaning to do it for an absolute age and im glad I have finally.
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Thought id drop in and post a little more up.
Turns out the sump bolt had actualy just twisted and wasnt making a seal any more. So i nipped it back up, and no more leak! Does need to be replaced though, there only half of it left! :blink:
The black vr6 wheels have gone, had to give those back to a friend that I borrowed them from. So i am now rocking the silver, battered, hacked to pieces wheels, as showing previously in the thread :lol:
The VR has now done well over 2000 miles in just over a month of being in the car :unsure: Hasnt skipped a beat. I still haven't gone through tightening things up since the last bolt was done before it was on the road, so I could be a due a gearbox to fall out shortly :ph34r:
As soon as my pay gets in, my order is going in with duff for my solid front mount. I am still sporting my 8v vibra mount squashed into position up front!!!
Still saving for the TH lines.... gonna be a while i think <_<
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Small update. Solid mount finally arrived (thanks duff!). Swapped it out for my old vibra technics mount.
Its safe to say that its fubared and only good for spare/emergencies. Where it had to be squashed into possision the rubber had slowly started to split.
The solid mount makes the world of difference! It feels so much tighter. Changing up and down the gears seem smother also. It generally just improves and tightens up the whole feel and experience of the VR in the MK2.
On a sadder note. I ve blown my front components. I must have clipped the amps pretty bad, and basically just sent a voltage down to the speakers as they both went up in a puff of smoke! Bye bye voice cores! Hopefully have a brand new set I can grab from a friend over the coming week. Il replace them properly and foam pad out the pods and make the best of them as I can.
2300+ miles and counting since engine has been in the car..... :blink:
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Car looks sick mate, 5 doors all the way! lol
Get the ATS cups back on it, although the BBS do look stealth!
Ad
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Cheers mate. Its actually running an even worse for ware silver set of BBS now. Id still be running the cups if I could but, the brakes would physically not fit, plus I am now 5 stud.
Saving steadily for my TH-lines though :)
Heres how it sits currently. Just trying to source a cheap and cheerful sprayer to sort a front bumper I have out. I can then finally fit my front fogs again!
(http://img.photobucket.com/albums/v615/madmanluke/car001.jpg)
(http://img.photobucket.com/albums/v615/madmanluke/car002.jpg)
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Well ive popped the cherry. I knew it would happen. Smashed my sump today (really not quite sure on what as i didnt stop immediately to check the sumps condition). Turned up to the place I was heading, reversed into my spot and noticed damp water drip marks leading into my bad. Got out to have a check to see if it was mine, and it sure was. Oil gushing out, just infront of the sump bolt! I thought it would just be water I was leaking!
So... I let it wet its pants and headed off to halford to source a new sump plug, some quick steel and oil. Apparently Halfords no longer sell sump plugs? Strange...
So now is the real questions/desitions time. I think I am able to just about weld the hole up my self to get me through the next couple of days. The thing I am worried about is setting light to the oil inside the sump? The sump is completely dry again now as I wanted to keep my fresh 5 litres, but i dont want to ignite any residue. Any one welding a sump up whilst still on the engine? Any issues?
I read some where of some one that takes your old sump, but is able to cut it down 1 1/2 inches and re weld it back up. Can any one point me in the right direction? I cant seem to find to much.
I have been told to stay away from the r32 sump as its alloy - although its shallower, it could be more risky as any hit to it could make it crack easier?
Any way, typical, photo's or it didnt happen:
Check out the new grill also. The Red strip needs to be removed and re-done, as the guy who did it before didnt make the most neat job of it. But it will do for now:
(http://img.photobucket.com/albums/v615/madmanluke/photo-4.jpg)
Half a sump bolt - Standard.
(http://img.photobucket.com/albums/v615/madmanluke/photo1.jpg)
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England's finest roads - 3
Luke's sump - 0
Three times in a week!
Looks like im going to have to take a deep breath, and take it dry up the chuffer from VW for the R32 pick up and also have the sump shortened. Cant forget another 6 liters of oil.....FEK SAKE!
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Well, I started work on the sump yesterday. Everyone like pictures so...why not...
Axel stands, not an unusual sight.
(http://img.photobucket.com/albums/v615/madmanluke/P1010689-1.jpg)
The welder was out, as I had one sump bolt where the head had rouned off. I had tried everything! Bigger allen keys hammered in. Weld an allen key to it - that failed.....Out came the trusty dremel. I seem to have a habit of cutting sh!t up to remove it? haha
(http://img.photobucket.com/albums/v615/madmanluke/P1010693-1.jpg)
Naked:
(http://img.photobucket.com/albums/v615/madmanluke/P1010690-1.jpg)
Some comparisons, cant seee too much to be fair:
(http://img.photobucket.com/albums/v615/madmanluke/P1010694.jpg)
(http://img.photobucket.com/albums/v615/madmanluke/P1010696.jpg)
New R32 oil pump and pick up on:
(http://img.photobucket.com/albums/v615/madmanluke/P1010697.jpg)
The plastic baffle needs to be modded to get the dip stick in the right place. The r32 dipstick is located about an inch to the right. I didn't manage to get a photo of the finished product, but, basically, cut a nice healthy hole just to the left of the bolt, where the original dipstick hole is
(http://img.photobucket.com/albums/v615/madmanluke/P1010698.jpg)
Finished product:
(http://img.photobucket.com/albums/v615/madmanluke/P1010700.jpg)
(http://img.photobucket.com/albums/v615/madmanluke/P1010709-2.jpg)
(http://img.photobucket.com/albums/v615/madmanluke/P1010701.jpg)
(http://img.photobucket.com/albums/v615/madmanluke/P1010707.jpg)
I am looking to get a sump guard fabricated for me, as I didn't manage to get a plate welded to the bottom.
I think i will also see If I can get away with hockey pucking all of the mounts, as the sump still sits just below the subframe.
Semi successful, if extremely expensive. It cost me just over 280 quid to do the whole thing!
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Bit of an update. The engine had been running a little hot over the past few days. So I decided to hit straight for the thermostat. £16 and a couple of hours later, job done! temps are back down to normal again.
I also pucked the front mount out whilst the rad was out. No obvious clearance gains on the sump just yet as I still have not done the rear mounts. I need to get the correct size bolts still!
(http://img.photobucket.com/albums/v615/madmanluke/2af47b71.jpg)
(http://img.photobucket.com/albums/v615/madmanluke/34f70154.jpg)
I also decided to give it a quick clay - I'm glad I did! This was just off a small patch of the roof!
(http://img.photobucket.com/albums/v615/madmanluke/e1aac38d.jpg)
And now the obligatory blatant whoring of my car - just because its clean:
(http://img.photobucket.com/albums/v615/madmanluke/IMG_9703.jpg)
(http://img.photobucket.com/albums/v615/madmanluke/IMG_9800.jpg)
(http://img.photobucket.com/albums/v615/madmanluke/IMG_9708.jpg)
(http://img.photobucket.com/albums/v615/madmanluke/IMG_9819-2.jpg)
(http://img.photobucket.com/albums/v615/madmanluke/IMG_9751.jpg)
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Rear mounts are now pucked now that I sourced some high tensile bolts. sump now clears the sub frame by about 1cm. Its VERY tight under the bonnet how ever! I may have to shave the pucks down a little, or look into modding my bonnet to fit 100%
for now though its fine. exhaust seems to be blowing a tiny bit more, but i cant seem to solve that. I think I just need it up on a ramp and have a quick once over all the bolts and check they are sealing again.
(http://img.photobucket.com/albums/v615/madmanluke/77e681c3.jpg)
(http://img.photobucket.com/albums/v615/madmanluke/516534ab.jpg)
(http://img.photobucket.com/albums/v615/madmanluke/77e681c3.jpg)
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Feel free to post any comments on this thread guys. I get countless Pm's about this project. I am more than happy to give people help, and obviously publicly put it up to help others. Ask away
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Only just realised i posted two of the same images.
Here is the one it should have been, showing the clearance.
(http://img.photobucket.com/albums/v615/madmanluke/058f07de.jpg)
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inbox is full mate and yes still have them
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PMs cleared. Thanks dude
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After picking up a set of spanking new g60's for 300 squidies, ive set about getting as much prep work done to my arches as possible, so I can just go out and buy wheel, and hopefully just fit them!
Well I have started to attack the arches already. Got the rears fitted first. I am still using the rivets to hold the rears on for now. My plan is to have the rears rolled and flared out to match the plastics. Just waiting of quotes and money to do so. Il then be able to seal them on.
Will shave a lot more off these when I actually have the wheels to fill the arches ;)
(http://img.photobucket.com/albums/v615/madmanluke/304909d8.jpg)
This is the rears with standard gti fronts. Just for all those that say gti's are the same as the g60's. Your just wrong :) they are a good 20mm wider :)
(http://img.photobucket.com/albums/v615/madmanluke/f3fdf1ba.jpg)
And the fronts (still have front left to cut out yet)
(http://img.photobucket.com/albums/v615/madmanluke/67b8b626.jpg)
Could maybe take more out?
(http://img.photobucket.com/albums/v615/madmanluke/ed40f5a3.jpg)
Tuck much?
(http://img.photobucket.com/albums/v615/madmanluke/cdcf7180.jpg)
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Bit of a pointless post really. Im trying to save for a largish update.
My wheels have STILL not landed in the UK. Ive spoken to a few people and we have all come to the conclusion that there must be an issue with Shmidt as people are waiting on things like dishes to arrive. Its been well over a month now.
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Minor update:
280mm momo - Ticks box in scene list *sigh* Will no doubt be chopping it out for something with some fluff on to match the dash at a later date :)
(http://img.photobucket.com/albums/v615/madmanluke/IMG_9975.jpg)
Got these free from a mate - so why the hell not? I removed the badges from them and they look pretty good. Nice and simple. Il probably remove them and just put them back in for shows :)
(http://img.photobucket.com/albums/v615/madmanluke/IMG_9978.jpg)
Larger update to follow soon hopefully. Come on rimstyle, hurrythef**kup!
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Coming soon. Lots of caliper shaving to be done:
(http://img.photobucket.com/albums/v615/madmanluke/photo-5.jpg)
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(http://img.photobucket.com/albums/v615/madmanluke/IMG_9988.jpg)
(http://img.photobucket.com/albums/v615/madmanluke/IMG_9995.jpg)
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two fouling wheels on standard wing arches:
(http://img.photobucket.com/albums/v615/madmanluke/e49aea79.jpg)
+
A man who knows what hes doing with an arch roller:
(http://img.photobucket.com/albums/v615/madmanluke/d06c2910.jpg)
=
Flared arches and Car back on its arse. I think the clearances are tighter than a cats bum! Still cant help but think it can go lower. Im sure it can, although il be getting back into sump smashing territory. Been there - done that.
(http://img.photobucket.com/albums/v615/madmanluke/211edfda.jpg)
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There's a nice little picture of me cleaning my car at Stoner Park Page 81 of PVW this month :)
Only a small picture but still chuffed none the less :)
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Sorry to double post up all my posts between this and my other thread. I want to keep this thread going so I can have something to go back to later on to show how it progressed :)
small update:
Had the centers from my wheels stolen from the car at Santa Pod for VAGFest. That was 50 quid down the drain just getting those ordered up to replace!
Since getting back, the car is feeling VERY underpowered and feels like its missing slightly. Got a new set of plugs on thier way to me. Thats another 40 quid.
Once that was sorted.... My right side sill decided to fall off and bend its self out of shape. Another 104 squiddies later, and I have a brand new set of sills for both sides ordered up.
I feel raped :(
(http://img.photobucket.com/albums/v615/madmanluke/001007349048.jpg)
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Went up to my works office tonight, decided to drop into here for a quick few snaps as I had the camera on me.
Il upload the rest soon.
(http://img.photobucket.com/albums/v615/madmanluke/IMG_0008.jpg)
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Thanks for all the comments guys. Glad others are enjoying it too.
Not good news today. I lost my side skirt and front g60 arch at about 80 mph today. Feck knows where it went :( sp of any one finds a genuine g60 arch somewhere between Birmingham and Leeds, let me know!
Just preying that i can get a new one to replace it.
Il upload the rest of the photos soon WITH arches.
(http://img.photobucket.com/albums/v615/madmanluke/aed637bf.jpg)
:(:(:(:(:(:(:(:(
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Here are the rest:
(http://img.photobucket.com/albums/v615/madmanluke/IMG_0010.jpg)
(http://img.photobucket.com/albums/v615/madmanluke/IMG_0021.jpg)
(http://img.photobucket.com/albums/v615/madmanluke/IMG_0030.jpg)
(http://img.photobucket.com/albums/v615/madmanluke/IMG_0032.jpg)
(http://img.photobucket.com/albums/v615/madmanluke/nobonnet.jpg)
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[quote name='Fastmonkey' date='19 July 2010 - 10:18 PM' timestamp='1279574281' post='2981439']
Oh mate, you've had some bad luck lately. Get a lottery ticket it's got to turn soon ;)
[/quote]
It can't get any worse can it? .....Can it?
Of course it fecking can! I should have got that ticket mate!
SO....Aside from all of me loosing niegh on £100 worth of arch and side skirt. Today I thought Id go off to the scrappy. I had been told there was a nice mk2 sitting in there. We all know mk2's just dont come up in scrappy's any more. So off I went.
Had a pretty good go at this mk2 and cam away with a new passenger electric window motor (Oh, I never mentioned before. My brand new leccy motor only lasted me 3 weeks before it died last week), new window switches all round, roof lining (better nick than mine) plus a few odds and sods. Got the lot for about £30 i think! Bargain!
Of I go to the local petrol station before I go home to get a drink. Pulling out of the petrol station, I pull away.... DONK. Thats strange..... Accelerate away again....DONK! :ph34r:
f**k sake! :angry: :angry: :angry:
Pulled over to find the engine leaning right over forward leaning against the rad fans. So I'm now missing the bolt to hold my engine in place at the front, and the hockey puck to keep it raised up!
On closer inspection I find the bolt....but with the other half still inside the engine mount! A bad situation made even worse!!
Luckily i had my trolley jack with me incase i needed to get under the car at the scrappy. Here is where the fun begins!
I have no axel stands with me, and need to be able to get the car up in the air high enough so that I can get my jack under the engine, to remove the rear hockey pucks. So I am just off a duel carriage way just of J1 M25... What can I use?
VOILA!
(http://img.photobucket.com/albums/v615/madmanluke/1109b848.jpg)
So.... rear pucks out.....
Front mount fixed... Is there any thing these bad boys cant fix!!
(http://img.photobucket.com/albums/v615/madmanluke/34985abb.jpg)
That saw me home safley.
King bodge is availible for rental mon - fri @ £10000 PHr
Please get in contact for any information... :lol: :lol: :lol:
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Just a couple of photo's that a couple of guys have snapped of my car over the past few days up at Ace Cafe and prept.
Thanks to the guys that snapped them.
Up at ace:
(http://farm5.static.flickr.com/4091/4835915054_df57352045_b.jpg)
(http://farm5.static.flickr.com/4145/4835915058_785f56e424_b.jpg)
(http://farm5.static.flickr.com/4147/4835915068_392c162554_b.jpg)
(http://farm5.static.flickr.com/4126/4835973538_d2f0fd84e4_b.jpg)
Prept:
(http://i43.photobucket.com/albums/e369/DanDiesel/Prept%20vs%20Players%202010/38.jpg)
(http://i43.photobucket.com/albums/e369/DanDiesel/Prept%20vs%20Players%202010/39.jpg)
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Had a bit of a leak up at ace cafe last night. Managed to pop the main high pressure hose off the power steering pump. Fixed it on the side of the road fortunately.
(http://img.photobucket.com/albums/v615/madmanluke/e0203781.jpg)
And today; il let the pictures do the talking. Il take some finished product ones when i have some light tomorrow.
(http://img.photobucket.com/albums/v615/madmanluke/07082010310.jpg)
(http://img.photobucket.com/albums/v615/madmanluke/07082010315.jpg)
(http://img.photobucket.com/albums/v615/madmanluke/f6bf6104.jpg)
(http://img.photobucket.com/albums/v615/madmanluke/07082010323.jpg)
(http://img.photobucket.com/albums/v615/madmanluke/06e241ac.jpg)
(http://img.photobucket.com/albums/v615/madmanluke/07082010325.jpg)
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Its not the most photogenic stuff in the world it turns out. lol In the flesh its a lot nicer. I need to ebay a suede brush also to get it all looking consistent.
My SLR lens has literaly just packed up so not the best shots in the world. the focus ring is stuck...
I still have the sun visors to do. I think il get my mum at them with a sewing machine!
Here are a few quick snaps
(http://img.photobucket.com/albums/v615/madmanluke/IMG_0149.jpg)
(http://img.photobucket.com/albums/v615/madmanluke/IMG_0155.jpg)
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Think I'm getting close to needing a notch....?
(http://img.photobucket.com/albums/v615/madmanluke/0bb23867.jpg)
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I ignored thhe above, and lowered it another 12mm for edition!
Thought id put a little update.
Only minor things. The car has been running great - s not much to report!
I dont have a picture of this, but I pulled the camber out of the front wheels so they now sit dead flush with the front arches. Pretty pleased with that as I was looking to buy 6-8mm adaptors, so it saved me about £30! :lol:
All trivial stuff but its starting to make the difference to me. Its all in the detail. Something my car lacks at the moment lol
Oil breather:
(http://img.photobucket.com/albums/v615/madmanluke/Player%202010/IMG_1281.jpg)
Original and genuine golf ball gear knob and I have also FINALY replaced that damn mk3 handbrake lever for what should really be there!
(http://img.photobucket.com/albums/v615/madmanluke/Player%202010/IMG_1277.jpg)
A couple of pics from edition/prept/ nw dubs tunnel runs:
(http://i674.photobucket.com/albums/vv110/andypipkins/NWdubs/NWMADS%20Tunnel%20Run%20august%202010/IMG_7669.jpg)
(http://i674.photobucket.com/albums/vv110/andypipkins/NWdubs/NWMADS%20Tunnel%20Run%20august%202010/IMG_7667.jpg)
you can semi see how much of a difference the camber has made on the car now in this actualy...
(http://img.photobucket.com/albums/v615/madmanluke/ED38X/IMG_0528-1.jpg)
[
(http://img.photobucket.com/albums/v615/madmanluke/Player%202010/IMG_1264.jpg)
Getting fairly happy with how it is all going with it now. I am after some new speaker pods from shakey, and possibly a bit of a twist for the inlet manifolds again. Not sure how/when that will work out if at all just yet.
Major thing for me right now? Save. Save hard. I want some fresh paint!
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All the photos have vanished :grin:
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yeah i cant see them either bandwidth exceeded it says
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Working on it. Too many photos viewed this month!
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Photo bucket is back!
Well. Horn issue resolved... For now. Its only one half of the two tone hone i have managed to get hold of.
So i sounds like a complete pofter when using the horn now! Meep meep!!!
Step one in my engine bay cleaning complete. I have a LONG list of things i want to do when january comes round. The car will be coming off the road again, but hopefully i will be under a roof working in a proper garage, not my drive in the snow this time!!!
At the moment, the most expensive bit I can see being is some paint, but I need Shakey to PM me back! (hint haha) Everything else seems to be pretty inexpensive, but labout intensive. I wont reveal too much.
The wiper is staying off, and i have some plans for that to be sorted while the car isnt going any where also.
Stage one - Relocate washer bottle to boot. Complete. (must cut the mount off the turret later: (sorry for naff photo's)
(http://img.photobucket.com/albums/v615/madmanluke/IMG_7932.jpg)
(http://img.photobucket.com/albums/v615/madmanluke/9a8e5e47.jpg)
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Had a set of VDO guages turn up yesterday.
Today i sorted out the wiring loom for them to run and also got a two pole oil pressure sender.
Does any one know how easy it is to change what colour they light up? They light up orange currently.
I need to cut my console up yet. That will happen tomorrow. I also need to figure out if the housing that came with it will fit into that space.
(http://img.photobucket.com/albums/v615/madmanluke/IMG_8048.jpg)
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Well heres what happened today. I kinda liked the guages down in the console, but thought f**k it. I wanted to try my headunit down there so I went and done it :)
Im still yet to get the guages in and working. It took a little while to relocate the headunit. I need to get a Din sized plate for VDO guages. Any one got one that will fit into the original headunit space and looks factory? If not, i might have to fork out £40 for one at BBT :(
Some Pics:
(http://img.photobucket.com/albums/v615/madmanluke/bb58c356.jpg)
(http://img.photobucket.com/albums/v615/madmanluke/0f240081.jpg)
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All finished up, and working a treat..... just want a boost gauge in there now tough :ph34r: :lol:
(http://img.photobucket.com/albums/v615/madmanluke/IMG_8074.jpg)
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Decat turned up the other day :)
(http://img.photobucket.com/albums/v615/madmanluke/dff3196b.jpg)
Decided to fit it and so glad I did. Its no louder than it was before just poodling about, but it has a little more of a roar now when on the pedal. Its got almost an r32 sound to it from the exhaust end too!
I just had to have my exhaust pretty much cut up and re welded so that it actualy sat straight and that I didnt have to use Jubilee clips as hangers any more :lol:
Awful picture:
(http://img.photobucket.com/albums/v615/madmanluke/a3a75086.jpg)
Only gripe. Hot tuning cant drill holes for sh!t. Wrong size, and pretty much completely out of position to bolt it up to the 6 branch. (6 branch is drilled correctly as the cat bolted straight in)
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Not much happening the past few months. Im trying to not spend any money on the car. I dont have the money any way!
Looking to start work on cleaning up the bay mid this year. Rear washer bottle is already done as posted above. Ive now collected some slimline fans, and the next step is to find an ally rad I like. My preference will be to get one custom made with a top fill built in.
Just reinsured her. Tax is due before the 30th this month, then I have MOT next month. Fun times!
Just a little video of the exhaust. For someone elses benefit but it would be rude not to include it in this thread.
http://www.youtube.com/watch?v=-knrejkqrCg
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i am using a hot tuning 6 branch and de-cat i cant get it to seal properly its blowing where that wire ring goes
did you have any issues like this and it fits crap
your exhaust sounds the awesome listened to that 2 times now lol what system is it and what size??
i am running a hottuning 6 branch decat and jetex system
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Hey rob
I have exactly the same issue. I have the hottuning branch too . You can hear it on the video although the camera amplifies it more than it actualy is.
I can only really hear it when cold, not so much when warm and it's only a faint ticking noise. Id be tempted to run a fixed 6branch and have a decaf with a gauze In to allow for movement if i was that bothered about it.
It used to be a scorpion exhaust for a mk2. It's since been b!tched to take my decat and has had all sections cut out a re welded to mak it fit as it should. The obly it's left of the scorpian exhumed is the centre silencer, the pea shaped one under the rear bench then the back box. All pipes between them are now technically powerflow. It's a bit of a lash up.
But a they say; lash up luke haha
Sorry about spelling etc; on the iPhone lol
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does your 6 branch have the gauze on and the springs i managed to seal the decat to the 6 branch it just blows where the gauze is (wire ring)
i even tried fitting a gasket still no joy
what bore is your exhaust
i bought a brand spanking new exhaust for my g60 never ended up fitting it now its on the golf
needs small adjustments but it fits
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yeah it has the ring and the two bolts to clamp down.
I think its just one of those things mate, your never going to get it sealed 100%.
the bore is just the standard 2.5"
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Well the golf is now of the road and ive got my self a 'Benz! to drive around daily. its a c180. 1.8 auto. its looooverly. paid the heafty sum of £400 for it and it even came with an immaculate burberry interior!
Heres some pictures:
(http://img.photobucket.com/albums/v615/madmanluke/_MG_0391.jpg)
(http://img.photobucket.com/albums/v615/madmanluke/_MG_0390.jpg)
Check out my stichin'
(http://img.photobucket.com/albums/v615/madmanluke/_MG_0395.jpg)
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And so it begins...
Much like the start of my VR build, i've given it one more wash
(http://img.photobucket.com/albums/v615/madmanluke/_MG_0489.jpg)
Noticed that the birth mark on my FL wheel is getting bigger/darker. Will have to have that wheel refurbed when ever it comes back on the road. Got to love lacquer peel.
(http://img.photobucket.com/albums/v615/madmanluke/_MG_0493.jpg)
The engine bay certainly took a battering over christmas. Its a state with salt EVERYWHERE! Luckily this is why its all coming off the road any way.
(http://img.photobucket.com/albums/v615/madmanluke/_MG_0502.jpg)
(http://img.photobucket.com/albums/v615/madmanluke/_MG_0503.jpg)
Tucked up under its cover
(http://img.photobucket.com/albums/v615/madmanluke/_MG_0505.jpg)
A friend of mine has just got a half finished mk2 vr project so I am going to be busy doing that with him also. This is going to be a long process getting the bay how I want it. Ideally, what i can see before it comes back on the road is a full resprey. But i doubt il have the funds for anything like that...
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Stage 1:
Took the engine out tonight. Started at 8, finished at half 11.
Lots of pictures. Everyone loves pictures....
(http://img.photobucket.com/albums/v615/madmanluke/_MG_0541.jpg)
(http://img.photobucket.com/albums/v615/madmanluke/photo-7.jpg)
(http://img.photobucket.com/albums/v615/madmanluke/IMG_0548.jpg)
What a mess!! Lots to sort out now...
(http://img.photobucket.com/albums/v615/madmanluke/IMG_0545.jpg)
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More from a few hours today. Sorry for sh!tty iphone pics
Took all my g60's off. don't want some chancer having these off the car while it sits for abit. Wernt going to get away with them quickly any way. Took me nearly 2 hours to hack away at all the tiger seal.
(http://img.photobucket.com/albums/v615/madmanluke/e35e2da1.jpg)
Lots stripped out:
(http://img.photobucket.com/albums/v615/madmanluke/704be05a.jpg)
Began tidying up the wiring loom inside. The alarm that was wired in was f**king everywhere. I'm still trying to tidy that up so i have some hope of putting it back in again.
Got the engine loom out. Only have the rear clusters left plugged into the fuse box at the moment so lots to put back!
Mid way through:
(http://img.photobucket.com/albums/v615/madmanluke/f8081572.jpg)
(http://img.photobucket.com/albums/v615/madmanluke/260abe93.jpg)
All the carpets are obviously up. I want to dynamat the whole floor pan now as the original underlay is not worth keeping. Only thing Im worried about is whether to run the engine loom under the dynamat inside or over the top... not sure how im going to run the loom at all inside but we will soon see. I have to do the same with the brake lines also.
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Started on the looms today.
heres how it came out the car. Mk3 lighting loom included as well as rad fan loom.
(http://img.photobucket.com/albums/v615/madmanluke/815cdfcf.jpg)
And after a lot of stripping poop out that I didnt need. This is what I am left with. Nothing extended yet. Waiting untill I have the lump back in the car before I start on that.
(http://img.photobucket.com/albums/v615/madmanluke/8a402f4e.jpg)
All the stuff no longer needed:
(http://img.photobucket.com/albums/v615/madmanluke/46e00c09.jpg)
Im looking to ditch the OEM fan control stuff completely so I don't need that big rad fan controller that the VR uses. And also to cut down on wires again.
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One last one, took even more out.
All ready to be put back in the car and figure out how and where I route them.
(http://img.photobucket.com/albums/v615/madmanluke/3ffc37d3.jpg)
Everything that I pulled out of just the engine loom. Still shocked to be honest
(http://img.photobucket.com/albums/v615/madmanluke/eaffbd08.jpg)
Next.. lighting loom...
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doing great work mate.. rather you than me attempt that loom !! ive got my mk3 abf loom here and im still scared of it lol
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A little more from today.
The engine wiring is now in place. It wont be put in its place 100% until I have all my sound deadening down as I need to cut the deadening round the looms. The lighting looms are also run down the legs also now. Will start trial fitting it and getting it wired and cleaned up with the front bumper and slam panel in possibly next weekend.
I started to remove all the factory wax like sound deadening from the floors ready for the first batch of superlite to be layed once the looms are finalised and tested.I hope to have all my battery relocation stuff soon so I can start getting onto testing. The last big push after testing is to get the scuttle panel out and have the spot welds, re-welded, rear wings cut/welded, remove the wax from the engine bay, and then paint it.
Progress? I'm not sure....
(http://img.photobucket.com/albums/v615/madmanluke/IMG_1252.jpg)
car looking sorry for its self:
(http://img.photobucket.com/albums/v615/madmanluke/IMG_1253.jpg)
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had a little present turn up today. Two bulk pack's of 'Superlite' that turns out not to be that light... haha 9.7 kilo's a box, so totalling just under 20 kilo's for two boxes. I think il need another box or so to finish doing everything I want to. Looking back on it, id probably now not bother with the stuff as its a huge expense I could do with out. But needs must for my long term vision for my audio. I still need to source some mk2 underlay to go back ontop of this.
(http://img.photobucket.com/albums/v615/madmanluke/IMG_1256.jpg)
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Got cracking on the scuttle over the weekend. Wow. What a sh!t job! Not doing this again!!!!! Still got to get the side bits off so thats for next weekend.
(http://img.photobucket.com/albums/v615/madmanluke/IMG_1259.jpg)
Started to lay some dynamat also, but didnt get any pics.
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Scuttle is off and started welding the holes in. getting there slowly.
(http://img.photobucket.com/albums/v615/madmanluke/photo1-1.jpg)
Lots of filler,sand, filler, sand, filler, sand to be done when it gets to that stage!
(http://img.photobucket.com/albums/v615/madmanluke/photo-8.jpg)
hopefully have the engine test fired again next week once all my new battery cables arrive.
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Small Fortune. Defined by these 8 things:
(http://img.photobucket.com/albums/v615/madmanluke/IMG_1299.jpg)
Engine is going back in tomorrow for a test run now I have these. Just to make sure I havent f**ked any thing up... Y'know haha.
got to think of something to do with the fuel lines. they look sh!t as they are flapping about in the bay. Any ideas?
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As my cables arrived i thought id throw the motor back in and test out my loom extensions. Engine runs fine. Good news! Means that now (in short) the only things I have left to do are:
1. Build a rad fan switch system to turn slim lines on and off
2. Put front bumper back on and test lights/turn signals etc (ground front right lighting loom locally or run cable back inside to earthing point)
3. finish dynamating the rest of the car fully.
4. Remove engine
5. Grind back welds, finish new welds.
6. finish taking back all the wax
7. start prepping bay, filler/sand, filler,sand haha
8. primer and paint.
9.Tidy up sub frames (will be going for shot blast and powder coat along with polybushes in the winter)
10. run brake lines
11. engine back in
12. interior back in
13. Done?????
Ignore my topgun costume. As awesome as it is, they are my new overalls haha
[media]http://www.youtube.com/watch?v=eqZUVZ8I3qk[/media]
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Got started on the rad fan loom today. Slim lines mounted up fine and run fine. Need to get hold of a 2 pole rad fan switch for the radiator before I can test to make sure they kick in fine. Got to do a bit more fab work to get the radiator to mount to the front cross member and the front slam panel also.
(http://img.photobucket.com/albums/v615/madmanluke/_MG_1309.jpg)
Plugged in the interier looms again, clocks work, dipped and full beam, hazards, side lights, wipers and fogs all work fine. Just need to test the brake pedel switch once i find that and the washer bottle.
Good days work today. Just waiting on that rad fan switch, them its all coming back out again and then the cosmetics really kick in.
(http://img.photobucket.com/albums/v615/madmanluke/_MG_1311.jpg)
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Small update from today. Got the rest of the welding done. So thats both rear quarter arches cut out and welded, all holes that I wanted welding up in the by (not many) and a couple of other little bits and bobs.
Nearly finished with my sound proofing. I have only two sheets left so I need to keep those for my two remaining doors to sound deaden. That will be it for now as my sound gear will only be a small install for the remainder of the year with an addition of new speaker pods . Next year Il be looking at getting in touch with in car studio to figure out a cool little - but powerful setup. Wont be for a while yet though. At least the main arse ache is done.
Engine bay as it is now:
(http://img.photobucket.com/albums/v615/madmanluke/_MG_1704.jpg)
Inside as it is now:
(http://img.photobucket.com/albums/v615/madmanluke/_MG_1710.jpg)
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Yeah well I was talked out of getting any one else to do the prept/paint so Im diving in to do it myself now. :lol:
Started to order up bits I need. Namley dremel bits so I can get into some really awkward places down the back of the turrets to grind back welds. Got some etch primer also. Next is to get some filler and decide whats the best route for getting paint. The bay will be primed and painted at a garage I have use of with a compressor, but I know nothing about paint, so don't know where to get paint from for the gun?
Any way, got the engine up on the engine stand today. Yeah. This got in a STATE quickly... :lol:
(http://img.photobucket.com/albums/v615/madmanluke/_MG_1726.jpg)
(http://img.photobucket.com/albums/v615/madmanluke/_MG_1727.jpg)
(http://img.photobucket.com/albums/v615/madmanluke/_MG_1729.jpg)
(http://img.photobucket.com/albums/v615/madmanluke/_MG_1733.jpg)
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.....................
(http://img.photobucket.com/albums/v615/madmanluke/_MG_1734.jpg)
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Oops.
Fully powder coated and fully polybushed front crossmember, subframe and rear beam.
Brembo discs and red stuff pads all round
New bearings all round
Goodridge braided lines
Boot rubber
New heater fan so no more squeak hopefully!
Ally crack pipe
handbrake cables
new throttle cable
power steering pump
(http://img.photobucket.com/albums/v615/madmanluke/_MG_1745.jpg)
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sh!tty Iphone teasers of things coming together slowly. Just waiting on new seals for everything and I can really start putting it back together.
(http://img.photobucket.com/albums/v615/madmanluke/ce9944cf.jpg)
(http://img.photobucket.com/albums/v615/madmanluke/6cd078c3.jpg)
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another iphone photo update
(http://img.photobucket.com/albums/v615/madmanluke/190c25a7.jpg)
(http://img.photobucket.com/albums/v615/madmanluke/8f875cd3.jpg)
(http://img.photobucket.com/albums/v615/madmanluke/998b758d.jpg)
(http://img.photobucket.com/albums/v615/madmanluke/1554d92d.jpg)
(http://img.photobucket.com/albums/v615/madmanluke/1af6447f.jpg)
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Thought id update my main build thread.
Its off for paint in the engine bay! Huge thing to tick off the list - its now just a case of getting all the little bits (and theres a lot!) together, installed then bolting the engine in.
off it goes! Hoping to have it back for next saturday.
(http://img.photobucket.com/albums/v615/madmanluke/05d1233d.jpg)
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Its home :)
(http://img.photobucket.com/albums/v615/madmanluke/_MG_2531.jpg)
(http://img.photobucket.com/albums/v615/madmanluke/_MG_2533.jpg)
(http://img.photobucket.com/albums/v615/madmanluke/_MG_2525.jpg)
(http://img.photobucket.com/albums/v615/madmanluke/_MG_2535.jpg)
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(http://img.photobucket.com/albums/v615/madmanluke/_MG_2655.jpg)
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Things will start ramping up in a little over a week.
(http://img.photobucket.com/albums/v615/madmanluke/_MG_2685.jpg)
(http://img.photobucket.com/albums/v615/madmanluke/_MG_2688.jpg)
(http://img.photobucket.com/albums/v615/madmanluke/_MG_2702.jpg)
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Well another weekend gone. Things have progressed quickly. Had an issue with the fuel pump I bought where it was just literally pouring fuel out of the casing. So a new fuel pump housing later and job's a good'n
(http://img.photobucket.com/albums/v615/madmanluke/IMG_3872.jpg)
With that sorted and the final banjo bolt for my goodridge lines was nicked from an old brake flexi I had kicking about. That meant I could bleed the brakes and clutch. That also means it moved under its own power for the first time in 11 months!
[media]http://www.youtube.com/watch?v=VE7yO7J7h44[/media]
Jeez I was happy! So with that the rest of the dash was whipped in, two fronts seats and 3 point harnesses in, arches on (side skirts to happen later in the week) its starting to look a little more like a car!
(http://img.photobucket.com/albums/v615/madmanluke/IMG_3878.jpg)
The aim now is to have it on the road and road legal for the weekend!!! Things have to happen quickly, but there isn't much left to do.
Finished up tonight with a little bit of experimenting on the audi haha
(http://img.photobucket.com/albums/v615/madmanluke/IMG_3880.jpg)
Until the weekend hopefully......
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(http://farm7.staticflickr.com/6052/6371185299_22a9d569cb_b.jpg) (http://www.flickr.com/photos/22669616@N05/6371185299/)
_MG_3054 (http://www.flickr.com/photos/22669616@N05/6371185299/) by luke.pappin (http://www.flickr.com/people/22669616@N05/), on Flickr
(http://farm7.staticflickr.com/6105/6371197949_8089e57896_b.jpg) (http://www.flickr.com/photos/22669616@N05/6371197949/)
_MG_3056 (http://www.flickr.com/photos/22669616@N05/6371197949/) by luke.pappin (http://www.flickr.com/people/22669616@N05/), on Flickr
(http://farm7.staticflickr.com/6093/6371226771_2a800faa67_b.jpg) (http://www.flickr.com/photos/22669616@N05/6371226771/)
_MG_3072 (http://www.flickr.com/photos/22669616@N05/6371226771/) by luke.pappin (http://www.flickr.com/people/22669616@N05/), on Flickr
(http://farm7.staticflickr.com/6118/6371214225_694c9ec4b9_b.jpg) (http://www.flickr.com/photos/22669616@N05/6371214225/)
_MG_3064 (http://www.flickr.com/photos/22669616@N05/6371214225/) by luke.pappin (http://www.flickr.com/people/22669616@N05/), on Flickr
(http://farm7.staticflickr.com/6101/6371238885_331ee774d4_b.jpg) (http://www.flickr.com/photos/22669616@N05/6371238885/)
_MG_3080 (http://www.flickr.com/photos/22669616@N05/6371238885/) by luke.pappin (http://www.flickr.com/people/22669616@N05/), on Flickr
(http://farm7.staticflickr.com/6048/6371251173_722b82c5ff_b.jpg) (http://www.flickr.com/photos/22669616@N05/6371251173/)
_MG_3086 (http://www.flickr.com/photos/22669616@N05/6371251173/) by luke.pappin (http://www.flickr.com/people/22669616@N05/), on Flickr
(http://farm7.staticflickr.com/6216/6371259437_f442a3207b_b.jpg) (http://www.flickr.com/photos/22669616@N05/6371259437/)
_MG_3088 (http://www.flickr.com/photos/22669616@N05/6371259437/) by luke.pappin (http://www.flickr.com/people/22669616@N05/), on Flickr
(http://farm7.staticflickr.com/6233/6371270587_ef258fe2e1_b.jpg) (http://www.flickr.com/photos/22669616@N05/6371270587/)
_MG_3097 (http://www.flickr.com/photos/22669616@N05/6371270587/) by luke.pappin (http://www.flickr.com/people/22669616@N05/), on Flickr
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Haven't updated this in a while if any one is still following this. I have had issues with the charger leaking oil massivley so the charger has needed a rebuild long before I got hold of it.
This is how it went down last night after attempted no 2 at getting this rebuilt.
So I started off the Charger rebuild again last night.
(http://farm6.staticflickr.com/5034/6913955684_9108cac5e1_b.jpg) (http://www.flickr.com/photos/22669616@N05/6913955684/)
_MG_4675 (http://www.flickr.com/photos/22669616@N05/6913955684/) by luke.pappin (http://www.flickr.com/people/22669616@N05/), on Flickr
All was going fairly well.
(http://farm6.staticflickr.com/5460/7060041781_c03e278054_b.jpg) (http://www.flickr.com/photos/22669616@N05/7060041781/)
_MG_4684 (http://www.flickr.com/photos/22669616@N05/7060041781/) by luke.pappin (http://www.flickr.com/people/22669616@N05/), on Flickr
Now that I had the correct imperial allen socket (3/16th if any one needs to know) the mounting plate came off fine this time. But, there are 10 gearbox casing bolts. As always, one had already been attacked before and was rounded. Tried several different stud extracting methods but nothing was biting. Out came the drill....
(http://farm8.staticflickr.com/7069/6913960114_c2030630fd_b.jpg) (http://www.flickr.com/photos/22669616@N05/6913960114/)
IMG_4687 (http://www.flickr.com/photos/22669616@N05/6913960114/) by luke.pappin (http://www.flickr.com/people/22669616@N05/), on Flickr
........
(http://farm8.staticflickr.com/7203/6913962584_e0d1324343_b.jpg) (http://www.flickr.com/photos/22669616@N05/6913962584/)
_MG_4695 (http://www.flickr.com/photos/22669616@N05/6913962584/) by luke.pappin (http://www.flickr.com/people/22669616@N05/), on Flickr
Finally managed to get it off. Had a quick feel of all the bearings. Wow...... These were long shot. As in, so far gone probably another 1k and these would have been eating them selfs alive and throwing sh!t all around the place. Nice to see that vortech have left all bearing info off these so you can't find out what bearings are needed.
(http://farm6.staticflickr.com/5075/7060049127_3451c53ca1_b.jpg) (http://www.flickr.com/photos/22669616@N05/7060049127/)
IMG_4699 (http://www.flickr.com/photos/22669616@N05/7060049127/) by luke.pappin (http://www.flickr.com/people/22669616@N05/), on Flickr
So..good thing I started this at least. You only need to press the output shaft out. The large input shaft wiggles its self loose since the casing is closed where you would press the input out.
(http://farm6.staticflickr.com/5462/7060050349_cbc3e5139c_b.jpg) (http://www.flickr.com/photos/22669616@N05/7060050349/)
IMG_4701 (http://www.flickr.com/photos/22669616@N05/7060050349/) by luke.pappin (http://www.flickr.com/people/22669616@N05/), on Flickr
(http://farm8.staticflickr.com/7126/6913999654_5222571f4e_b.jpg) (http://www.flickr.com/photos/22669616@N05/6913999654/)
_MG_4703 (http://www.flickr.com/photos/22669616@N05/6913999654/) by luke.pappin (http://www.flickr.com/people/22669616@N05/), on Flickr
Pulling the bearings off
(http://farm6.staticflickr.com/5343/7060087969_60a440d02f_b.jpg) (http://www.flickr.com/photos/22669616@N05/7060087969/)
_MG_4704 (http://www.flickr.com/photos/22669616@N05/7060087969/) by luke.pappin (http://www.flickr.com/people/22669616@N05/), on Flickr
Brick wall......
Once I started pressing bearings and seals back in, it soon came apparent that one bearing one was wrong. The output shaft on the gearbox side just plain didn't fit. It fits on the gear shaft, but not into the gearbox casing. You can see the new bearing sitting onto of the outer casing of the old bearing in this pic. Its pretty sizeable difference!
(http://farm8.staticflickr.com/7184/7060089761_dab6fce176_b.jpg) (http://www.flickr.com/photos/22669616@N05/7060089761/)
IMG_4706 (http://www.flickr.com/photos/22669616@N05/7060089761/) by luke.pappin (http://www.flickr.com/people/22669616@N05/), on Flickr
So..... This is where my charger ended up and will stay until I can get hold of the correct bearing.... sh!tballs!
(http://farm6.staticflickr.com/5192/7060112289_fb9cdeb2de_b.jpg) (http://www.flickr.com/photos/22669616@N05/7060112289/)
IMG_4714 (http://www.flickr.com/photos/22669616@N05/7060112289/) by luke.pappin (http://www.flickr.com/people/22669616@N05/), on Flickr
So... i'm gonna email the guy that supplied the bearings, see what he can do to either get me the correct bearing asap, or try and get hold of a part number and source the one bearing here...
The saga continues......
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So i managed to get the charger rebuilt, but I am being cursed by an ongoing issue with the engine over fueling and/or missing on cylinders.
Either way, it has come to the end of the road with this shell and I am working on something else quite special now. I just need to find a cure to get this engine running issue.....
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Not supposed to comment in here but you don't update your dub rides thread anymore.. WTF?... what's going to happen to this? And what are you on with now?
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I'll reply back in my other thread. I thought I should update this at least once! haha
Yeah ive been a bit sucky with updating my build thread. Lots of things happening. Happening fast. haha
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I should probably update this too. I sold the shell onto a good friend a little while ago now.
I had an offer come up on something I couldn't really turn down. So in the end I just went for it.
For what I am now working on, you can use this link to where I am now picking it all back up from.
http://www.golfgtiforum.co.uk/index.php?topic=149923.550