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Model specific boards => Golf mk3 => Golf mk3 gallery => Topic started by: jv on 09 February 2007, 12:19

Title: Len405 - mk3 16v
Post by: jv on 09 February 2007, 12:19: Don't tell me it's time for the blue lights to go Len? :tongue:
Title: Re: Len - mk3 16v
Post by: Len on 10 February 2007, 10:25: Thanks John - nah blue lights are staying!

Bit of a potted history on the Car! Bought in Feb 2003 so had it nearly 4 years.
This is the first photo I ever took of it.

(http://i176.photobucket.com/albums/w170/Len405/Golf.jpg)

That was taken early June 2003 after RTTS, hence the mud spatter!
At that time all I had done was the new Sony Headunit, the alloys as you see and changed the rear light clusters!
It is a 1997 P reg. I paid Ãƒâ€šÃ‚£2900 for it when it had 98k on the clock with 2 previous owners. An estate agency then when it was traded in the woman who looked after the cars in that company bought it for herself, she chose this one out of 3 others, so it was the best!
A 16 valve to which I have added a K&N induction kit.
Back in the late summer I bought a second hand cat back exhaust system from Hypermonkey on here. A Magnex twin pipe outlet.
Title: Re: Len405 - mk3 16v
Post by: Len on 10 February 2007, 10:33: I then changed the door speakers to Sony 3 way in the front and Infinity components in the rear.

Next was some Sony 3 way 6 x 9's on an MDF parcel shelf with an unknown amp Billy lent me.
Oh I mention Billy - he is my Son-in-law and the one whose fault it is I bought this car! :grin:

No pics of this.
Title: Re: Len405 - mk3 16v
Post by: Len on 10 February 2007, 10:37: I'll move on to the other exterior mods.

Twin headlights.

(http://www.yourimagehost.com/is.php?i=120784&img=Dsc00623.jpg)
Title: Re: Len405 - mk3 16v
Post by: Len on 10 February 2007, 10:40: Then at E38 in 2005 I bought a mesh grille, painted that myself which I was quite chuffed with!

(http://www.yourimagehost.com/is.php?i=120785&img=Dsc00794.jpg)

You can also probably see the crystal indicators and the Vr6 chin spoiler.
Title: Re: Len405 - mk3 16v
Post by: Len on 10 February 2007, 10:47: There was also the built in sub box and 4 way amp install thats around here somewhere that I will post in here at some point. (when I find it!)

The future! Here's what I have planned.

The body kit - pics below.
Full respray - well the exterior only.
New alloys - atm I'm looking at BK299 with gold spokes.
A chip/remap. No idea where this will get done yet, still to be researched.
Title: Re: Len405 - mk3 16v
Post by: Len on 10 February 2007, 10:51: Body kit by Ibher Design. Purchased through STX Styling.

(http://www.yourimagehost.com/is.php?i=120788&img=002202.jpg)

(http://www.yourimagehost.com/is.php?i=120787&img=P0940102.jpg)
Title: Re: Len405 - mk3 16v
Post by: Len on 10 February 2007, 11:00: Oh yes forgot two things.

New rear roof spoiler, think I've found one I like but gonna keep on searching.
3 in 1 fogs/indicators with non orange bulbs.
Title: Re: Len405 - mk3 16v
Post by: Len on 11 February 2007, 13:27: This here link will take you to the thread/blog I did on my sub box build.

http://www.golfgtiforum.co.uk/index.php?topic=31055.0
Title: Re: Len405 - mk3 16v
Post by: Len on 12 February 2007, 19:45: And here's a link to the Amp fixing section and the final install photos!

http://www.golfgtiforum.co.uk/index.php?topic=35556.0
Title: Re: Len405 - mk3 16v
Post by: Len on 12 February 2007, 19:51: Forgot something!

Along with body kit and respray I intend to take off the plastic arches and change the side mouldings to the narrow type.
Title: Re: Len405 - mk3 16v
Post by: Len on 25 February 2007, 17:21: Thought I would post a pic of how its is now before I start messing with it!
Been this way since earlt summer last year after I eventually got around to fitting the bottom spoiler I got off Phil (golfpro)

(http://www.yourimagehost.com/is.php?i=117547&img=Dsc00944.jpg)

pic taken at E38 last year!
Title: Re: Len405 - mk3 16v
Post by: Len on 15 March 2007, 09:22: Been a bit slack and not said owt for a while!

Things have stalled a bit mainly because I am having trouble sorcing the correct body side mouldings (door rubbing strips) that I want.
Carl has been most helpful and hopefully I should have them next weekend.
Also been attending a few events - Ultimate Dubs last weekend and Viva Skeg Vegas this coming weekend, so that got in the way a bit. But hey ya gotta go show yer face and support fellow nutters!

So the plan is - get door mouldings and take off plastic arches next weekend. See how bad the metal is underneath!

Then fit the front and rear bumpers.

Then the side skirts.

Rear roof spoiler, plus new front fog/indicators.

Full exterior respray!
Title: Re: Len405 - mk3 16v
Post by: Len on 24 March 2007, 16:13: Just taken off the plastic arch trims and body mouldings.

was fine no probs and no RUST!!! well just a tiny bit on one inner edge.
So well chuffed.

Evidence that the front offside wing has been resprayed at some time as there is a paint ridge left now.

Went to eurocarparts this morning and I think i have sorted my body moulding problems!!!
Have to wait until Monday evening to see if they are in fact the correct ones though!
Title: Re: Len405 - mk3 16v
Post by: Len on 26 March 2007, 20:22: Yes got some!

2 bits missing though as one was incorrectly ordered and another didnt turn up!
But should have all of them by the weekend.

Sprayed up a couple of the smaller pieces in Matt Black to see if I prefer that to body colour.
Title: Re: Len405 - mk3 16v
Post by: Len on 27 March 2007, 15:01: Made some decisions today and ordered some bits!

This roof spoiler -
http://www.body-kit.co.uk/acatalog/info_RS9004.html

And these jewel/chrome fog/indicators -
http://www.body-kit.co.uk/acatalog/info_VW23L90.html
with the chrome bulbs.

They should arrive at the end of the week!

On a roll now, which means I must start doing the bumpers!!
Title: Re: Len405 - mk3 16v
Post by: Len on 28 March 2007, 13:24: Oh just for everybody's information those new body mouldings cost me Ã‚£178.58 inc VAT.
Eurocarparts seem to be able to get them fairly easily, either from another branch or by special order.

That and the two items I bought yesterday makes about Ã‚£330 so far this week.

Ã‚£580 for the body kit.
Respray will now be about Ã‚£800 - Ã‚£900
If I go for the BK299 wheels thats another Ã‚£600.

Why am I spending nearly 2.5k on a car that will only be worth about that after all the work!
Why coz I like the car and intend to keep it and enjoy it.

Oh if anyone now thinks I rich then forget it! I am spending my Tax rebates from the last couple of years!
Title: Re: Len405 - mk3 16v
Post by: Len on 02 April 2007, 13:34: Why do things never run smoothly! :angry:

Blooming roof spoiler! It dont fit the existing fixing holes!
Will have to drill through the metal of the hatch!

Also I will have to fill in the 3 holes in the glass too!
Title: Re: Len405 - mk3 16v
Post by: Len on 02 April 2007, 13:41: Oh yes just thought I would mention here as well.

I was contemplating a chip/remap whatever. But after the RR session on Saturday and a result of 173.7 bhp I wont be bothering!
Title: Re: Len405 - mk3 16v
Post by: Len on 10 April 2007, 09:21: Well I made a start on the body kit!

As soon as I took the rear bumper off I knew I was going to have problems!
The side mountings on the new one wasnt going to fit!
So I had to take off the mountings from the old bumper and glass/screw/bond them to the new one.
Then I had to make up 3 bottom fixings and glass those on. Then I had a problem with the exhaust touching!
Well its on there and painted matt black for now.

Was gonna start on the front but havent finished fixing on the mesh yet.

So had a better look at one of the side sills. Took the old stuff off and cleaned it all up and it looks good - no rust, all metal work in good condition. The sills will have to be glued on as there's no way I'm drilling into anything in that area. So will order some stuff off ebay.
Title: Re: Len405 - mk3 16v
Post by: Len on 16 April 2007, 20:25: A few photos!

First 3 are the new bumper fitted and painted with spray can matt black.
(http://i176.photobucket.com/albums/w170/Len405/Dsc01001.jpg)

(http://i176.photobucket.com/albums/w170/Len405/Dsc01000.jpg)

(http://i176.photobucket.com/albums/w170/Len405/Dsc00999.jpg)

This is with the original side skirts taken off, cleaned and checked and painted with hammerite where necessary. (edges)
(http://i176.photobucket.com/albums/w170/Len405/Dsc01002.jpg)

These are the offending side mounts! This is the front bumper which is having the mesh fixed on.
These two mounts will have to be cut off and new ones made.
(http://i176.photobucket.com/albums/w170/Len405/Dsc01011.jpg)
Title: Re: Len405 - mk3 16v
Post by: Len on 16 April 2007, 20:33: To fix the mesh on the back of the Front bumper, I am using body filler to first fix it to the sides of the apetures. Once secure I am using "No Nails" as a filler and further fixer.
(http://i176.photobucket.com/albums/w170/Len405/Dsc01009.jpg)

Then on top of all that I am using wide strips of glassfibre to layer it back onto the bumper.
(http://i176.photobucket.com/albums/w170/Len405/Dsc01007.jpg)

All this is on the inner/back of the new bumper so will not be seen at all.
Title: Re: Len405 - mk3 16v
Post by: Len on 16 April 2007, 20:40: having had a real good look around the car now I have discovered a few problems with the offside front wing. Few bad rust spots, a bad dent and a bit of miss shape.
So this is now an excuse to fit a vented wing! :grin:
Title: Re: Len405 - mk3 16v
Post by: Len on 17 April 2007, 20:40: Grrrrrr! blooming yourimagehost decided to bug me around, so just spent the last hour opening a photobucket account and reloading loads of photos! :angry:
Title: Re: Len405 - mk3 16v
Post by: Len on 23 April 2007, 16:15: Oh well looks like I might have to forget the vented wings. DPM autostyling say that the German supplier has no stock!
:angry: :cry:
Cant keep waiting as time is running out!
Title: Re: Len405 - mk3 16v
Post by: Len on 24 April 2007, 10:09: Now work is stopped due to coolant leak! :angry:

Totally F*CKED OFF!

Was gonna post some more pics last night, instead I spent 2 1/2 hours doing what should have been an easy job!

Bloody cars!
Title: Re: Len405 - mk3 16v
Post by: Len on 24 April 2007, 20:11: Well here's the pics I would have posted last night!

(http://i176.photobucket.com/albums/w170/Len405/Dsc01015.jpg)

(http://i176.photobucket.com/albums/w170/Len405/Dsc01018.jpg)

(http://i176.photobucket.com/albums/w170/Len405/Dsc01016.jpg)

(http://i176.photobucket.com/albums/w170/Len405/Dsc01017.jpg)

These show the mesh now fully fixed and glassed in. Then sprayed with matt black.
Might give it a few more coats just to make sure its well covered. Not easy spraying mesh!
Then a couple of good coats of lacquer! As that will be the finished article. Not doing the mesh body colour. It will then match my mesh grille.
Title: Re: Len405 - mk3 16v
Post by: Len on 30 April 2007, 09:39: BLOODY NIGHTMARE!!!

The new front bumper wouldnt fit! :angry:
Nobody tells you anything and there were no instructions with the kit, so I didnt know that the inner bumper was as deep as it is or that this was critical to the bumper fixing.
Basically what that means is the dimension from the top of the bumper down to the vented blocks must be 180mm.
It wasnt due to all the lovely filler and glassfibre and mesh that I spent hours fixing! :angry:

So I have had to grind ALL that off! :cry:

Also the two outer vent pods for want of a better word, were made too big. In that they made them too long coming out from the front.
So I ended up taking the mesh off both the 2 outer pods. grind it down, trial fit, grind down and shape, trial fit, final grind.
Then I still couldnt get the right space between the upper and mid pieces.
So i had to cut into the pods and bend them down.
Well now it will fit.
I have joined back up the cuts I made and left the resin to set well. This evening I will be putting new mesh back onto the side pods. Once that is set then 2moro evening I will be fitting it!

I do have some pics of all this but havent been arsed to even download them from the camera yet!
Title: Re: Len405 - mk3 16v
Post by: Len on 01 May 2007, 21:20: Ah well its now back to where it was last week and should now fit!
waiting for the fresh paint to dry now.

So to start off here's a couple of pics of of the problem side mounts.

(http://i176.photobucket.com/albums/w170/Len405/Dsc01036.jpg)
That shows the differences between old and new.

(http://i176.photobucket.com/albums/w170/Len405/Dsc01038.jpg)

This is the old mount fixed onto the new bumper.
Title: Re: Len405 - mk3 16v
Post by: Len on 01 May 2007, 21:24: Now the problems I had with the two side pods.
The next 2 pics show the alterations I had to make and a piece of wood wedged in to make the 180mm dimension I need.

(http://i176.photobucket.com/albums/w170/Len405/Dsc01041.jpg)

(http://i176.photobucket.com/albums/w170/Len405/Dsc01040.jpg)
Title: Re: Len405 - mk3 16v
Post by: Len on 01 May 2007, 21:28: Next are the repairs I had to make to the outer surface of the bumper due to cutting and rejoining.

(http://i176.photobucket.com/albums/w170/Len405/Dsc01042.jpg)

(http://i176.photobucket.com/albums/w170/Len405/Dsc01043.jpg)

(http://i176.photobucket.com/albums/w170/Len405/Dsc01044.jpg)
Title: Re: Len405 - mk3 16v
Post by: Len on 01 May 2007, 21:29: Nearly finished!

(http://i176.photobucket.com/albums/w170/Len405/Dsc01046.jpg)
Title: Re: Len405 - mk3 16v
Post by: Len on 04 May 2007, 14:52: Well I fitted it last evening! Not 100% happy with it and now I know all the pinch points I can fine tune a few bits and get a better fit.

So I'm gonna delay the respray until after RTTS (my original target)

Have taken a few shots and will post them as soon as I can.

Will definitely have to be lowered. So might get and do that before RTTS!

Oh and I may have made a mistake over the fog/indicators! Perhaps should have gone for smoked instead of crystal. But I will reserve judgement on that until after the paint!
Title: Re: Len405 - mk3 16v
Post by: Len on 04 May 2007, 18:38: Right here's a few pics.

(http://i176.photobucket.com/albums/w170/Len405/Dsc01054.jpg)

(http://i176.photobucket.com/albums/w170/Len405/Dsc01053.jpg)

(http://i176.photobucket.com/albums/w170/Len405/Dsc01052.jpg)

(http://i176.photobucket.com/albums/w170/Len405/Dsc01051.jpg)
Title: Re: Len405 - mk3 16v
Post by: Len on 04 May 2007, 18:39: As its painted matt black it dont really bring it out atm.
Title: Re: Len405 - mk3 16v
Post by: Len on 11 May 2007, 20:32: Well thanks to the guys at Cox Clifford last saturday who informed me that the CAT was knackered thats gonna be the job for tommorow!
I dont fancy those flippin bolts down under the car! They have obviously never been off before, so are gonna take a bit of shifting! Plenty of WD40.
Might even get a me mates air gun and a few sockets and use the darn compressor thats in my garage!!!!

Then if that bit of work goes o.k. I will get on and fix the side skirts!
Title: Re: Len405 - mk3 16v
Post by: Len on 14 May 2007, 09:04: Did the CAT saturday. Went fairly well except for undoing the lambda sensor!
Roof aerial I had to combine old and new as the fittings were different!

With other complications I didnt start doing a side skirt until Sunday.
Well that not as easy as I thought either! :angry:
Oh well I'll get there eventually!
Title: Re: Len405 - mk3 16v
Post by: Len on 14 May 2007, 13:05: Have had to bring wheel plans forward because my existing tyres are virtually dead. About half a mill before illegal!

Had decided upon BK299's with Gold centre. just the spokes and hub bit really with the rim chrome.

So I rang Larkspeed this morning as they were the best price I had found for those wheels. Guy says he will check with the supplier and get back to me. All hell breaks loose! Or rather thats how it felt!
Manufacturer dont do these to fit my car! In fact they have only ever made them for Scoobies! So back to searching! The very helpful man at Larkspeed says he will do some searching for me and ring back in an hour. I think yea alright never to be heard from again!
But how wrong was I! Not only does he ring me back but he has sorted a solution for me to use the Scooby wheels! Apparently he has worked out how to utilise some spacers with hub ring locators etc.

So back on track!
Title: Re: Len405 - mk3 16v
Post by: Len on 15 May 2007, 12:36: Finished the drivers side, side skirt last evening! well it needs a bit more painting but its on there!
I used the mastic/adhesive stuff I got off Wayside and its good stuff. Messy but good.
felt secure but just to make sure I put a self tapping screw at either end into the wing returns in the wheel arches.

More pics to follow when it stops raining!
Title: Re: Len405 - mk3 16v
Post by: Len on 18 May 2007, 09:18: Wheels arrived yesterday and they look totally gorgeous! Cant wait to get them on the car!
Think I have worked out the spacers and long studs.

Now do I do the lowering springs whilst I have the wheels off? Hmmmmm will have to see if all the bolts undo!
Title: Re: Len405 - mk3 16v
Post by: Len on 19 May 2007, 16:57: More bloody problems!
Last night tried to undo the front strut top mounts. Did one side fine but the other wouldnt budge. Under the pressure being exerted the top piece spalled out. In other words the inner bit where the hex head goes in burst open!
So I wont be fitting the lowering springs!
There is a solution to the problem in that I will have to cut the rod of the strut and have new shockers! Was gonna get some Spax adjustables anyway!

So today I'm going quite well, fixed the second side skirt and painted the calipers.
Fitting new wheels, well the studs are too long! sort that and fix the front. Move on to the rear and the spacer wont fit over the inner hub piece! so lets see how good Larkspeed are now then!
Tried to explain it over the phone, but that was hard so have emailed them a couple of photos and waiting to hear back now!

So atm I can fit the front wheels - but not the back!
Title: Re: Len405 - mk3 16v
Post by: Len on 21 May 2007, 08:57: Wheel problem got resolved yesterday! Thanks to Billy! Cheers mate!

Just rang him to chat and tell him of my problems and said dont suppose you got any spacers lying around? As it happens yes!

So the wheels are on!

They look really LUSH!

Photos will be posted later!
Title: Re: Len405 - mk3 16v
Post by: Len on 21 May 2007, 20:56: As promised some photos!

(http://i176.photobucket.com/albums/w170/Len405/Dsc01060.jpg)

(http://i176.photobucket.com/albums/w170/Len405/Dsc01062.jpg)

(http://i176.photobucket.com/albums/w170/Len405/Dsc01064.jpg)

(http://i176.photobucket.com/albums/w170/Len405/Dsc01066.jpg)
Title: Re: Len405 - mk3 16v
Post by: Len on 29 May 2007, 20:59: Well I tried to go see the paint sprayer today! No luck! He away for a few years at Her Majestys Pleasure!

But tried another recommendation and although a bit dearer have booked it in for the 11th June.

They also suggested painting the mesh gold to match the wheels!
Hmmmmm.........
Title: Re: Len405 - mk3 16v
Post by: Len on 31 May 2007, 10:09: Have also decided I dont want to change the roof spoiler, so I'm keeping the standard one and having it colour coded.
Title: Re: Len405 - mk3 16v
Post by: Len on 10 June 2007, 17:23: Well it goes in for body repairs and painting tommorrow!

so by next weekend I should be posting some more photos!

then I need to do rear brakes and bearings! ready for an MOT the following saturday! :sad:
Title: Re: Len405 - mk3 16v
Post by: Len on 14 June 2007, 09:34: Body shop having problems! Well I think they are just generally behind with work.
So not getting my car back until Monday! But they've knocked Ã‚£100 off so not all bad.
Going to have a look at it Saturday morning so i'll see how good they are as they say it will be painted by then just not put back together!
Title: Re: Len405 - mk3 16v
Post by: Len on 19 June 2007, 20:47: Back from bodyshop this evening! Took these just before the heavens opened!

(http://i176.photobucket.com/albums/w170/Len405/Dsc01092.jpg)
(http://i176.photobucket.com/albums/w170/Len405/Dsc01091.jpg)

(http://i176.photobucket.com/albums/w170/Len405/Dsc01090.jpg)

(http://i176.photobucket.com/albums/w170/Len405/Dsc01089.jpg)

(http://i176.photobucket.com/albums/w170/Len405/Dsc01088.jpg)
Title: Re: Len - mk3 16v
Post by: Len on 04 February 2008, 20:54: Bout time for an update!

Well I have finally decided on a remap and have found a place in Bristol and going to take a chance and see what I get for my money.

Cant put it off any longer and I will be ringing Venom tomorrow to order the coilovers!
Having looked at many and the cheapo ones on ebay I have decided to stick with Joe's recomendation and get FK Konigsports.
Title: Re: Len405 - mk3 16v
Post by: Len on 14 February 2008, 13:43: The coilovers have arrived! well billy just phoned to say that had arrived at his work place. Go over and pick em up from him later!
just have the problem of fitting them now!
dunno if I'm gonna get time this weekend and then car is back in bodyshop on Monday!
Hmmmmmm decisions!
Title: Re: Len405 - mk3 16v
Post by: Len on 14 February 2008, 19:54: Just been and picked em up from Billy. Mmmm look gorgeous!
How can you drool over a set of springs and shocks! :laugh:
Title: Re: Len405 - mk3 16v
Post by: Len on 18 February 2008, 08:43: Well I kinda chickened out yesterday! Decided to leave fitting the coilovers until next weekend.
There is a good reason, the car is in the paintshop for a bit of work and therefore I cant drive it to bed them in! And I really want to bed them in before I get the geometry checked.

I did do something yesterday - cleaned the K & N.
Boy was that dirty! Used the K & N cleaning kit and followed the instructions, hope it was fully dry!
Title: Re: Len405 - mk3 16v
Post by: Len on 27 February 2008, 19:50: Well I had the remap done today!
car feels 10 times better, much greater and faster response.
Sounds louder too, which I cant quite work out why! :huh:

No figures to report so whens the next RR day!
Title: Re: Len405 - mk3 16v
Post by: Len on 03 March 2008, 08:39: Well I chickened out and didnt fit the coilovers at the weekend.
Decided it was a bit dicey due to holiday. If I had run into problems etc. and I wouldnt be able to drive it around to settle in and not get the geometyr sorted. So small postponement for now.
Title: Re: Len405 - mk3 16v
Post by: Len on 20 March 2008, 12:54: Was meant to do coilies last weekend but illness got the better of me!

So its Easter and will do them 2moro, Good Friday.
Title: Re: Len405 - mk3 16v
Post by: Len on 21 March 2008, 20:20: Well the front is done!

Just such hard work!

Oh I have heard several people say you dont need spring compressors! OH YES you do!
Not for taking them out, but for stripping the original struts for the bits you need.

I thought I was being clever to get the ride height! I put the wheel back on, just a couple of nuts hand tightened and then with a jack under the bottom wishbone lifted up the wheel until the car just moved off the axle stand. Did this on the first side to a height I thought was about right, took a few measurements and set the other side the same.
Didnt work out when I actually dropped the car on the floor though!!!! :laugh:
So its a bit low at the front atm!
Doing the rear tomorrow so will wait and see if that raises the front a tad, as atm its very nose down! :grin:
Title: Re: Len405 - mk3 16v
Post by: Len on 21 March 2008, 21:14: Darn! Been trying to get some photos out of my phone! This new one dont wanna play! Bugger!
Will take some pics before I start tomorrow.
Title: Re: Len405 - mk3 16v
Post by: Len on 24 March 2008, 10:02: Did the rears on Saturday. Loads of niggly problems, like as the struts are shorter on the nearside you have a problem with the bottom bolt fouling the exhaust back box! So if like me you chose to do up the offside first, the bottom bolt on the nearside wouldnt go in!
So I had to undo the top mount on the offside so the beam would drop down to allow me to fit the nearside bottom bolt!

Grrrrrrrr!

Plus things like the instructions saying to strip the old struts to fit the bumpstops and cover, but when you try to fit these onto the coilovers you find they wont go inside the springs! Bah!

So just a load of wasted time and effort! But if I was doing it again............

Oh I figured out why my little ruse didnt work on setting the ride height on the front! The anti-roll bar!
If I had jacked up both lower wishbones at the same time then it would have, but singly the anti-roll bar acted in its normal way.
Title: Re: Len405 - mk3 16v
Post by: Len on 25 March 2008, 13:08: Reset the height yesterday morning. Took me about an hour doing the front first then the back to match.

Got a bit of a problem on the front in that its slightly different height side to side, but am going to wait until I have the geometry realigned on saturday before I check it again and make any final adjustments.

Car feels great to drive now! No more body roll.
Waiting for a dry day to check the roadholding! :laugh: :evil:
Title: Re: Len405 - mk3 16v
Post by: Len on 28 March 2008, 20:59: Getting tracking etc. done in the morning and will then do a final measure check to ensure car is level.

In meantime here are a few pics!

(http://i176.photobucket.com/albums/w170/Len405/DSCN0221.jpg)
(http://i176.photobucket.com/albums/w170/Len405/DSCN0222.jpg)
(http://i176.photobucket.com/albums/w170/Len405/DSCN0223.jpg)
(http://i176.photobucket.com/albums/w170/Len405/DSCN0224.jpg)
(http://i176.photobucket.com/albums/w170/Len405/DSCN0225.jpg)
(http://i176.photobucket.com/albums/w170/Len405/DSCN0226.jpg)
(http://i176.photobucket.com/albums/w170/Len405/DSCN0227.jpg)
Title: Re: Len405 - mk3 16v
Post by: Len on 30 March 2008, 14:18: Tracking/camber/toe all done now and set right! Some of the before figures were well out!

So did a measure check all round this morning and all is good! So wont be changing anything for a while.
Title: Re: Len405 - mk3 16v
Post by: Len on 07 April 2008, 13:17: RWYB Santa Pod yesterday (6/4/08)

Well that remap didnt do much for power! Unless Daves car has something that he didnt know about as we were pretty evenly matched. Me being slower!

So its back to the drawing board power wise and a stiff talking to for the people that did it!
Title: Re: Len405 - mk3 16v
Post by: dubsport on 07 April 2008, 13:26: *gulps* im actually warming to the blue lights ...

looks awesome in this pic

(http://i176.photobucket.com/albums/w170/Len405/DSCN0223.jpg)

:afro: :afro: :afro:
Title: Re: Len405 - mk3 16v
Post by: Len on 08 April 2008, 13:59: Thats not allowed!!! Somebody liking the blue rear lenses!! :shocked:
Title: Re: Len405 - mk3 16v
Post by: BobbyT on 15 April 2008, 17:08: time for a charger len :wink:
Title: Re: Len405 - mk3 16v
Post by: Len on 08 May 2008, 20:50: Actually been seriously considering Nitrous! :evil: :laugh:
Title: Re: Len405 - mk3 16v
Post by: Len on 19 January 2009, 14:31: Thought I had better add something in here as its been a while!

Not done a lot!

Bought another set of rear light clusters from jamie off here which are a bit darker! But still BLUE!!
Also got some spray tint off ebal and coated the side repeaters!
Overdid that a bit so will have to strip that off and give them one fine coat instead of loads! lol

Here's a tip for all Mk 3 owners if you want to reduce noise in cabin a little.

Under rear seat.
Lift up seat base and you will see bare metal now as this is where the main exhaust box is (under the seat) its a good idea to soundproof this area.
Now I had some of the expensive sound matt spare (forgot name!) so I used what I had which virtually covered all the metal.
I had some sound deadening material that I took out of my old 405 and laid that on first. Then I tidied up all the amp/speaker/CD player cables and added another layer of spare matting to cover the whole area.
Will get some pics up when I can.
This does make a good difference!
Title: Re: Len405 - mk3 16v
Post by: Len on 16 March 2009, 17:12: Well thought I should do another little update!

Finally got around to fitting all of the leather interior! With assistance from Billy!

No point in posting pics as its just a standard set with rear headrests.

Oh the ICE sounds a bit better! Found one of the rear door speakers was not connected properly!
Also I fitted some dynamat in all 4 doors. Just a small area about a foot square behind each speaker, outer skin.
Title: Re: Len405 - mk3 16v
Post by: Neaty on 16 March 2009, 17:16: Quote from: Len on 16 March 2009, 17:12
Well thought I should do another little update!

Finally got around to fitting all of the leather interior! With assistance from Billy!

No point in posting pics as its just a standard set with rear headrests.

Oh the ICE sounds a bit better! Found one of the rear door speakers was not connected properly!
Also I fitted some dynamat in all 4 doors. Just a small area about a foot square behind each speaker, outer skin.

Post a picture anyway.
Title: Re: Len405 - mk3 16v
Post by: Len on 16 March 2009, 17:18: Will have to wait til the weekend! Cant do any up here! (Rotherham)
Title: Re: Len405 - mk3 16v
Post by: Len on 16 March 2009, 17:21: Oh and its about as clean as its ever been inside since I had it!

Billy made me clean it while front seats were out!
Title: Re: Len405 - mk3 16v
Post by: Len on 18 March 2009, 11:35: Well after incident in petrol station Monday, I have started the road to repair!

Went and picked up a set of crystal indicator/fogs last evening locally to me here (Swinton/Rotherham)
Only needed the offside indicator but a lot cheaper than buying a new set!

Work will start in earnest at the weekend.
Title: Re: Len405 - mk3 16v
Post by: Len on 20 March 2009, 20:49: Couple of pics of the leather interior!

(http://i176.photobucket.com/albums/w170/Len405/Photo0030.jpg)

(http://i176.photobucket.com/albums/w170/Len405/Photo0031.jpg)
Title: Re: Len405 - mk3 16v
Post by: Len on 20 March 2009, 20:50: (http://i176.photobucket.com/albums/w170/Len405/GetAttachmentaspx.jpg)

That awful photo!
Title: Re: Len405 - mk3 16v
Post by: Len on 22 March 2009, 12:29: Some pics of the repair!

Bumper off!
(http://i176.photobucket.com/albums/w170/Len405/DSCN0343.jpg)

Glassfibre repairs on inside

(http://i176.photobucket.com/albums/w170/Len405/DSCN0342.jpg)

(http://i176.photobucket.com/albums/w170/Len405/DSCN0348.jpg)

(http://i176.photobucket.com/albums/w170/Len405/DSCN0349.jpg)

Start of filling and sanding on outside
(http://i176.photobucket.com/albums/w170/Len405/DSCN0350.jpg)
Title: Re: Len405 - mk3 16v
Post by: Len on 14 April 2009, 13:02: Plans:-

Been thinking about doing the dash/door speaker thing for a long time. Did it in my Pug 405 so I know its a good thing! Well was a bit different in that the door speekers in that are 6x9's!

Also having been inspired by Shady I have sourced some boot stays and will be doing the bonnet!
Title: Re: Len405 - mk3 16v
Post by: Len on 17 April 2009, 13:08: Volksmania tomorrow to get hatch stays.

Speakers have arrived so need to sort out wiring and the place I'm putting this tiny amp!
If that dont work then I may have to ditch the 6x9's!! :shocked:

But we'll see!
Title: Re: Len405 - mk3 16v
Post by: Len on 17 April 2009, 13:25: Just for the record the speakers are :-

SPL Dynamics HF-6.1 going in the front doors amped seperately.

Alpine SPG-10C2 in the dash run off the HU.

Only problem is the little amp as Billy gave it me years ago and dont know anything about it! :laugh:
Title: Re: Len405 - mk3 16v
Post by: Len on 19 April 2009, 18:26: Well the very experienced guy at Volksmania advise me NOT to use the hatch stays! he says they are too powerful as the hatch is much heavier than the bonnet. The danger he says is you may crease the bonnet!
So I didnt get those. Got a set of clocks though, white dials so going to source some blue LEDs etc.

Played around with that little amp and not going to bother!
Made a decision to try out the new speakers off the existing amp, so have taken out the 6x9's! :shocked:
Time will tell, see if I like it!
Title: Re: Len405 - mk3 16v
Post by: Len on 20 April 2009, 23:36: Well I fitted the new Alpine mid/tweeters in the dash this evening and then started on the new door speakers.
Well I didnt get far!
Had a look at the squeegy grommet thing that goes between door and A post! Well thats a nightmare! Its a multipin socket thing and no way through there for a wire!

So may have to drill my own hole! Sounds drstic but cant see any other way round it!

Hoping for some info on this (see thread in Audio)
Title: Re: Len405 - mk3 16v
Post by: Len on 23 April 2009, 21:14: Last couple of evenings I have finally fitted the tweeters from the Infinity Reference componets in the rear doors! Only taken me about 4 years!
And tonight after sorting the wires without help! I fitted the crossovers!

So they are sorted!

As for the front door speakers after a few helpful and some less helpful suggestions I have decided to go my own way and drill holes in the metal door and frame!
Billy can sort me some grommets and cable protection stuff so hopefully I can drill holes lower down which mean not having to take much of the dash out! With luck if I caqn get them off it will just be the footwell kick/side panels!
We'll see!
Title: Re: Len405 - mk3 16v
Post by: Len on 28 April 2009, 19:40: Did a bit of investigation today and managed to take off the footwell kick panels and therefore could see behind them!
Can see a good route for the cable holes. Only bad thing is its a double skin area so drilling will be a problem.
Will definitely have to undo the door stay to enable drilling!

So just need to get some stuff off Billy now then can do this!
Title: Re: Len405 - mk3 16v
Post by: Len on 30 April 2009, 12:29: Ordered some bonnet stays from Volksbits which came today and have fitted them!

Oh and the blue dash lights came as well. So bit of work involved there!
Title: Re: Len405 - mk3 16v
Post by: Len on 06 May 2009, 11:25: Fitted bonnet stays!

Pic to Follow!
Title: Re: Len405 - mk3 16v
Post by: Len on 06 May 2009, 11:26: Did door speaker wiring!

http://www.golfgtiforum.co.uk/index.php?topic=115291.0
Title: Re: Len405 - mk3 16v
Post by: Len on 06 May 2009, 11:28: Next is the Alpine HU and 6 disc CD player!

And the new clocks too!

Also doing the BMW rear wiper that Guy has sorted for us!
Title: Re: Len405 - mk3 16v
Post by: Len on 06 May 2009, 14:38: Photos of new HU and CD player

(http://i176.photobucket.com/albums/w170/Len405/DSCN0383.jpg)

(http://i176.photobucket.com/albums/w170/Len405/DSCN0385.jpg)

These are going in at the weekend with Billy doing most of the work! :wink:
Title: Re: Len405 - mk3 16v
Post by: Len on 10 May 2009, 17:56: HU and CD player and also instruments dials all fitted thanks to Billy!

he also found that there was already a fused feed direct from the battery into the car, so that was used to connect up to the amp! Soon blew though as it was only a 7.5 amp! :grin:
Title: Re: Len405 - mk3 16v
Post by: Len on 11 May 2009, 08:58: Right have some piccies now!

First off those bonnet lifters!
(http://i176.photobucket.com/albums/w170/Len405/Photo0032.jpg)
(http://i176.photobucket.com/albums/w170/Len405/Photo0033.jpg)
Title: Re: Len405 - mk3 16v
Post by: Len on 11 May 2009, 08:59: Now a couple of the instrument dials

(http://i176.photobucket.com/albums/w170/Len405/Photo0034.jpg)
(http://i176.photobucket.com/albums/w170/Len405/DSCN0386.jpg)
Title: Re: Len405 - mk3 16v
Post by: Len on 11 May 2009, 09:01: New HU in place

(http://i176.photobucket.com/albums/w170/Len405/DSCN0387.jpg)
Title: Re: Len405 - mk3 16v
Post by: Len on 11 May 2009, 09:03: Couple of pics of the RH dash speaker in place.

(http://i176.photobucket.com/albums/w170/Len405/DSCN0388.jpg)
(http://i176.photobucket.com/albums/w170/Len405/DSCN0389.jpg)

The second one was taken through the windscreen.
Title: Re: Len405 - mk3 16v
Post by: Len on 12 May 2009, 15:44: Finally got around to going to the local BMW dealer today to get the 1 series rear wiper arm.
Hopefully picking it up later so will post some pics of it done!
Title: Re: Len405 - mk3 16v
Post by: Len on 01 June 2009, 12:15: Piccie of new rear wiper!

(http://i176.photobucket.com/albums/w170/Len405/Photo0041.jpg)
Title: Re: Len405 - mk3 16v
Post by: Len on 01 June 2009, 12:17: That dont look so good so here's another

(http://i176.photobucket.com/albums/w170/Len405/Photo0040.jpg)
Title: Re: Len405 - mk3 16v
Post by: Len on 01 June 2009, 12:29: Here are a few pics of the door wiring!

(http://i176.photobucket.com/albums/w170/Len405/DSCN0373.jpg)
(http://i176.photobucket.com/albums/w170/Len405/DSCN0376.jpg)
(http://i176.photobucket.com/albums/w170/Len405/DSCN0378.jpg)
(http://i176.photobucket.com/albums/w170/Len405/DSCN0380.jpg)
Title: Re: Len405 - mk3 16v
Post by: Len on 08 June 2009, 15:37: Well I had a problem with the idle sensor on the throttle body and I think I sorted it but to make sure I went to Volksmania and bought another one!
So before I swapped it over thought I would give it a polish up!
Here's a few pics!

(http://i176.photobucket.com/albums/w170/Len405/ShinyBody1.jpg)
(http://i176.photobucket.com/albums/w170/Len405/ShinyBody2.jpg)
(http://i176.photobucket.com/albums/w170/Len405/ShinyBody3-1.jpg)
Title: Re: Len405 - mk3 16v
Post by: Len on 08 June 2009, 15:39: Oh and I finally got fed up with the K&N filter not fitting properly!

Sp also whilst at Volksmania I bought an air box!

Drilled a few holes in it! Took out all the hot air flap thing inside and blocked off the hot air opening!
Just have to get a good panel filter now!

Pics to follow!
Title: Re: Len405 - mk3 16v
Post by: Len on 26 August 2009, 11:43: Have some induction roar back again! Bought a K&N panel filter!
Title: Re: Len405 - mk3 16v
Post by: Len on 17 September 2009, 10:28: Just some general work to do, new middle exhaust mounts and a new PAS drive belt to fit.

Last weekend I had to fix one of the rear bumper mounts. One of the 3 lower mounts that I had to make and fix with glassfibre to the bumper. Fitted the bumper back in a "new" position, which turned out to be wrong! So that needs to be sorted as well.
Title: Re: Len405 - mk3 16v
Post by: Len on 17 September 2009, 15:24: Over 10,000 views to this thread! Hmmmm must be doing something right!
Title: Re: Len405 - mk3 16v
Post by: Len on 28 September 2009, 13:37: Fitted the Powerflex exhaust mounts!
Bit of a pain as ya cant get car up off the ground very high with jacks and axle satnds!

Has made a huge difference to the sound transmitted, exhaust is now the quietest its ever been!
Really glad I spent a little extra on those mounts.

New Tyres are ordered and should be fitted this week.
Got em through mytyres and chose the Uniroyal Rainsports.
Title: Re: Len405 - mk3 16v
Post by: Len on 14 October 2009, 09:05: Went to Basingstoke last evening and bought a strut brace off Russ, cheers mate! :wink:
Its a polished alloy adjustable one from FK, brand new never been fitted.
So thats the next job! Might have it done ready for Sunday. (Brecons drive)

Now this effectively my second car (have a W reg Passat 1.8t) and I stay gainfully employed this car will get some much needed performance upgrades!

Plans are bigger brakes, then clutch, then engine work.
Title: Re: Len405 - mk3 16v
Post by: Len on 26 October 2009, 09:23: Went to start the car to turn it around so I could fit the strut brace.
Battery flat! Grrrrr! :evil: :angry:

Then I discover that my battery charger is knackered! Grrrrr!

So off out to buy a new charger. Takes a long charge but it does seem to have held the charge, after leaving it disconnected overnight, so battery ok.

That means I have some electrical problem! Or it may just be the alarm discharging the battery. car was only stood for 12 days so I'm surprised its flattened the battery in that time!

Oh well will have to keep an eye on it.

I did manage to site the strut brace and plan how to fix the disturbed pipes!
Title: Re: Len405 - mk3 16v
Post by: Len on 28 January 2010, 21:02: Well have finally gotten around to fitting the strut brace!

Very fiddly!

The easy bit was setting it in position and marking the holes to be drilled.
Did that with a punch, well I actually ground an old thin screwdriver to a point and banged it with a hammer! :grin:

Started using a small battery drill and when that lost power used my big hammer drill on mains (sans hammer!)
That cut the steel like butter!

Then the hard bit!
Drilled holes with car on ground, so then had to jack up car and take wheels off.
Then the really hard bit of getting the bolts to thread up from under neath the strut housing!
Then just as difficult tightening up the nuts because the bolt head was turning so 2 lots of sockets!

I had drilled the holes the day before and painted the exposed surfaces and left them to dry overnight.
That took about an hour.
Next day took me about 3 hours in total.
Title: Re: Len405 - mk3 16v
Post by: Len on 05 February 2010, 20:42: Spose I'll have to add a pic or two! :rolleyes:

eventually..........
Title: Re: Len405 - mk3 16v
Post by: Len on 05 February 2010, 20:42: Gonna start the sills next week! :shocked:
Title: Re: Len405 - mk3 16v
Post by: Len on 08 February 2010, 20:20: Well not started those sills yet as I may do a bit of work on the passat!
So here are those promised pics of strut brace.

(http://i176.photobucket.com/albums/w170/Len405/DSCN0446.jpg)
Title: Re: Len405 - mk3 16v
Post by: Len on 08 February 2010, 20:26: A few more.

(http://i176.photobucket.com/albums/w170/Len405/DSCN0447.jpg)

(http://i176.photobucket.com/albums/w170/Len405/DSCN0448.jpg)

(http://i176.photobucket.com/albums/w170/Len405/DSCN0449.jpg)
Title: Re: Len405 - mk3 16v
Post by: Len on 10 February 2010, 14:02: Used a bit of soft tape ( think it was pipe repair tape) around that top ally pipe at the 2 closest places and a cable tie.
Title: Re: Len405 - mk3 16v
Post by: Len on 02 April 2010, 10:09: Have finally started the work on a smoothed tailgate!
Well I had stripped it and started sanding off the paint when the Mouse went pop!
Bought a replacement and a Dremel set so will get on with it again!

Will add pics soon
Title: Re: Len405 - mk3 16v
Post by: Len on 15 April 2010, 20:53: Made the cuts! (yesterday)
Got some sheet metal today so bit of cutting/bending then the welding up!
Have taken pics of work so far and will post as soon as I can be bothered to load them up! :grin:
Title: Re: Len405 - mk3 16v
Post by: Len on 16 April 2010, 09:50: Some photos -

The hatch stripped off and ready to cut!
Some surface rust around number plate lights!

(http://i176.photobucket.com/albums/w170/Len405/DSCN0454.jpg)
Title: Re: Len405 - mk3 16v
Post by: Len on 16 April 2010, 09:51: First cuts!

(http://i176.photobucket.com/albums/w170/Len405/DSCN0456.jpg)

not very straight! :laugh:
Title: Re: Len405 - mk3 16v
Post by: Len on 16 April 2010, 09:53: The other side was better but no photo! :cry:

So then I bent up the sloping sides so they are now kind of vertical.
(well at 90 degrees to the plate back)

(http://i176.photobucket.com/albums/w170/Len405/DSCN0457.jpg)
Title: Re: Len405 - mk3 16v
Post by: Len on 16 April 2010, 09:55: So here is both sides now ready to weld up and infill metal.

(http://i176.photobucket.com/albums/w170/Len405/DSCN0458.jpg)
Title: Re: Len405 - mk3 16v
Post by: Len on 16 April 2010, 10:00: Got some nice sheet metal from a local steel stockholders so will be cutting and welding that onto the hatch to fill the two holes!

Oh and a folded piece across the top to replace the plastic lip.

Next problem is going to be a hatch release button.
May be able to use the old one turned around 180 degrees but that depends how that positions the rod attachment!
Have thought of trying a Passat boot release as that would suit but again depends on the rod attachment!
Title: Re: Len405 - mk3 16v
Post by: Len on 05 May 2010, 16:59: Not done anything on this since last post as I got on and finished my pond/waterfall! :grin:

Will be back on it tomorrow!
Title: Re: Len405 - mk3 16v
Post by: Len on 18 September 2010, 16:50: Had a job to do on the Golf ( PS drive belt ) so thought while I was at it I would do a new cold air feed.
A couple of pics.

(http://i176.photobucket.com/albums/w170/Len405/DSCN0520.jpg)

I had a kind of trumpet end from out of the bottom of the airbox so made this fit into the mesh.

(http://i176.photobucket.com/albums/w170/Len405/DSCN0521.jpg)

Here's the shiny new ducting going into the airbox!
Title: Re: Len405 - mk3 16v
Post by: Len on 18 September 2010, 16:51: Seem to have the car bug again so maybe I'll get back onto that tailgate!
Title: Re: Len405 - mk3 16v
Post by: Len on 25 October 2010, 13:04: Bought a new interior!

Pics will follow soon!
Title: Re: Len405 - mk3 16v
Post by: Len on 07 November 2010, 14:20: Those new interior pics!

(http://i176.photobucket.com/albums/w170/Len405/DSCN0543.jpg)

(http://i176.photobucket.com/albums/w170/Len405/DSCN0542.jpg)

(http://i176.photobucket.com/albums/w170/Len405/DSCN0541.jpg)
Title: Re: Len405 - mk3 16v
Post by: Len on 24 January 2011, 13:02: Well we did fit the loom to wire in the Heated seats!

Well actually Billy did it with some little help from me! :grin:

That was during Xmas break.

Now having trouble starting so will have to turn it over more often!
Title: Re: Len405 - mk3 16v
Post by: Len on 16 February 2011, 13:19: Been to busy to post on here!

But did do some work on the smoothed hatch last weekend!
Well I cut some metal and tack welded one side piece to fill a big hole! :grin:
Title: Re: Len405 - mk3 16v
Post by: Len on 20 February 2011, 15:53: The tack welded piece didnt look right so off it came! Here's a reminder of the holes either side of the number plate recess.

(http://i176.photobucket.com/albums/w170/Len405/DSCN0565.jpg)
(http://i176.photobucket.com/albums/w170/Len405/DSCN0566.jpg)

Here is the new metal just placed in position

(http://i176.photobucket.com/albums/w170/Len405/DSCN0568.jpg)
(http://i176.photobucket.com/albums/w170/Len405/DSCN0567.jpg)
Title: Re: Len405 - mk3 16v
Post by: Len on 20 February 2011, 15:56: So next I weld them in place. Yes the welding is crap and one day I will learn to seam weld, but its solid and thats all that counts!

(http://i176.photobucket.com/albums/w170/Len405/DSCN0573.jpg)
(http://i176.photobucket.com/albums/w170/Len405/DSCN0570.jpg)
Title: Re: Len405 - mk3 16v
Post by: Len on 20 February 2011, 15:57: Then a touch of grey primer and a little filler!

(http://i176.photobucket.com/albums/w170/Len405/DSCN0576.jpg)
Title: Re: Len405 - mk3 16v
Post by: Len on 20 February 2011, 16:01: So now the next step is to sort the hatch latch!

Idea to use a Passat boot latch is out! Passat works on electric not air! :cry:

So next I will try sinking the old mechanism into the hatch, a cut and bend and a metal infill to rotate it about 80/90 degrees. And then of course see if I can make new connecting rods. Should be fun!

As a last resort I can cheat and get a solenoid one!
Title: Re: Len405 - mk3 16v
Post by: Len on 21 February 2011, 15:10: A mk4 one is electric as well! :angry:

Think I'm gonna tour a few scrappies before I try and fit the old one at a different angle.
Title: Re: Len405 - mk3 16v
Post by: Len on 27 February 2011, 14:32: Right the latch problem is now sorted.

Pictures and words.

(http://i176.photobucket.com/albums/w170/Len405/DSCN0577-1.jpg)

Thats how it sits as standard.

(http://i176.photobucket.com/albums/w170/Len405/DSCN0578-1.jpg)

Thats approx how I need it to sit.
Title: Re: Len405 - mk3 16v
Post by: Len on 27 February 2011, 14:34: Now this is the latch how it looks as standard.
You see the angled flange, which is on both sides, I cut that nearly all the way down so I could change the angle.
(http://i176.photobucket.com/albums/w170/Len405/DSCN0579.jpg)
Title: Re: Len405 - mk3 16v
Post by: Len on 27 February 2011, 14:37: So next I used a load of filler to hold the flange in the new position and this is how it sits in there.

(http://i176.photobucket.com/albums/w170/Len405/DSCN0582.jpg)
Title: Re: Len405 - mk3 16v
Post by: Len on 27 February 2011, 14:39: Here's a couple of pics with the connecting rods attached.

(http://i176.photobucket.com/albums/w170/Len405/DSCN0583.jpg)

(http://i176.photobucket.com/albums/w170/Len405/DSCN0584.jpg)
Title: Re: Len405 - mk3 16v
Post by: Len on 27 February 2011, 14:42: As you can also see I cut out a big sqaurish hole where the VW badge indent was!

So next will to cut and shape the flat metal plate that will cover the latch.
Will leave the VW hole til last so I have some access to the back of the latch and find a way of securely fixing it!
Title: Re: Len405 - mk3 16v
Post by: Len on 28 February 2011, 19:52: 20,000!! :shocked:

Well at least some take notice!
Thank you!
Title: Re: Len405 - mk3 16v
Post by: Len on 05 March 2011, 13:47: Did a bit of playing around today as you can see from the pics in Dub Rides.

http://www.golfgtiforum.co.uk/index.php?topic=59754.msg1730381#new

Also been measuring up the plate to go over the front and working out that it cant be dead flat, it will have to bow outwards in the middle.
Plus the top of the recess is not straight! So will have to curve that as well.
So much for the easy bit! :rolleyes:
Title: Re: Len405 - mk3 16v
Post by: Len on 12 March 2011, 12:23: Well it was relatively easy! But lot more work to get it to look right!

Oh and the plate has a double section edge, I bent over 1/2 an inch and hammered it flat. Did this for a smooth edge and a little extra strength as I will be pulling the hatch open with this plate.

(http://i176.photobucket.com/albums/w170/Len405/DSCN0591.jpg)

(http://i176.photobucket.com/albums/w170/Len405/DSCN0593.jpg)

(http://i176.photobucket.com/albums/w170/Len405/DSCN0598.jpg)
Title: Re: Len405 - mk3 16v
Post by: Neo Badness on 30 March 2011, 19:19: Nice. Good effort there. Always fancied having a bash at this myself but never have the time it seems :cool:
Title: Re: Len405 - mk3 16v
Post by: Len on 04 April 2011, 16:47: Well I have decided I dont like how it is! So that plate will be coming off!

I will have to find a way of sinking the latch in so it doesnt create a hump in the plate!
Title: Re: Len405 - mk3 16v
Post by: Len on 04 April 2011, 16:48: Fitted a new tyre front nearside and noted a water leak!
New radiator required.
Title: Re: Len405 - mk3 16v
Post by: Len on 28 April 2011, 12:58: New radiator was a complete and utter pain to do!
Bumper and all lights out! Crossmember off and coz I have aircon getting it out past the other rad was not easy!

Anyhow job done and all fine.
Title: Re: Len405 - mk3 16v
Post by: Len on 28 April 2011, 13:01: Smoothed hatch has reached an impass again!
Dont like the hump in the middle caused by the boot latch sticking up!
So will have to cut the plate off and sink the latch down in somehow!
Well I know how I'm going to do it, going to be reall fiddly!
Title: Re: Len405 - mk3 16v
Post by: Len on 28 April 2011, 13:04: New saga about to start!

Getting another engine to work on!
Rough plans are gas flowed head with bigger valves and new cams.
Bigger displacement, not sure how big yet.
Throttle bodies and tube exhaust manifold.
Plus an entirely new ECU system.
Not sure if I can run without a CAT yet, still chatting with ECU company about that!

Hoping to do bottom end myself, head off to somewhere.........
Then bolt on the rest! :wink:
Title: Re: Len405 - mk3 16v
Post by: Neo Badness on 28 April 2011, 22:24: Overbore and diesel crank to 2100cc?

Sounds like a plan though...
Title: Re: Len405 - mk3 16v
Post by: Len on 29 April 2011, 14:19: Maybe even a 100mm crank and 2.30 !!!! :evil:

Not certain yet but aiming to crack 200bhp!
Title: Re: Len405 - mk3 16v
Post by: Neo Badness on 29 April 2011, 22:25: Quote from: Len on 29 April 2011, 14:19
Maybe even a 100mm crank and 2.30 !!!! :evil:

Not certain yet but aiming to crack 200bhp!

100mm crank, does that not restrict the rev's to 5000rpm or something? From what I gather it will be a low revving torque monster though.
Mmmmmm punchy.
Title: Re: Len405 - mk3 16v
Post by: Len on 04 May 2011, 21:43: Not sure of actual revs etc and even final spec etc. As really I am still exploring the options.
Engine bloke said about this 100mm crank and 2.3 litres so yea why not! I prefer torque to revs!
Title: Re: Len405 - mk3 16v
Post by: Len on 08 May 2011, 12:36: Well the 100mm crank is way too expensive so back to a diesel :sad:
Title: Re: Len405 - mk3 16v
Post by: Len on 10 June 2011, 16:26: getting whole diesel engine for £150.
A brand new crank is around £365 tahts the best I was quoted.
And anyway even a brand new one would have to be balanced with the flywheel and may need some fine grinding!

So once car is pronouced fir for another year, (MOT) the engine build will start in earnest!
Title: Re: Len405 - mk3 16v
Post by: Len on 18 July 2011, 08:52: Engine build on back burner for now as I want to change the look.
Doing front bumper/headlights etc. as you can see in Dub Rides.
Then finish the rear hatch.
Will put selected pics in here when all done.
Title: Re: Len405 - mk3 16v
Post by: Len on 31 August 2011, 19:36: Final Pics of new front

(http://i176.photobucket.com/albums/w170/Len405/DSCN0648.jpg)

With old grille
(http://i176.photobucket.com/albums/w170/Len405/DSCN0649.jpg)
Title: Re: Len405 - mk3 16v
Post by: Len on 31 August 2011, 19:38: After Action I will finish the rear hatch as then I can get both front and back painted properly!

Then it will be on with those engines!
Title: Re: Len405 - mk3 16v
Post by: Len on 09 February 2012, 09:22: Well I have done nothing!

Have got hold of a lower glovebox so will fit that soon.

Still undecided about engines! Looking at VR6's as an alternative!
Title: Re: Len405 - mk3 16v
Post by: Len on 12 February 2012, 13:36: A few more pics.
With revisions to front.

(http://i176.photobucket.com/albums/w170/Len405/DSCN0655.jpg)

(http://i176.photobucket.com/albums/w170/Len405/DSCN0645.jpg)

Still not decided.
Title: Re: Len405 - mk3 16v
Post by: Len on 12 February 2012, 13:38: Pics of new sub and amp

(http://i176.photobucket.com/albums/w170/Len405/DSCN0652.jpg)

(http://i176.photobucket.com/albums/w170/Len405/DSCN0653.jpg)

(http://i176.photobucket.com/albums/w170/Len405/DSCN0654.jpg)
Title: Re: Len405 - mk3 16v
Post by: Len on 12 February 2012, 13:39: Pic of lower glovebox

(http://i176.photobucket.com/albums/w170/Len405/Photo0029.jpg)
Title: Re: Len405 - mk3 16v
Post by: Len on 14 September 2012, 12:53: Had to replace the CD autochanger.

Must think about doing a cambelt change, unless I get back to doing the other engine! :rolleyes:
Title: Re: Len405 - mk3 16v
Post by: Len on 19 February 2013, 20:06: The rear hatch stalled because I couldnt make the release button work.
So have gone against my wishes and will be getting hold of a boot popper!
The hatch will get done, in a few months time! :grin:
Title: Re: Len405 - mk3 16v
Post by: Len on 30 September 2013, 13:02: The engine build is now most definitely going ahead!
Well I have just paid out a LOT of money for JE pistons and Integrated Engineering conrods!
That does include all the rings and bolts etc. but with the dreaded VAT and shipping from USA over a grand! :cry:

means I cant back out now! will be doing all I have planned.
Title: Re: Len405 - mk3 16v
Post by: Len on 03 January 2014, 12:34: Have neglected this thread in favour of Dubrides but will record the full build up and costs here when finished.
Title: Re: Len405 - mk3 16v
Post by: Len on 26 May 2014, 19:56: Have been very remiss about posting photos so here are a few.
These were taken by Jean-Paul of JNL Racing who did the headwork for me.

This is the chambers cleaned
(http://i176.photobucket.com/albums/w170/Len405/HeadCleaned_zpsc0743950.jpg) (http://s176.photobucket.com/user/Len405/media/HeadCleaned_zpsc0743950.jpg.html)

This is the top cleaned
(http://i176.photobucket.com/albums/w170/Len405/HeadTopClean_zps56036de0.jpg) (http://s176.photobucket.com/user/Len405/media/HeadTopClean_zps56036de0.jpg.html)

Exhaust ports
(http://i176.photobucket.com/albums/w170/Len405/ExhaustCleaned_zpsb4040ce7.jpg) (http://s176.photobucket.com/user/Len405/media/ExhaustCleaned_zpsb4040ce7.jpg.html)

Inlet ports
(http://i176.photobucket.com/albums/w170/Len405/InletCleaned_zps8a3b7949.jpg) (http://s176.photobucket.com/user/Len405/media/InletCleaned_zps8a3b7949.jpg.html)

Throats cut
(http://i176.photobucket.com/albums/w170/Len405/ThroatsCut_zps9af10d32.jpg) (http://s176.photobucket.com/user/Len405/media/ThroatsCut_zps9af10d32.jpg.html)

Valve seats done
(http://i176.photobucket.com/albums/w170/Len405/Valveportsdone_zps29285ec8.jpg) (http://s176.photobucket.com/user/Len405/media/Valveportsdone_zps29285ec8.jpg.html)
Title: Re: Len405 - mk3 16v
Post by: Len on 26 May 2014, 19:59: Unfortunetly I do not have pics of the finished head with the cams in etc.
Because when I picked it up it was wrapped in cling film and told not to open it until I was putting the engine together!
Which was simply to keep dirt etc. getting onto the bearing surfaces!
Title: Re: Len405 - mk3 16v
Post by: Len on 26 May 2014, 20:03: Here is a view of the head, partly opened by me to paint the front to give you some idea of the amount of clingfilm on it!

(http://i176.photobucket.com/albums/w170/Len405/026_zpsb23b05a1.jpg) (http://s176.photobucket.com/user/Len405/media/026_zpsb23b05a1.jpg.html)
Title: Re: Len405 - mk3 16v
Post by: Len on 26 May 2014, 20:04: The block, wrapped also!

(http://i176.photobucket.com/albums/w170/Len405/027_zps9c779d28.jpg) (http://s176.photobucket.com/user/Len405/media/027_zps9c779d28.jpg.html)
Title: Re: Len405 - mk3 16v
Post by: Len on 26 May 2014, 20:05: The block with the new oil pump and oil cooler fitted

(http://i176.photobucket.com/albums/w170/Len405/005_zpsd582c9bc.jpg) (http://s176.photobucket.com/user/Len405/media/005_zpsd582c9bc.jpg.html)
Title: Re: Len405 - mk3 16v
Post by: Len on 26 May 2014, 20:09: An end view of the assembled engine ready to go back in

(http://i176.photobucket.com/albums/w170/Len405/Picture341_zps9e52d69b.jpg) (http://s176.photobucket.com/user/Len405/media/Picture341_zps9e52d69b.jpg.html)
Shows the vernier pulley!

And here is another view of the assembled engine and gearbox prior to hoisting in.

(http://i176.photobucket.com/albums/w170/Len405/Picture342_zps6981094e.jpg) (http://s176.photobucket.com/user/Len405/media/Picture342_zps6981094e.jpg.html)

And ready to hoist!

(http://i176.photobucket.com/albums/w170/Len405/Picture340_zps56dc66c8.jpg) (http://s176.photobucket.com/user/Len405/media/Picture340_zps56dc66c8.jpg.html)
Title: Re: Len405 - mk3 16v
Post by: Len on 26 May 2014, 20:11: Back in before all the fun started!

(http://i176.photobucket.com/albums/w170/Len405/Picture344_zps2d789349.jpg) (http://s176.photobucket.com/user/Len405/media/Picture344_zps2d789349.jpg.html)
Title: Re: Len405 - mk3 16v
Post by: Len on 26 May 2014, 20:20: Bit annoyed that I cant find some photos! I know I took some of the flywheel that spikenipple did for me.
I have the before pics but not the finished ones!