Author Topic: New member MK2 Golf 20v OEM+ (Pic Heavy..for those that remember dial up)  (Read 1940 times)

Offline cupracraig

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Hi, i'm craig, just joined up. I've had my mk2 for about 5 years now and heres some of the work that i have carried out on it, all myself, learning along the way.
I've just picked up a mk7 golf 1.4TSI ACT Bluemotion DSG as my new daily, it will probably get a remap but nothing more.

here's a bit of the cars journey

Refurbished the mk2 rear calipers, adding stainless nipples with new covers and painted in Dark Anthracite which i will paint the fronts in too

20180206_182456 by Cragmire40D, on Flickr

20180206_182202 by Cragmire40D, on Flickr

Brake lines replicated

rear beam blasted

Bumper removed and checked the area, looks really good

found a couple of little problems:

loose underseal removed and area prepped for new

Rear beam and brackets painted with Raptor Paint[/img]

Stripped down the rear ARB to bare metal as it seemed to have some worming under the powdercoat, painted with etch primer then Upol-Raptor, let it all cure for a week and i re-fitted it all with all new bushes.

car all complete for the year and im trying to drive it as much as possible

worked well as my wedding car :) 3 adults and my 2 kids in it and no rubbing

IMG_3571 by Cragmire40D, on Flickr

IMG_20180617_171944_919 by Cragmire40D, on Flickr

papped up the gorge :)

Took the golf for a drive through my local hotspot and took some photos with my new phone, what an upgrade from my old Galxy S5!

IMG_20180726_212554_489 by Cragmire40D, on Flickr

IMG_20180726_212738_538 by Cragmire40D, on Flickr

IMG_20180726_212352_857 by Cragmire40D, on Flickr

Went out in the car yesterday after a quick clean and some weekend maintenance, the car feels really dialled in, the handling is lovely, the power delivery is great.. still need to go get the car booked in for some winter paint love. i want to get the engine stripped out again and painted as i never did that when putting it in, also the gearbox soda blasted and painted.

couldn't help but take more photos on the way home from a little meet

Saturday afternoon got busy!

Intercooler out (need to make up some good brackets for that again as i didn't like how it was sat at an angle before)

cooling system out - getting completely replaced

Alternator and bracket - out to be refurbished.

This is the offending pipe!

The near side of the engine has a coolant housing that the temp sensor goes into, so i whipped that off while i clean up the engine of all the muck and grease, as it came of, the rubber o'ring came away in 2 that's likely where the little dribble of coolant has come from and possibly not the pipe in the pictures above, but that needs replacing anyway.

Going to fit a catch can so whipped out all the oil breather pipes, the one that goes into the block obviously split as it came out..just brittle. so ordered a new part there, that will go into a silicon pipe to a catch can and then one from the cam cover to the catch can...then delete the PCV (puck) valve.

then took out the alternator and the bracket behind it that supports the power steering pump. I'll sand them back and clear coat them... not sure how to restore the alternator yet though but just want that back to OEM looking and clear coated.

loads of cleaning to do! should be a good week for progress

Another busy weekend pushing on with the car.

Finished cleaning up the cam cover, masked up ready to paint

Idle pulley bearing was rough so took that apart, cleaned up all the aluminium, chemically treated it and then cleaned again and clear coated it... i also did this with the bracket on the front of the engine for the alternator

Took the bearing out thinking i could just replace it... looks like its easier to just replace the assembaly

Stripped the alternator to check the bearings as it sounded a bit gritty..

Outer shaft bearing in the casing is all good... inner is gritty..Part number for it in pic. ordered a new bearing and will replace that.

did loads more cleaning up of the alternator casing, i will clear coat this when done.

and put some of it back in to get an idea of how its looking.

Well i picked up the new used box from a seller i have known about for a long time so that gave me some confidence in what he was saying... So many people have tried to sell me duff box's or just come across as such cowboys.

Photo from the seller below. pretty oily and grimey but came out of a running Octavia VRS and the gearbox was running smoothly.

got busy with the oven cleaner and some other cleaning products and it really did a good job on removing all the grime! the only issue was some surface corrosion that i've began cleaning off before clear coating the box.. i don't want to paint it silver as it just looks wrong... black would be good but keep it original looking and clear it.

half way through clearing it up my second Dremel died.. thats 2 now in the space of 2 years... going to buy a cheap one this time as im sick of the cost of a dremel against the length of life

Got busy at the weekend with the gearbox.

I Had a few hours on Saturday while the boys were at their nannas for lunch so i built the crane up, wheeled the car out and got busy

First job was disconnecting the driveshafts and getting those off. For anyone wondering, you need to have the wheels off and undo the lower suspension bolts, then you will have enough room to slip them out.

Out with the old box... ewww..grotty

On goes the new box

Time for the bay to get some more TLC

Checked the turbo over and its got Zero play, happy days! i did come across an issue when removing the TIP that theres a rubber O-Ring that seals it onto the Turbo, that has split.. so now i'm just tempted to change it to a Silicon TIP. i'll see how much the o-ring is first

mental week, not able to get much done sadly.

Fitted the new starter motor

I also decided to debaffle the turbo outlet (charge pipe). Theres no performance gain to be had, just sounds better :)

got busy on the car lately, my dad suffered a major stroke and im in hospital several hours a day. Outside of visiting times, i needed something to focus on that i could just be alone and take my mind off the worry. turns out you can get lots done in short times.

New starter motor.

Painted up the intercooler to add to the stealthy look

Engine going in

Tax and insure it today and finish off the front end tonight when im back from the hospital.

cannot wait to drive it again.

nice to be out and about in it this weekend :)

well they arrived and all look very good. totally refurbished with all new bolts, sliders, stainless bleed nipples, rubbers and pistons.

started looking at changing over the turbo for a k03s hybrid... so will need to re-evaluate of its easily mappable or not, last time i looked it was not...things could have changed


Online Watts

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Fantastic job, looks great :smiley: Good write up too, keep it coming!
2019 Oryx White 5dr TCR.

Was - 2015 Tornado Red 3dr GTI PP, manual, Santiagos, Audi short shifter.

Offline cupracraig

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long time since the last update but here goes.

I changed the scuttle for an SWG one
IMG_20200118_171938_262 by Laxadams, on Flickr

Sourced some Audi guages to refurbish:
IMG_20200131_222945 by Laxadams, on Flickr

Sourced a leather steering wheel
IMG_20200213_174355 by Laxadams, on Flickr

Added some Gerth
IMG_20200302_145145 by Laxadams, on Flickr

Added a silicon TIP..but have since added a over sized one:
IMG_20200311_202555 by Laxadams, on Flickr

IMG_20201013_113544_713 by Laxadams, on Flickr

new grill
IMG_20200331_085710 by Laxadams, on Flickr

Changed the air box set up
IMG_20200419_115620 by Laxadams, on Flickr

Got vandalised
IMG_20200528_210657 by Laxadams, on Flickr

Stripped it down:
IMG_20200530_173635 by Laxadams, on Flickr
IMG_20200530_135418 by Laxadams, on Flickr
IMG_20200530_113131 by Laxadams, on Flickr
2020-06-01_10-58-17 by Laxadams, on Flickr
IMG_20200604_130919 by Laxadams, on Flickr
IMG_20200604_154915 by Laxadams, on Flickr
IMG_20200607_115718 by Laxadams, on Flickr
IMG_20200619_140827 by Laxadams, on Flickr
IMG_20200619_145637 by Laxadams, on Flickr

Offline cupracraig

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proceeded to tidy up the internal loom
2020-07-02_10-20-52 by Laxadams, on Flickr
2020-07-02_10-21-03 by Laxadams, on Flickr

Sent the car off for some rust repairs and new paint up front
IMG_20200703_101649 by Laxadams, on Flickr

Refurbished the driveshafts
IMG_20200726_182824 by Laxadams, on Flickr

did away with the stereo and made up a bracket for the guages
IMG_20200803_132610 by Laxadams, on Flickr

IMG_20200803_132629 by Laxadams, on Flickr

Said goodbye to the K03 and tidied up the back of the engine before installing a K03s
IMG_20200823_212121 by Laxadams, on Flickr

2020-08-24_09-47-07 by Laxadams, on Flickr
2020-08-24_09-47-16 by Laxadams, on Flickr

Got working on the engine loom and relocating that
IMG_20200829_205401 by Laxadams, on Flickr

some of the wires had seen better days as below: so replaced them all after
IMG_20200829_204947 by Laxadams, on Flickr

IMG_20200909_113128 by Laxadams, on Flickr

IMG_20200903_223031 by Laxadams, on Flickr

New underlay to replace the worn bitumen stuff
IMG_20200909_100110 by Laxadams, on Flickr

IMG_20200909_215002 by Laxadams, on Flickr

IMG_20200909_214957 by Laxadams, on Flickr

More loom things:
IMG_20201205_125025 by Laxadams, on Flickr

IMG_20201218_145924 by Laxadams, on Flickr

IMG_20201218_151432 by Laxadams, on Flickr
IMG_20210104_214059 by Laxadams, on Flickr

Made new looms for Foglights and indicators
IMG_20210124_220814 by Laxadams, on Flickr
IMG_20210124_220337 by Laxadams, on Flickr
IMG_20210205_174119 by Laxadams, on Flickr

Tidied up lighting looms
IMG_20210123_210731 by Laxadams, on Flickr

IMG_20210128_202745 by Laxadams, on Flickr

Cleaned a few things:
IMG_20210129_081804 by Laxadams, on Flickr

Bay looking a bit cleaner
2020-12-22_08-25-13 by Laxadams, on Flickr

IMG_20210129_173138 by Laxadams, on Flickr

refurbished these:
149210821_161205862323549_4848028347506056130_n (1) by Laxadams, on Flickr

and thats wher i'm at. Car all running and just waiting to paint the inner arches before bolting it back up

Offline Al1040

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What a fantastic job, clearly a labour of love.
Well done
67 Plate Mk 7.5 GTD DSG

Online Guzzle

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Wow, someone's been busy.👏
7.5 GTD