GolfGTIforum.co.uk
Model specific boards => Golf mk3 => Golf mk3 gallery => Topic started by: Dan_GTi8v on 21 September 2010, 17:39
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Just some pics for now to get an idea of what people think :)
(http://i147.photobucket.com/albums/r309/Danuk100/Golf%20sept%202010/CIMG0497.jpg)
(http://i147.photobucket.com/albums/r309/Danuk100/Golf%20sept%202010/CIMG0498.jpg)
(http://i147.photobucket.com/albums/r309/Danuk100/Golf%20sept%202010/CIMG04972.jpg)
(http://i147.photobucket.com/albums/r309/Danuk100/Golf%20sept%202010/CIMG0499.jpg)
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looks very clean. not a fan of the wheels but looks a nice motor
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yeah wheels are gonna change, but i'll most probably be changing to bigger discs after I stick the 20vt in so figured I may as well wait untill then and get some 16s :)
Body will be staying as it is though I just need to get the skirts and rear painted to match the rest. Gonna get quotes on a bit of welding I need on the sill to floor panels on both sides and a couple of rust patches on the doors, so i'll most probably get it done at the same time
Just need some wonga!
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go for 17's IMO would look :cool:
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Better wheels and lowered would be ace.
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Not normally a fan of bodykits but I quite like that rear bumper :smiley:
Looking good :afro:
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will look 10 times better with bigger alloys mate, nice clean car tho!
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Not a fan of the rear lights or valence and don't like the plates or the wheels, but looks like a very clean car and I'm liking your plans a lot :cool:
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Not keen on the rear valance or rims as has already been mentioned but looks like a nice ride with sweet plans :cool:
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I wasn't keen on the rear at first, just wanted the skirts to save messing about with all the original bits that were in a bit of a state, but the idea grew on me more and more :) I'm quite pleased with how it looks now though, I'm not usually a fan of bodykits but I always like to be unique :P
The lights were on there when I got the car, not sure what I'm gonna do with them atm
As for lowering, its already lowered 40mm on Wietec Ultra GT :P wouldnt wanna go any lower as I wouldnt be able to get into the carpark at work lol, and I dont wanna start making it impractical
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Started sourcing parts now.
Have a mapped and immob defeated AUM ecu, and a loom on the way so I can start trying to figure that out. I know a loom will most probably come with the engine but I'd rather have the management sorted before I get that far as once I start it needs to be in and out of the garage within a week. I promised my Dad lol! sucks not having a garage of my own :(
Also in the process of looking for an ABF flywheel (think I've found one) 16v engine and gearbox mounts, and 16v master and slave clutch cylinders
After getting paid at the end of the month I'll be getting some VR spec engine mounts, qPeng downpipe and possible a merc sprinter intercooler, though I need to go measure up to make sure it will all fit
Finally it feels like I've started :)
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Sounding good. You will be really really pushed to be in and out in a week, but if you do more research that would ever think you'd need and put the time in during that week, you might just get it done, or at least drivable.
I'll let you know how I get on with wiring this coming weekend :)
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I'll have my dad helping, back in the early 80s he had an xr3i that he took apart and rebuilt so I'm hoping that will be a bit helpfull :P
I'm gonna try and get as much done as possible before taking the car down, so if all goes to plan I shoud be able to drive down thereand take old engine out, replace the brackets, mounts, etc and bolt new engine in the first day, then spend the rest of the week f**king about to get it running!
I've been doing a lot of reading up and asking lots of questions (not much else I can do atm!) so I'm hoping I'll know enough to get most of it done without too much guess work. Only bad thing is the more research I do the longer the shopping list seems to get!
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Got a few bits this week, abf flywheel came and some abf brackets on the way soon. Havn't got round to starting the loom yet but hopefully will start this weekend
Managed to de arch today, but uncovered quite a bit of rust! Birthday next week so I've asked to get it sorted for that and depending on the price maybe get the couple bits of spraying done that needs doing :)
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This is sounding like a regular read for me to keep upto date on what you are doing, like it so far. Are you going to keep it gti looking or advertise the fact that you are running a 20vt?
I looked at getting a merc intercooler for my mk2 but i decided to go for something a little small but does the job just as well plus i found it loads easier to fit as the merc one is farely big.
Here is what i bought and after mounted:
(http://i966.photobucket.com/albums/ae146/peej1981/My%20StreetSleeper/IMAG0390.jpg)
(http://i966.photobucket.com/albums/ae146/peej1981/My%20StreetSleeper/IMAG0432.jpg)
(http://i966.photobucket.com/albums/ae146/peej1981/My%20StreetSleeper/IMAG0434.jpg)
I bought it off ebay for £70, small, light weight, good for 350bhp and the best part is its shiny :grin:. Maybe worth looking into as think you will find it easier to fit and have more options as to were to fit it, i.e high or low :smiley:
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^^Are you not blanking too much of the radiator with it mounted like that. :undecided:
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No as i am running a vr6 rad which is a lot bigger then the standard one and is able to handle it, the intercooler is only covering the top section of my rad leaving the bottom free for air and even then the air being pushed through the intercooler seems to be going through to the rad too, the engine temp seems to sit nicely at around 90 and never goes above it so alls good. I prefer this intercooler as it is a lot easier to work with and mount, the only mod i had to make for mounting it was to cut a section out of the slam panel. Plus the other reason for it is that i didnt want it to be on show either (sleeper look), i have changed the grill now to a single light grill and you cant really see it now :cool:
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loking forward to updated on the engine install. sounds like you and your dad will crack it in no time
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ebay FMIC ftw :cool:
loking forward to updated on the engine install. sounds like you and your dad will crack it in no time
+1 can't wait to the see the updates of the old engine out, new one in, etc!
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This is sounding like a regular read for me to keep upto date on what you are doing, like it so far. Are you going to keep it gti looking or advertise the fact that you are running a 20vt?
I wont be actually doing the conversion untill the new year unfortunatly :( Up untill then I'll just be getting all the parts together and sorting as much as I can before dropping the engine in
Probably wont keep it GTi looking, aleady took the arches off and replaced with cl trim and the front badge is gone so all it really has is the rear GTi badge, which will probably come off :P Not gonna go out of my way to make it look like a conversion, but you will more than likely be able to see the intercooler so anyone who knows what there looking at will know its a turbo. Going for the same fmic LL has used and mounting it in the same place :)
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This is sounding like a regular read for me to keep upto date on what you are doing, like it so far. Are you going to keep it gti looking or advertise the fact that you are running a 20vt?
I wont be actually doing the conversion untill the new year unfortunatly :( Up untill then I'll just be getting all the parts together and sorting as much as I can before dropping the engine in
Probably wont keep it GTi looking, aleady took the arches off and replaced with cl trim and the front badge is gone so all it really has is the rear GTi badge, which will probably come off :P Not gonna go out of my way to make it look like a conversion, but you will more than likely be able to see the intercooler so anyone who knows what there looking at will know its a turbo. Going for the same fmic LL has used and mounting it in the same place :)
Cool beans. That's the way get more info and gather as many parts as you can. You'll still forget things. I've been telling my mate to get this and that and that is all you need. Then the next week I'm like, "Hey, you got new rear wheel bearing? You'll need them." Haha, its hard to think of everything you need and that's what takes time with the conversion, ordering parts/waiting.
Its normally a really important part and without it you can't do anymore work. Turns out the time you are working is Saturday Eve! That's always the way, need to wait AGES until you get the part.
You live near GSF, EuroCarParts, etc?
Good stuff on the cooler. Needs a little bit off the slam panel (VR slam panel) and a bit off the bumper.
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yeah theres an ECP 2 mins from my flat and a gsf couple of miles away. I'm only doing the engine on mine as its already a GTi and I've done the suspension with Wietec's with VR top mounts and 16v exhaust system already
Pretty sure the full list of what I need is
*Cable to hydro clutch parts (master cylinder, slave cylinder, and fluid lines)
*Engine and Gearbox brackets
*Engine and Gearbox mounts
*Engine AUM
*Gearbox 02a
*Intercooler
*Boost pipes
*VR Clutch
*ABF Flywheel
*Downpipe from QPeng
*Sports cat (Miltek)
*MK4 PAS Pulley
*SAI block off plate
*Forge TIP
*Forge 007 recirculating dump valve
and the future will bring 16' monzas and 312mm brakes, bodywork sorted and the black ABS plastic painted properly, and a new interior (thinking about some cloth recaros not really a fan of leather, but might changed in time :)) but that can come after the engine work is finished (and I have some money!)
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Got some pressed plates and autohaus wolfsburg surrounds today from dubmeister. Depending how fricking cold it is tomorrow I might give the car a wash and get some pics with the plates and de-arch
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if you get stuck with the loom give me a shout. I have a man who can make an oem mk4 loom a plug&play job in to pretty much whatever car you like.
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Sounds good Dan. You'll need various lengths and sizes of silicon/vacuum hosing. You can ebay that and get it to you in a couple days no worries.
Don't forget a VR/16v slam panel and rad. Bigger rad and a big enough gap for the fmic to fit in. You can use a 8v i think, just means more trimming for the cooler and a smaller rad.
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or do wat i did cut the 8v slam panel up and make a vr rad it haha
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if you get stuck with the loom give me a shout. I have a man who can make an oem mk4 loom a plug&play job in to pretty much whatever car you like.
I found a good guide to the loom on clubgti, its for a mk2 but been told its exactly the same for the mk3 as its the same fusebox, just need to check the connections match up on one of the plugs
When I get round it doing mine I may do a guide for it as it seems to be a popular thing to do. If it all goes bang then I might have to take you up on your offer :P
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if you get stuck with the loom give me a shout. I have a man who can make an oem mk4 loom a plug&play job in to pretty much whatever car you like.
I found a good guide to the loom on clubgti, its for a mk2 but been told its exactly the same for the mk3 as its the same fusebox, just need to check the connections match up on one of the plugs
When I get round it doing mine I may do a guide for it as it seems to be a popular thing to do. If it all goes bang then I might have to take you up on your offer :P
Yer that looks like a good guide to steal some info.
+1 on topher's comment. I might be hitting you up about the loom, see how I get on with finishing the wiring. I'm worried as so far it seems to be far less complicated than I thought :D
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Not only was it fricking cold, it was fricking snowing! So needless to say I got nothing done. Guess we'll see what tomorrow brings :)
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Starting to think this time of year is not a good time for a conversion, especially since I dont have a garage :P
Got some brackets in the post today though, think its the front and rear engine brackets bit I'm not 100% sure lol
(http://i147.photobucket.com/albums/r309/Danuk100/20vt%20conversion%20parts/CIMG0499.jpg)
Gonna paint them up before fitting
What other brackets do I need, think its just a gearbox bracket is that correct? Haynes says theres 3 engine but not sur eif they are including the gearbox in their total
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Left one is the front mount (for box and engine)
Right one is the rear engine mount (left side of bay when looking the car face on)
The 3rd one is usually on the gearbox. All the 02A boxes I have seen have had the mounts on them.
The winter is a great time to clean/paint as many pieces as you can and do as much prep work possible, for sure :afro:
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for box and engine, you mean it bolts to both of them? :P
Its frustrating with the weather now, I'm getting to a point where I can start doing stuff and its always to f**king cold! plus as I work nights its a pain in the ass as im getting up around 4pm and its already f**king dark!
Hate this time of year
Excluding the gearbox and engine itself as I'm not getting these untill its ready to go in, all I need to get now is the clutch, mounts, cat, and downpipe. Convinced the GF to get me an intercooler for xmas :) and the piping can can be sorted once its all in and I can see whats needed
Fighting the urge atm not get the new stringed mustang guitar for rockband 3 lol, but its so fricking cold I'm just sat indoors dreaming about 1.8ts and its not good for my health! (nearly bought it today but the release dates been put back ANOTHER week ffs!)
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Lol at new guitar - I know, I know :D
Yeah the front mount bolts on with the starter.
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Update is long past due here I think
Aiming to get it done sometime in March. What I have so far is
ECU
Brackets
Downpipe
Intercooler
Boost Piping kit
16v Hydro Clutch setup
ABF Flywheel
Forge SAI Block plate
Engine Loom
Once I can source a mk4 pedal sensor plug I'll be sending the loom off to get that made plug + play (best £100 I'll spend in a while!) so all I need now are the mounts and a VR6 clutch, and ofcourse the engine and gearbox which will be got once everything is ready to go in. Dont think im forgetting anthing?
Something I thought about earlier today is how the 16v hydro parts actually fit to the car, I know the master piston clips to the back of the pedal, but I have no idea about the rest of it! Can anyone enlighten me? :)
Getting the wiring sorted is a big weight off my mind and has made me really feel like I'm getting somewhere now (even though I havn't actually done anything) it's all basically waiting on when I can get the loom finished, been told march shouldn't be a problem so if all goes to plan I only have another month to go woohoo!
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£100 is a great deal on the wiring bud, I'm still doing it and not sure if its going to work. I reckon it will but I'll see. Well worth the money though getting it done, especially for that price!
Coming along well though, what 02A box you going for? Don't know about the hydro clutch, its easy to pipe in in the engine bay, just run brake line from the box to the pedal and it gets its source of fluid from the brake fluid reservoir I think. Might need a new reservoir?
Rubjonny would be the man to ask!
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Yeah I've been talking to Rubjonny a lot, if I was him I'd be sick of me by now lol he must have a lot of patience :P It's actually him whose doing my wiring for me :) I just need to get a mk4 throttle pedal and sensor wiring plug from somewhere, pedals easy enough but the plug is proving to be a b@stard to find
Regarding the gearbox, tbh I havn't given it much thought lol I dont know how many different ones there are for the 16v mk3, most I see are CDA though so probably that one?
Also regarding the clutch, yeah your right about how to plumb it all in, may need a new reservoir it depends if mine has the blanked off bit that the 16v one has or not. The bit im not sure about is how the cylinders themselves are held in place. The closer I think I'm getting the more things I find that I need to know!
Given myself 12 days off work in march starting from 18th so I'm hoping by then I'll have everything I need and know everything I need to know to crack on and get it finished in time!
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CDA is a G60 box. Just search 02A gearbox ratios in google (or similar) and you'll get links to forums listing all the different 02A boxes and ratios, etc.
Cylinders are usually bolted in place via two bolts.
You'll find that, I keep learning things and finding things out when it was too late!
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Conversion has finally started!
My 12 days off in march were spent sat on my arse waiting for parts to arrive, which I should of taken as a sign of how well things were gonna go lol
Started yesterday, took a day to get all the front off and the gearbox out, then today was spent trying to get the engine out. f**king nightmare! haynes can f**k off with their 4 spanners! Hardest part was seperating from the exhaust, ended up grinding all the bolts off, and took a facefull of anti-freeze in the process (yes we did drain the system! but was a load in one of the pipes)
Now its all out though, so from now on will just be working with new nuts and bolts, and relativly new parts. No more of this pissing about with rusty old pieces of crap!
I'll be working tomorrow untill 1, then its all systems go again, tomorrows job is changing the mk3 pedal for a mk4 electronic throttle, fitting clutch cylinders, removing all the sai n112 n249 and evap system from the 1.8t, fitting brackets and mounts, and that will probably be enough. Cant do much more than that as I'm waiting for a starter motor to arrive (forgot the 020 starter wont fit 02a!)
Also need to work out how to wire the clutch switch wiring from the new loom into the brake switch on the mk3, may leave this untill thursday though, also need to label up the new loom
Pics will follow, havnt taken a great deal yet but tbh not much has happened looks wise, I have them on my dads camera atm so will try and get some up tomorrow. Oh and I also need to have a word with Venom, recieved a new K&N apollo cold air intake today, except it wasnt in the bloody box!
Good times :grin:
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^^^ sounds great!... is this going to be a fast moving project then, don't forget to post illustrated updates to keep the punters happy. :grin:
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yeah planning on finishing it by next week lol, I'm back to work on the 16th so it needs to be finished by then. I'll try and get lots of pics but cant promise anything as most of the work seems to get done when we're rushing to finish something or under pressure from the women!
Deffinatly planning on lots of pics though :cool:
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OK, pics so far as promised. Didnt get much done today due to work and had to scrap the old engine, got £7 rofl, better than nothing though needed shot of it asap
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/DSCF0972.jpg)
Closer look at the soon to be mullered 2.0 8v
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/DSCF0970.jpg)
Bumper off
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/DSCF0973.jpg)
Radiator off
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/DSCF0974.jpg)
Gearbox out after a LOT of F'ing and blinding!
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/DSCF0975.jpg)
Here its lifted on the hoist but the manifold is still connected, This is what we spent most of the day trying to remove, in the end we just grinded it off lol
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/DSCF0976.jpg)
Here its lifter properly and all seperated
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/DSCF0979.jpg)
And finally here it is in the back of the land rover!
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/DSCF0980.jpg)
Now for the new beast! Its an AUM from the mk4 GTi, all the sai n112 n249 and evap has been removed and forge blanking plate fitted, but here you can see it still connected. Can also see my new DPA box in the corner
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/DSCF0971.jpg)
And heres my first job for tomorrow, trying to remove the old and fit this new ABF cable shifter.
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/CDw1bqQWkKGrHqVi0E0GpQqZ0BNPtjGBw_12.jpg)
Other jobs for tomorrow include bolting the 02a starter to the box, changing the clutch for the VR6 one and fitting an abf flywheel, trying to somehow bodge on the mk4 pedal, and trying to lable up the loom ready for when we drop the aum in (planning for saturday)
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Finally some pics! :cool:
Good work so far, we want more pics and lots of em with this build. good luck dude :afro:
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Nice bud, glad to see you've made a start on the car :)
You keeping the aircon?
Piccies ftw :D
Let me know if you need anything bud ;)
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Just on a break atm lol .Thx for comments :)
LL yeah I'll be keeping the aircon compressor connected but wont be rigging it up just yet, all the inside stuff is already there but I had to butcher the old pipes a bit to get them off so i'll be getting some new ones at some point
All I've done so far today is cut out the old throttle pedal and fit the clutch master cylinder. Didnt take any pics of this as its fairly straight forward but I'll get some later when I decide how I'm gonna fit the mk4 pedal, also need to go down to halfrauds and get a torx bit for the new clutch
Cant remember what else I was gonna do lol but I'll take some pics of it anyway if I remember :P
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Don't forget to fit a new receiver / dryer to the air con system when you rebuild it.
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is that the can that sits in the front bottom corner on the drivers side?
Took a few pics of the new forge dv that I got after breaking the old plastic one, and a couple of other bits and pieces, but left the camera in my dads garage :(
Fitted the new vr mounts and pulled all the carpet and stuff out the drivers footwell to investigate further about the mk4 pedal, will get a better look in the light and see what we need to make up to mount it. Also need to go back to halfrauds and get a refund for this torx i bought lol its the wrong thing, I need a 12 point spline bit but need to look up what size
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OK progress for today
1.8t with the SAI n112 n249 and evap removed, lookes a bit tidier :)
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/DSCF0982.jpg)
And heres the pile of crap I removed from it
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/DSCF0983.jpg)
Managed to break the top off the diverter valve in the process :(
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/DSCF0981.jpg)
Sounds like a good time to get a Forge 007p!
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/DSCF0984.jpg)
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/DSCF0985.jpg)
Next I started work on the new engines clutch and flywheel setup, needed an M6 12 spline socket to take the old clutch plate off, ended up buying a set for £16 with included 7 sockets M4 up to M14 which was a good price I think, and also lucky as after I got the clutch off I needed an M10 spline to get the flywheel off. No pics of me taking it off but got some of the new flywheel and new clutch kit
Before
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/DSCF0986.jpg)
After a good clean
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/DSCF0987.jpg)
New Sachs clutch kit
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/DSCF0988.jpg)
I managed to get the flywheel on but couldnt get the clutch on as I need some new bolts, the AUM bolts were too short to reach the thread on the ABF flywheel.
Tomorrow could be the day the engine goes in! Though not sure as we may need to move the brake servo to fit the bracket for th new throttle pedal, and we wont have the bracket made up untill sunday.
Other jobs for tomorrow include removing the old cat, dropping the old shifter and fitting the new cable shifter, fitting the clutch if I manage to get new bolts, and depending how hard it will be moving the servo with the engine in possibly dropping it in!
Hoping to get a lot done tomorrow :)
And after looking at the post preview, before anyone says it, no it isnt a real Monet in the broken DV pic :grin:
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OK, no engine dropping today, but did get some other stuff done.
Made up a template for the throttle pedal which will be made tonight, removed the cat, swapped over the shifter for cable, and trial fitted the new downpipe. Also spent ages getting some stones out of one of my drive shafts as it dropped down on the stones while we were pushing it back :rolleyes:
Also had to bodge up a kind of bracket to hold the shifter in at the front as its a slightly different design. May get some more pics of progress tomorrow if I remember :)
Oh and fitted a new dipstick guide as I snapped the old one :grin:
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ok, progress has been made! Left the camera at the garage so no pics from today but have a few from the last couple days
16v cable shifter in place, with a bracket bolted at the front to stop it dropping down, 8v had a single bolt here but the 16v is slightly different design, may change it b4 i finish up but it does the job for now
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/DSCF6003.jpg)
and here's what I've been doing for the most part since last update. Wiring! as it stands now I have all the old wiring out of the way, whats being kept has been intergrated with the new loom and its all in, taped up, and tucked away nicely. but this was it yesetrday morning
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/DSCF6002.jpg)
Also what I dont have pics of is the pedal bracket I've made up. its pretty good if I do say so myself! Pics are on the camera but as said I left it at the garage so i'll try and get them uploaded tomorrow. I've also taken out all the crap thats not needed on the aum (throttle cable clutch cable ignition coil and some aircon bits and pieces) and fitted the new hydraulic clutch master cylinder
First job of the day tomorrow is to go to VW and pick up the flywheel and clutch bolts I ordered and also a new brake pedal position sender clip which I snapped when removing the servo. After the servo and brake master cylinder are back on and pipes are secured I'm pretty sure I'll be set ready for the engine to go in, then I get the fun job of trying to work out where everything goes!
Oh and I also had to order a new radiator fan control relay as my current one is a 2 plug aircon unit, but new loom has the plug for non aircon. Still deciding wether I'm gonna mess about with aircon at a later date or not
And thats where things stand so far :)
Bring on the trumpets! tomorrow!
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Proper preparation prevents piss poor performance!
I didnt have the right tool for the new clutch bolts and shops were closed by the time I realised so nont engine dropping today, its 100% going in tomorrow though
Heres the new pedal bracket I made up
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/DSCF6021-1.jpg)
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/DSCF6022-1.jpg)
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/DSCF6023.jpg)
Its a pretty snug fit, havn't fit it in yet as I'll need to mod the carpet a bit and also wanna wire in the plug first, its pretty good though sits just lower than the brake pedal and when fully pressed the stop underneith just barely touches the plate. the bracket itself slots in between the raised bit where the wheel arch starts and the other black piece of metal on the bulkhead which I forget what its for, possibly part of the pedal box
and heres a couple of the engine as it stands now, need to mod one of the pipes running to the intercooler so it runs down the other side, and also need to fit the rear engine bracket and gearbox once I get the tool needed for the clutch.
I snapped one of the rear bracket bolts in the block trying to fit it earler today so need to get that out first before refitting it :(
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/DSCF6038.jpg)
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/DSCF6039.jpg)
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looking good
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Today was the day, and it didnt go as well as I'd hoped :(
But first things first
Day was started by going to a tool shop and getting the right tool for the clutch bolts
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/DSCF6042.jpg)
guy in the shop said it was a really weird size, m7 and the head is something like 11/32? cant see myself ever using that socket again :grin:
so got back the the garage and cracked on
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/DSCF6043.jpg)
Action shots!
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/DSCF6045.jpg)
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/DSCF6046.jpg)
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/DSCF6044.jpg)
Heres how the bay looked b4 it was dropped in, wiring all nicely tucked away. Could do with a clean though, but no time for that!
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/DSCF6047.jpg)
Dad posing
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/DSCF6049.jpg)
More action shots!
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/DSCF6051.jpg)
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/DSCF6052.jpg)
And now the bad news. Front engine bracket is wrong :( the engine sits too high at the front and looks like its tilting backwards, its also really tight with the bonnet
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/DSCF6053.jpg)
You can just see in this pic where the bracket doesn't sit fluch on the mount. The bolts just in to hold the engine in place while we moved it back round the side of the house.
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/DSCF6054.jpg)
I've had enough of pissing about with ebay and scrappies for one week so just ordered the bracket from VW. £50 or there abouts but at least I know the right part is on its way. Wont be there till monday so in that time I'm gonna get everythign else done and at least get it running so all we need to do on monday is change the bracket and its all finished :)
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No fcuking about! :cool:
Looks like this will be loads of fun when you are finished with it! :grin: :cool:
Good progress so far, keep us updated...with lots of photos :smiley:
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Time is becoming an issue now, need this finished by Thursday or I'm walking to work! Fairly confident I'll have it driveable sometime tomorrow, though I've decided to bypass the intercooler for now untill I order some proper pipe and hose instead of arsing around with this universal kit which is clearly inadequate!
Anyway on with the update
Forgot to get a before pic, but heres the new bracket fitted with the old one held up against it
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/DSCF6062.jpg)
More new bits! MAF, MAP sensor and a pipe to mount it in from Forge. All together the sensors and bracket put me back £270 from VW, but as said before I dont care anymore just need it finished :grin:
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/DSCF6063.jpg)
Apollo cold air intake kit from Venom, £140 delivered
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/DSCF6071.jpg)
Heres how the pedals look atm
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/DSCF6067.jpg)
Intercooler fitted
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/DSCF6068.jpg)
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/DSCF6070.jpg)
May need to trim these a bit :P
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/DSCF6069.jpg)
And heres how the bay looks b4 I finished today
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/DSCF6064.jpg)
Need to tidy this lot up at some point but for now as I said just need it running, gonna route the tip the other way like it is standard and just hook it up to the throttle body
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/DSCF6065.jpg)
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/DSCF6066.jpg)
I'll most probably order a load of pipe and hose from silicone hoses in the next couple of days, back to work Thursday and then off to spain on the 25th so wont have much time to do anything about it untill I get back
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Cracking progress. :cool:
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Top work mate, is that your mums kitchen the engine cranes sat in :laugh:
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Excellent work fella!
Loving the "no oil!" chalked on the inlet manifold! :laugh: :grin:
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what intercooler you using mate?
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lol yeah we took over the kitchen for the week :P No its my Dads garage dunno what the idea is with the tiled floor and kitchen cupbords though :grin:
that 'no oil' is actually painted on, dunno what the idea behind that is either but gonna be fun getting it off
Intercooler is just a £50 job from ebay, its a universal one from Toyosports
Thanks for the comments :)
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bodged up my turbo intake pipe with some silicon sealant just untill I do it properly, hope it holds :P
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/DSCF6072.jpg)
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/DSCF6073.jpg)
Managed to reoute the piping for throttle body to turbo intake, took ages! dont wanna think how long its gonna take to rig it all up properly to the intercooler!
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/DSCF6074.jpg)
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/DSCF6075.jpg)
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/DSCF6076.jpg)
Deffinatly need to do something with this lot as well, intake has crap all around it and will no doubt perform badly, and it also looks a total mess!
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/DSCF6077.jpg)
Thats all for today, tomorrow I just need to tidy up and hook up the alternator and starter, then I think the engine is done for now. After that I need to link up the downpipe to the rest of the system and put in the throttle pedal and finish that up. Hoping to be up and running by lunchtime but even I dont believe myself when I say that :grin:
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well needless to say it isn't running yet lol
Messed about a bit with the engine bay today, wired up the alternator and finished up other bits like connecting the starter and checking all the grounds are done. Managed to get the air intake into a better position behind the battery, think I'm gonna put the coolant and water bottle on the other side, then I can run some ducting for the intake around behind the battery and hook it up to one of the lower vents
Also ordered a load of silicon hose from apmotorstore.com, a bit cheaper than siliconhoses.com and has the other bits and pieces I need like some radiator hose and vacuum piping so ordered it all from there, should be here on Friday so if I get all the bits in the drivers seat done it should be a pretty quick job once it arrives.
Fitted the throttle pedal today, I'll finish up all that lot and I'll update tomorrow with pics :)
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forgot the camera yesterday so pics will come when I'm finished today. All my piping came today so will have a look at that as well. forgot yesterday was a bank holiday :rolleyes:
pedals are all done now just need to run the brake and clutch wires for the ecu to the brake light switch and installed a new brake light switch to the clutch pedal so it knows when its being pressed :)
Having a minor issue with the brake switch though, when I reconnected it all up to the servo the pedal seems to not travel back up as far as it did before so it doesnt quite reach the switch, which puts the brake lights on constantly as it thinks the pedal is pressed. see what happens once the brakes are bled and vacuum is back on the servo. fingers crossed :)
On the plus side though I turned it on yesterday just for a few seconds to see if it was all done right, started first time! :cool:
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Great news on it starting first time :cool: get some pics up so we can really see the progress :afro:
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some kind of tropical rainstorm going down in middlesex so pics tomorrow :)
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Middlesex? Whereabouts are you?
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Living in Chertsey which is technically Surrey, but the cars at my dads in Shepperton :) not far from you at all :P Drive through Ashford on my way to work depending which way I go
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Well done gtting it going first time bud, and looking tidy so far. think this is the route im going down soon.:afro:
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Where do you work then?
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Well done gtting it going first time bud, and looking tidy so far. think this is the route im going down soon.:afro:
Cheers :) Was actually pretty amazing lol best I was hoping for was for it to not blow up!
Where do you work then?
Work at Heathrow cargo terminal for Air Canada :)
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Cool sweet as,
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Just a quick update, going to Spain for a week tomorrow so heres how it stands atm. Pretty much ready to roll just need to move the coolant bottle over and work out the ducting for the air filter
Bad news is I found a pretty bad fuel leak when trial running and on further investigation founbd a big gash in the black fuel line. Managed to have about 5 litres leak out of it before I managed to stop it! luckily I caught most of it in a fuel can though, so first job on getting back is to get a new fuel line
Anyway, heres pics of how it stands now
Need to sort out these pedals at some point, previous owner bolted some universal momo pedals that are falling off
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/DSCF6083.jpg)
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/DSCF6085.jpg)
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/DSCF6086.jpg)
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Any updates my man? You driving this yet?
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loving the project, i wanna do this to mine next year hopefully, how much do you rekon it's cost altogether if you dont mind me asking?? looks like a pritty epic job!! good work
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Any updates my man? You driving this yet?
Just got back from Spain Monday night so plan was to order the new fuel line and get it done on Wednesday (Today) but the part is a 2 day order apparently so I'll be cracking on first thing tomorrow morning
loving the project, i wanna do this to mine next year hopefully, how much do you rekon it's cost altogether if you dont mind me asking?? looks like a pritty epic job!! good work
Not sure exactly, I'm guessing somwehere above £2500 but below £3000. It could be done for less than I spent but towards the end time became more important than money so started buying new instead of hunting around scrappies etc
Tomorrow should be the day its finally running, not got much to do to get it on the road now main thing is putting the new fuel supply line in, adjusting the gear linkage and a couple of wires need splicing in for the brake and clutch pedals. other bits and pieces need doing like the intercooler pipework but not too worried about them untill its at least on the road
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Its all going to sh!t!
Fuel pipe was an order from Germany which the guy at VW kindly didnt tell me, so it wont be here till next week! Doubt I'll get anything done today now as it cant move till I get the new pipe anyway, and as I'm on nights tonight and tomorrow think I'm gonna get some sleep and figure out how I'm gonna get to work next 2 nights and couple of day shifts next week
Not a happy man today :(
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looking good bud keep the updates coming
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aaaaaahhhhhh, shoulda ordered your parts b4 u got ur speedos off to spain. :laugh: :laugh:
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lol yeah cheers for the sympathy, weather was better over here anyway! Looking forward to finally having it on the road and giving your mk1 a good thrashing though :grin:
Sorry for lack of updates recently, now I'm back at work its getting harder to find time to finish this off. Today could be the day though! I'll update later with pics and stuff but for now I'll just say I've been battling a few unexpected problems :P Hopefully I'll be taking it for a test drive shortly (and probably find a load more things that need doing!)
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managed to drive it home :) got about 5 minuites down the road gave it a blast and the silicone sealant I used to bodge up one of the boost pipes popped off :( also getting a bit of exhaust rattle and coolant light is flashing, but not bad I'm pleased with it :) First job in the morning is to measure the bore size and order a reducer silicon pipe for the broken boost pipe, and have a look at the exhaust to fix the rattle
ordered a cold side dv relocation from forge today so once that gets here I can plan on what I need to get the intercooler rigged up properly. Got a bit late for pics so I'll try and get some up tomorrow
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Seeing threads like this has really got me contemplating having one of these engines in my valver at some point.
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Seeing threads like this has really got me contemplating having one of these engines in my valver at some point.
Go for it :smiley:
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Just dont do what I did and do it to your daily that you need to get to work in lol. I probably would of been fired without my fiancee and dad letting me borrow their cars
I've really enjoyed doing it though, already thinking about the next one! Though I should probably finish this one first :grin:
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Good luck with getting it finished. :afro:
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A 20vT is something I eventually want in the Anni. Looking forward to seeing this finished. :cool:
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Cheers for comments :) Just ordered the reducer pipe and clamp so that and the forge piece should come around the same time, I'm working sat sun mon nights this week then back to days on thursday so doubt a lot will get done this week but will fit the reducer and fix the rattle at least
Pics will follow some time tonight, need to get back round to the garage and pick up the jack and axle stands so I can work on it here, and fiancee wants to go shopping. Be taking her clio as she doesnt trust my mechanical skills lol
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No update yesterday as I was feeling far too lazy, but had some good news today, Mr. Postman turned up with a Forge coldside DV relocation kit and a silicon reducer pipe! Pretty good considering both were ordered using normal postage, reducer was only ordered yesterday afternoon as well :cool:
So I'll start with what happened over last couple weeks. I still havn't heard anything from VW about my fuel pipe, but last Thursday I got tired of waiting so attempted to make something up for the time being. Didnt get any pics as I figured I'd have the proper pipe by now and would take pics of that , but its basically a bit of rubber hose about 50mm long attached via a hose clip to a long piece of fuel resistant nylon hose that runs the length of the car the same route the original piece takes. Rubber end fitted to the fuel filter and other end to the original rubber hose to the fuel rail. It actually turned out pretty good so I'm in no rush to get the VW piece, but will still be fitting it when they get their finger out
So I thought this was it finished, started up, checked for leaks etc, and all looked good. Got in the seat and tried to move it, moved back a few inches, tried first, second, third, all good so far, then all of a sudden the gearstick went lose and I couldnt find any gears! f**ked about with the tower for an hour or so trying to figure out what was wrong, guessed it couldnt be the gearbox as it was fine a before so it must be the tower. Took the tower off and found that when I turned the lever the actual rod on the tower that connects to the box wasn't moving
Now after all that typing here are some pics!
Took the tower apart and checked all the parts...
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/DSCF6155.jpg)
and found this
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/DSCF6170.jpg)
The hole in the middle is supposed to have a spline that links it to the shaft so when the lever is turned the whole thing turns, but as you can see its completly rounded off, must of been well on its way out before I got it and the couple of gear changes I made were all it took to kill it
This is the part its supposed to join onto, you can see the spline its supposed to match up with
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/DSCF6157.jpg)
So anyway I ordered a new tower from a mk4 1.9tdi and fitted it, problem solved :)
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/DSCF6158.jpg)
and thats what happened last week! I'll update in a min with whats happened so far this week
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So, last update took me up to Tuesday. Had work Tuesday Wednesday so nothing happened those 2 days. Driving dads automatic freelander was an experience I'm not too keen on having again anytime soon :grin:
Work continued on Thursday. The morning was spent playing around with the linkage trying to get all gears feeling right, not sure whats wrong with it but atm I can find all gears easily but the position of the gear lever doesnt seem to move very much, looking at the stick its hard to tell if your in 1st 3rd or 5th, but its working at least so good enough for now
Had lunch and had a bit of time to myself killing nazi zombies on dads xbox :grin: then wired in the clutch and brake wires for the ecu and the diagnostics wires for the speedo. No pics of this unfortunatly but tbh they wouldnt be the most interesting pics in the world anyway
Next job was sealing the exhaust. Heres what I was dealing with after fitting the newly made pipe I made to join the downpipe to the catback system
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/DSCF6160.jpg)
Big gaps on both ends! This shoud fix it :grin:
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/DSCF6159.jpg)
Next major purchase will be a sports cat, probably a universal 200 cell Hoffman
Test drive time!
Its deffinatly a fun car to drive lol, told myself I wouldnt race it too hard untill the intercooler is finished and everything is checked over 1 last time, but there was no hope of that happening :grin: Took it down a side road near my dads and gave it a blast. something popped! Parked up and found the silicon sealant I used to seal the top boost pipe popped off :cry: So slowly drove it back again. Also noticed the coolant light was flashing so put a bit more antifreeze in it and the light went out
Heres what I found on opening the bonnet
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/DSCF6162.jpg)
Yesterday was another lazy day, so today I been busy again making this
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/DSCF6164.jpg)
into this
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/DSCF6169.jpg)
Also last job of the day, sorting out the exhaust banging on the valance
This
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/DSCF6171.jpg)
Became this
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/DSCF6172.jpg)
And thats me finished for this week! Dad's birthday today so we going out for a meal, then I'm on nights so will be sleeping now untill Tuesday, but next job up is fitting this lot :)
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/DSCF6163.jpg)
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/DSCF6165.jpg)
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/DSCF6167.jpg)
Also have a load of ally piping so together it should all be enough to join the intercooler, then I need to get some black couplers to replace the blue ones :grin:
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This is all of course if I dont die in a ball of flames on my way into work tonight :grin:
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Alternator died :( £140 spent on an RAC membership lol
Things still left to buy off the top of my head now are
New Alternator
Sports Cat
Couple of distribution blocks and wiring to move the battery
D90s!
Then its bodywork time. Need to earn some money first though :cry:
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Awesome work mate, loving the fact it's not gone as easy a you were hoping! :grin: :grin: but then again we all know this with engine conversions! :grin:
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Fantastic progress.... um I hate exhausts, mines giving me loads of jip at the moment!.. sounds amazing but it's not good. Keep it up, you're close now.
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what cat u using pal, and what system, (internal bore etc)
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Awesome work mate, loving the fact it's not gone as easy a you were hoping! :grin: :grin: but then again we all know this with engine conversions! :grin:
lol yeah I remember when I was thinking it would all be done in 2 weeks :grin: It's been fun though I'd do it all again, and its soooo worth it, still cant help grinning when I put my foot down :evil:
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what cat u using pal, and what system, (internal bore etc)
atm its running decat I'll be ordering one sometime next week, only had quick looks around but will probably go for a universal Hoffman 200cell, seen a few around for around £100. Cant remember right now but think my downpipe and exhaust are both 2.5' so will get the cat to match and get a sleeve or something to join it all up, think 2.25' may be too small to seal the ends around it. Not sure how much difference .25' would make on its performance cant imagine it would be too much though?
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yeah going 2.5 on mine but iv got a S3 engine in mine which will be mapped and also has the K04, so i think ill have to get a whole new system :undecided:
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yeah going 2.5 on mine but iv got a S3 engine in mine which will be mapped and also has the K04, so i think ill have to get a whole new system :undecided:
Jetex is available in 2 1/2" bore. :smiley:
http://www.jetex.co.uk/website/jetex_exhausts_chooser.php?mak=Volkswagen&mod=Golf+Mk3+8V%2F16V%2FVR6&mat=Stainless+Steel
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yes wayne, lookin at those, really wanted to stick with magnex but it lists the same system for the 8v, 16v and vr6 ???
i need to whip mine off and measure it
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yes wayne, lookin at those, really wanted to stick with magnex but it lists the same system for the 8v, 16v and vr6 ???
i need to whip mine off and measure it
Magnex from memory is a smaller bore.
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i'd be going for at least 2.5" on that type of engine.
Awesome build dude :cool:
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cheers :) Yeah I'll most likely go 2.5", I've been looking at this one
http://cgi.ebay.co.uk/Universal-2-5-200-cpi-Sports-Cat-Catalytic-Converter-/350462228431?pt=UK_CarsParts_Vehicles_CarParts_SM&hash=item51992d37cf
Only thing I'm thinking is its pretty small and not sure if the ends will be long enough to get a good hold on the sleeve, the whole thing is only 8" long
(http://imgs.inkfrog.com/pix/onlineautosport/184796163.jpg)
I'm running a jetex 2.5" system :) On the link Wayne posted its the top one, resonated with a mid silencer. Sounds nice and quiet now even with the 1.8t, but after around 3k-3.5k revs it starts to sound like a rocket lol. It pulls much better than I was expecting when the turbo kicks in, I love this car!
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im after non Res matey for deffo
and yea see what you mean about that cat, i notice Jetex do sports cats so iv mailled them about the bore size on that, 23O notes tho
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I'm thinking I may get the 2.5" and weld a sleeve to either end. when its all butted up nice and tight there shouldnt be too much strain on it to pull it down, just need to make sure I get all my lengths just right :)
Picking up a mk4 bora alternator today from a local breakers, so I wont need to keep bring my battery in with me and charging it up every day :grin: If all goes well I may get a new battery as well, all the manual charing cant of been good for it
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cat has been on hold since posting this, been having charging issues and also my fmic has been annoying me the way it fouls the bumper so much
fitted a new alt and that didnt solve the problem, so had a chat with rubjonny and after trying a few things found out that I'm an idiot and had it connected up wrong. I had the chunky positive wire connected to the negative terminal on the battery rofl :grin: anyway after feeling like a tit connected it up right and all is good
Job for the weekend now is taking the slam panel off and cutting the fan mounts off the drivers side, then moving the rad back 10mm or so and making up a new mount for the rad and fan so the rad sits straight in the slam panel, that way I should be able to have the FMIC sit high enough to not foul the bumper. If this works I'm gonna be a very happy dubber :P
other bits and pieces need doing as well, VW finally called me about that pipe that was a 2 day order 2 weeks ago :rolleyes: So I'll be fitting that as well. May even get my intercooler pipework done!
Looking forward for going to a drive though without the worry its gonna run out of juice :cool:
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Moving the rad was a bigger job than I thought, ended up taking all day so I didnt manage to get any piping done, but did move the rad back and mount the intercooler properly
This is how it looked before I started work, not much room as you can see
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/CIMG0506.jpg)
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/CIMG0508.jpg)
So started by taking it all apart again!
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/CIMG0509.jpg)
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/CIMG0510.jpg)
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/CIMG0511.jpg)
I tried just cutting the top and side so the fans pulled forwards kinda like a door, and fitting the rad on the passenger side using the original mounts but mounting it behind them instead of infront, but this moved the rad too far forward so I couldnt get the bottom hose connected as the crossmember was in the way :(
So I ended up cutting all the way down again cutting the original mounts off so there was around an inch gap so I could make up some new mounts. Pics are a bit hard to see whats going on, I was kinda rushing towards then end and also nearly knocked myself out standing up and cracking my head on an open cupboard door! Dad came home and thought someone had been murdered in the garage :grin:
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/CIMG0512.jpg)
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/CIMG0513.jpg)
and here it is fitted
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/CIMG0514.jpg)
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/CIMG0515.jpg)
And heres how the cooler sits now, a bit higher and much better clearnce on the bumper. Unfortunatly on the previous attempt at making it fit before I learned about moving the rad I cut all the fins out, regret it now and have put some black mesh there for the time being
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/CIMG0516.jpg)
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/CIMG0517.jpg)
Now I'm off to lay down and recover from my concussion
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It worked then? :cool:
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Yeah it worked great, cheers for the tips :) I'd probably have ordered a new cooler without your advice :afro:
Still havn't made up mounts for the passenger side yet but its pretty secure pushed up against the cooler. probably wont be until Monday now that I get another chance to work on it. Everything seems to be going well atm though :cool:
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I had the same thoughts at the time. But considering i had AC and didn't want to lose it. Although i still haven't had it charged up yet. :huh: Looks loike you could do with a new bumber now though.
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Yeah bumper has been added to my long list of things that need doing :grin: which rad did you end up using? Mines in pretty bad shape after all the moving around and being pushed up against things etc, and it wasn't too great to start with. I may also get some new fans eventually as well and tidy the whole thing up a bit, but I deffinatly have more pressing issues to deal with first!
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Yeah bumper has been added to my long list of things that need doing :grin: which rad did you end up using? Mines in pretty bad shape after all the moving around and being pushed up against things etc, and it wasn't too great to start with. I may also get some new fans eventually as well and tidy the whole thing up a bit, but I deffinatly have more pressing issues to deal with first!
I ended up getting a new rad same as the original. You would be best to keep the fans in it as the slimlines are not supposed to ba as good. Not that i've had any probs with mine so far, but i have to run them both as i originally only had one at a time running.
Try and get some flat ali sheet (Easy to bend) from B&Q for the brackets. I put one in front and behind the rad on the loose side.
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Seeing threads like this has really got me contemplating having one of these engines in my valver at some point.
If you have a valver already. You can add a turbo to that. :wink:
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Do you not have that IC piped up yet? once its all done, i'd definitely make a boost leak tester to make sure all your joints are tight. One of your pics shows a jubilee type clamp and its on a bend. Very suspect! I had lots of issues with leaks and had to find solutions for that.
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No the cooler still isnt connected up, its been top priority since getting it on the road, but times been short lately :(
The whole of the piping is gonna be redone when I finally do connect it all up. The bend you mean is the one on the reducer? its straight inside I've just pushed it right up as close to the bend as I could get it, Its mostly metal on the inside :)
That piece will be gone when it's finished properly as well as I'll be using a Forge dv coldside relocation so wont need that oe piece anymore, was just making the best of a bad situation when I joined it all up :P
Will hopefully have it all done properly tomorrow :)
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No the cooler still isnt connected up, its been top priority since getting it on the road, but times been short lately :(
The whole of the piping is gonna be redone when I finally do connect it all up. The bend you mean is the one on the reducer?
This one.
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/DSCF6169.jpg)
This would almost definitly be leaking on that jublilee clip. Those reducers can be cut down, but they dont like to seal on bends. I've just had to add diy beads to my pipes because i was having regular leaks.
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yeah I dont like this either, as usual I was rushed to get to work while doing this and never got round to doing it properly. I think I have everything I need ready to get it done tomorrow, if not next day delivery will sort it on Tuesday :)
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had the cooler all rigged up today, lowewed the car down and the passenger side was dangerously close to the driveshaft, it was gettign late so I had to just stick it back to how it was :angry:
Still have all the bends and everything made up though so it should only be an hour or so job to reroute the passenger pipework. Pics tomorrow :)
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How have you run the pipes? Under the car? :huh:
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Drivers side just goes straight down from tb to cooler, passenger side I had going along over the abs unit then down at an angle till it was level with the gearbox, then straight towards the ic
cant really see another way of doing it with the way I have everything else in there, really need to sort the battery location out so I can get some more room :(
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Drivers side just goes straight down from tb to cooler, passenger side I had going along over the abs unit then down at an angle till it was level with the gearbox, straight towards the ic
cant really see another way of doing it with the way I have everything else in there, really need to sort the battery location out so I can get some more room :(
Have you looked at my run from ic on passenger side? 90deg elbow > 45deg pipe section up behind headlight. Then you can pipe to turbo from there. Ideally pipes should be modded to give the right angles.
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Yeah that seems to be how most piping I've seen goes, I cant do that right now though as my battery and filter are both in the way. passenger side in my engine bay has far too much going on really need to move some stuff around. Plan is to move coolant and pas fluid to the other side and put the battery in the boot
I think when I redo it today I'll take out one of the bends by the gearbox so instead of going down then across it goes diagnally across straight to the bend on the cooler
On the look out for a decent weather proof distribution block atm, been told the bmw e36 one is good but I havn't got round to looking further than ebay yet :tongue:
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It's all piped in, pics are uploaded to photobucket but I have no time for a pic update right now, cutting it a bit fine to get to work on time as it is :grin:
If I get some down tiime later I'll try and do a piccy update :)
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OK so heres the pics from last couple of days, sorry some of them are hard to make out
Heres the piping I made up which I made from trial fitting etc, ended up having to mod the passenger side one again after these but didnt get any pics
Cold side with Forge DV relocation fitted, not the best cutting skills I know :grin:
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/DSCF6173.jpg)
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/DSCF6174.jpg)
Hot side piping before I clipped it all tgether
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/DSCF6175.jpg)
Cold side fitted
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/DSCF6177.jpg)
Hot side routing from the turbo over abs and down beside gearbox
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/DSCF6178.jpg)(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/DSCF6179.jpg)
Last pic s hard to make out I know but hard to get a good angle
And heres the bay as it stands now, still needs a tidy up, I'm working on a way to get the cold air feed over to the other side and possible coolant bottle as well so I can leave the battery where it is
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/DSCF6176.jpg)
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/DSCF6183.jpg)
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/DSCF6184.jpg)
And finally heres the cold air feed I fitted up quickly for the time being, does the job but isn't great which is why I'm working on moving it over. The ducting comes out of the wing and goes down into the bumper vent scoop thing
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/DSCF6180.jpg)
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/DSCF6182.jpg)
All looks a bit of a bodge job I know :grin: Its being hard work trying to get things done with the limted time I have and also having to keep it on the road for work etc, but its deffinatly coming along :) Next mission moving the cold air induction and getting the cat ordered and fitted
Edit: Some of the joins look a bit dodgey on the bends I know but I've done my best to only put the clamps on the straights just after the bends, I think they are all ok for the most part but once everything else is done I'll work on getting a boost leak kit thing or whatever it is you use :P
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You have alot of pipes in there. See what you mean about the battery. I that IOU would have deleted SAI system?
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Would it not be better to move the battery and coolant bottle to the drivers side.
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Surely it won't be that difficult?
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Wouldnt be difficult to move the battery no, its what I originally had planned to do, but I would still have just as many pipes and everything all over the passenger side so decided it would be neater to route the air feed pipes over to the drivers side instead.
Looking at the way the Forge tip replaces the oe part it looks like I can just clamp a silicon bend in place of the metal section and run an ally pipe up/across with another 90 degree bend taking it around the block and somehow incorporating the oe rubber piece with the cone onto the end of it so it positions it somewhere around the wing. That would also give more room to route the ducting as well and I'd imagine it would be a bit colder over there maybe too?
tshirt2k yeah thats why I deleted SAI n249 and n112, 1 to make more room and make things look a bit neater (lol) and 2 my generic map has the post cat mapped out
Every bit of work I get done my list of things to do seems to get longer!
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Would look tidier if you moved the coolant bottle but it is your choice.
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I'll be moving coolant as well. Was originally moving battery and coolant now I'm moving air feed and coolant :)
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Just bought a set of Superturismo's with 205/45/16 brand new tires fitted for £200, not bad I'd probably pay mor ethan that for the rubber! They look in good nick too, picking them up on Wednesday
Also ordered my Hoffmann sports cat with 2.25 ends so should fit without needing reducers
I'll give the car a good wash tomorrow, havn't cleaned it since putting the engind in :shocked: Then I'll get a good look at what bodywork needs doing and decide on doing it myself or getting it done professionally. Usually I wouldnt hesitate at getting it done properly but having to keep things on the cheep recently :sad:
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New plan is to sort the rust then just give it a quick coat and put some GTi trim back on to cover the shoddy spray job :grin:
Alloys look awesome if I do say so myself, f**king mission though pretty much the whole M1 is a 50mph average speed check :angry: so I only got back an hour or so ago
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Pics of the wheels? can't say you got something and not pictures up! What's wrong with you? :grin: :grin:
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Pics of the wheels? can't say you got something and not pictures up! What's wrong with you? :grin: :grin:
A+ waiting for pics :evil:
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OK just went out and took some quick pics :P been a busy boy last week or so (not with the car unfortunatly)
first off heres the new sports cat that came today, need to order some reducers and get them welded on, ends on it are only about 2cm far too short for clamps
Its a 200cell sports cat from Hoffmann, £109
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/CIMG0527.jpg)
and heres some pics of the car after a quick wash and new alloys fitted
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/CIMG0526.jpg)
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/CIMG0525.jpg)
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/CIMG0524.jpg)
Fronts are 205/45 rears are 205/50 guy I got them from was a bit of a plank, kept trying to convince me that I needed at least 215s on the rears with all the power I've got. In my front wheel drive car. I just had to keep smiling and nodding, £200 for superturismos in good nick with brand new tyres was a bit of a steal so sisnt wanna piss him off. Had to correct him when he tried telling me my 8v was 180bhp standard though and I must be running at least 250 now :grin:
Anyway back with the plans, you can just make out the big rust patch on the front arch, its like that in spots all over the arches and a bit of the doors, next job along with the cat work is grinding down the rust, treating it, and painting just to cover it up then putting the gti trim back over the top of it. Then its back to black time :)
Oh almost forgot need to paint the skirts, grill, and valance as well
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Not done much for a while now, waiting on parts time and money!
a few bits came today though
Cheapo code reader
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/CIMG0533.jpg)
Also got some bits of reducer pipe made up for my cat, gonna weld a piece on either end to make them long enough to clamp, the exhaust end will fit inside and clamp on, and I've got another clamp sleeve to go on the downpipe end. It all fits together like it is in the last pic. All piping is stainless and weling should be done on Friday to be fitted to the car soemtime over the weekend
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/CIMG0529.jpg)
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/CIMG0530.jpg)
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/CIMG0532.jpg)
Will need to chop a long section of the downpipe off to fit it all in
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Almost forgot, found some Morettes in the cupboard I forgot I had :grin:
Just need to be painted
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/CIMG0534.jpg)
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time for an update I think
done a bit since the last update but got lazy with the thread, should be doing some bits and pieces over the next month so I'll try and get my arse in gear :grin:
Since the last update I've finished all the exhaust system off with the cat etc all welded up into one nice piece, fitted the morettes, removed the skirts and rear valance (and it looks much better for it!) put the mudflaps back on, fixed all the arch rust and refitted the gti trim and also gave the suspension an overhaul with new bumpstops wishbones ball joints and drop links, and in the next few days I'll finally be sorting out those rear tyres. No more dragster looks for me! :grin:
Next few weeks (months) should see me finally sorting out the engine bay, I've ordered all the parts needed to properly relocate the battery. Only to the other side of the engine bay but it should give me more room and look a lot tidier. Will also be moving the coolant tank to the other side, simplifing the brake booster pipework and the pcv system, and installing an oil catch tank :)
Plans for the rest of the year are boost guage (yeah I know I should have one of these already) from 42 draft designts that fits next to the radio, leather interior or at least a set of recaro cloths, and whatever other impulse buys I happen to make
main point of this post is to get the thread going again so now I cant go back on my promises :grin: Will try and get some pics up after a wash and the new tyres fitted
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just read through ,nice project you got goin there dan ,dont suppose you would be wanting to offload them morettes in the future if you dont use them ,would go with my mystic blue gti nicely lol
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Glad its back up and running (even if I had forgot about it), but I was reading it before! Get some more pics up when you can mate. :smiley:
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d'oh page must not have refreshed before i posted lol,ignore my comment about your morettes as your running them lol
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Finally!!!!!
I was starting to wonder why you became a lazy sh!t. It's not that no one read the thread it's cuz you never updated it! i followed this thread from the start! :cool:
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lol, I did do a lot in a small space of time I guess I got a bit tired of having to write pages and pages of stuff when I already had loads of other stuff I should of been getting on with :tongue:
I'll try not to neglect the thread anymore :cool:
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Love them wheels mate, love thecar tbh. Ive read this but never commented. I await updates
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thanks very much!
those last pics are a bit old now, its looking a bit shinier and imo much better with the skirts and valance removed and gti trim back on, just looks a bit like a dragster now with the big profile rears :grin:
plan was to go down the garage and do them today but I was feeling far too lazy, maybe tomorrow after work :P
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Will look loads better with the smaller tyres :smiley:
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did a bit of work on the car today, as usuall it didnt go as planend but im happy with what I got done. keeping with the trend of the thread I have no pics :P This time its due to my phone being low battery and so it wouldnt let me use the camera :sad:
Started off by attempting to move the battery, took it all out and everything but discovered it wont fit on the drivers side and I dont have enough cable to put it in the boot so it had to go back in standard position for now, though I suppose a positive is I now know its deffinatly going in the boot :) Possibly in the spare wheel well but not decided yet, knowing my luck the first week of doing it I'll get a flat :rolleyes:
What I did get done however was moving the coolant bottle to the drivers side and editing out a lot of the brake booster system so now instead of a load of pipework making the place look a mess it just has one good vacuum source with a check valve halfway, which is all it needs tbh (imo, play with the brake system at your own risk etc etc :wink:)
The result is a tidier engine bay so I'm pleased so far, also trying to move the battery to the passenger side made me realise I need that space for a catch can anyway so another good thing came out of it.
I'll put some pics up tomorrow if I go to the garage, if not they will be in the next installment, which will hopefully include the PCV edit, catch can installation, and battery relocation. Exciting stuff! :tongue:
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My catch can came today, no pics as im at work but I'll try and get some up later tonight. Also on the lookout for a decent battery box to put in the boot, anyone have any suggestions?
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I suggest....
You post some pictures!!! :grin:
(http://www.striped-bass.com/Stripertalk/images/smilies/this_thread_is_worthless_without_pics.gif)
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Just a quick update with some teaser pics of whats to come in the next few days, just waiting for the battery cable to arrive
Catch can, £19.99 from Toyosports, 15mm inlets with a bleeder screw in the bottom and viewing tube to see how full it is. Also came with some clear tubing but I may not use it though it would be handy for checking for blockages etc
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/2011-09-22143152.jpg)
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/2011-09-22143411.jpg)
2 meters of 19mm ID oil resistant marine hose and a couple of 19mm-16mm plastic reducers. I'll be using the oe T piece with built in valve in it so this is all I'll be needing for the catch can install
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/2011-09-23224005.jpg)
Also got my battery box this morning, I'll be mounting it out of the way in the boot somewhere in the corner
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/2011-09-24155615.jpg)
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/2011-09-24155633.jpg)
All I'm waiting for now is the battery cable to arrive, I already have a couple of junction box's and all the ring terminals etc I'll be needing, just need the cable so I can move the battery as where it is now is where the catch can will be going
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where you gonna mount the catch can ? what made you go for one too ?
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at first it was just for cosmetics along with the brake booster pipes to get a load of clutter out from the engine bay, but after reading a few guides and the possible gains etc I wanna do it more for the engines sake as well.
Its basically just a can in the middle of the pcv system that 'catches' all the oily crap so it doesnt get put back into the engine when the air gets recirculated. If you pull the y shaped breather pipe off and see all the sh!t thats inside it, thats what it helps stop getting put back into the engine. I've also read it can help with fuel consumption something to do with keeping the octane level up in the petrol but i dont know much about that :P
edit forgot to say, gonna be putting it close to where the battery is now, exact location depends on what looks neatest with the pipe routing
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just replaced my PCV and one of the pipes was split.. tbh their was minimal mess in the pipes.
will look forward to your update :smiley:
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your'e lucky then mine was full of crap lol, one piece was split and full of some kind of black gunk, and the breather coming from the filter housing has brown watery gunk in it. I'm interested to see how much of this is caught in the can but even if its useless the engine will look tidier :P
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your'e lucky then mine was full of crap lol, one piece was split and full of some kind of black gunk, and the breather coming from the filter housing has brown watery gunk in it. I'm interested to see how much of this is caught in the can but even if its useless the engine will look tidier :P
I could be wrong but it might be worth getting a compression test on your motor if its breathing out too much sh*t.. could be a sign of worn rings???
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That's over reacting. :shocked: all breathers over time get oily crap in them and this degrades pipes over time. It's common. Using decent oil can help.
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That's over reacting. :shocked: all breathers over time get oily crap in them and this degrades pipes over time. It's common. Using decent oil can help.
Just a thought.
Over time yes but I don't know the history of the car and knowing that I keep on eye on it I assumed it was a bad problem as thats how it came across, especially since a catch can was ordered to help the situation.
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Some people just follow the crowd. I rebuilt my engine and fitted a can because I didn't have a place to plumb it back into the inlet. Although the engine doesnt breathe heavy, there is quite a bit of oily water that collects in it.
I can't see that being any good for combustion. But the breather had to be rerouted so some of the fumes get sucked in through the filter as the smells arent nice.
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I'm doing it mostly for cosmetics :grin: but I have heard it can help as well so thought why not. Its not gonna vent to atmosphere its just gonna sit inbetween the oil filter housing pipe and the pipe just after the maf
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heres a pic borrowed from vwvortex with a rough diagram of how its gonna be set up.
the T-piece is gonna be the original vw piece with the pcv valve in it, and I'm planning on keeping the hockey puck connected to the inlet as well, though will see if I do or not when I get round to fitting it as off the top of my head I cant remember where it sits in the pipe, I might lose that whole piece since most of it is plugged up anyway and just get a custom bit of pipe from somewhere
(http://www.vwvortex.com/bryan/faqpix/18t_enginebay_cleanup/030.jpg)
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Heres what I got done today, first chance I've had to work on it as the bits and pieces didnt arrive untill monday and had some other stuff to do during the week
I'll start off with the pics from last time of the brake booster junk that I pulled out, and how the engine bay looks atm. battery is missing in the pic as I was trial fitting it in the boot
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/2011-10-01162220.jpg)
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/2011-10-01162236.jpg)
hard to believe that took me the best part of a day to do :grin: looking at that it still looks a mess, I got my work cut out sorting all this out
so now what I did today. Started by taking the boot carpet out and making some space, and seeing where I could fit the box. I wanted it on the passenger side but as the spare wheel was in the way I decided to put it in the drivers side corner. In case you dont know where that is heres a pic :tongue: dunno why its sideways :huh:
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/2011-10-01134106.jpg)
Cut away a piece of the carpet so it can sit flush
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/2011-10-01140354.jpg)
I trial fitted the box at this point and decided against fitting it directly to the floor, so I went on the hunt for some wood to sit it on. Few minuites later I emerged from the garden shed victorious! Drilled 4 holes and fitted them to the floor as follows ( I need to polish my photo taking skills, somehow managed to get one upside down)
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/2011-10-01153148.jpg)
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/2011-10-01153844.jpg)
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/2011-10-01134136.jpg)
next up was the boot carpet, no pics of the process bit I basically cut out the shape of the box, leaving about half inch to an inch to fit underneith the box making it level with the wood and also making the fit look nice with no raggedy bits of cut carpet showing
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/2011-10-01161251.jpg)
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/2011-10-01161302.jpg)
and thats what I did today, looks pretty good if I do say so myself :smug:
Working nights tonight so depending how I feel tomorrow I may finish off the rest of this with the wiring etc and also need to either fit the existing tray into the box or get myself a custom one from somewhere. If I go down the custom riute I'll finish the pcv and catch can while I'm waiting
cheers :)
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Eventually I want to relocate mine, how much was that box? Looks tidy.
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It was £7.99 from a company called ZoomerRoo. cheap as chips :grin: its only made of impact resistant polypropylene though it needs a tray or something in there to hold the battery in place, there around 1 or 2 cm gap each side with the battery in there
My tray wont fit even if I cut it down due to how it hold it in place so I'll probably be buying a custom tray, something like ths costs £19.99 from the same company. should fit perfectly inside the box just need to measure it up
(http://i38.photobucket.com/albums/e114/tombroome/RubberBatteryTray.jpg)
In the meantime I'll run all the cables etc so all I'll need to do is bolt in the tray and fit the battery
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Cracking read. Keep up the good work!
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Cracking read. Keep up the good work!
cheers :)
Update coming today, been taking a few days to upload all the pics photobucket is taking an age to upload :angry:
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Guess I'll do the battery relocation first. I did this and the catch can at the same time over 2 or 3 days, but some of the pics are still uploading.
I didn't get a pic of all the bits and pieces I used, but basically its just 5 meters of welding cable, around 0-1 gauge (32mm squared) a positive and a negative battery clamp, a junction box, and various sized 8mm ring terminals
So, first off I routed the cable from the engine bay through the car and into the boot. Access to the grommet in the engine bay isn't great and I did try for a while to get it off but in the en I just cut through it and fed the wire through, needs tidying up later
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/2011-10-03170849.jpg)
I took all the interior trim off that needed to be removed, pulled back the carpet and fed it through up to the rear seats, following the wires that were already there through a tunnel thing under the seats and into the boot, then ran it around the edge of the boot under the carpet and up to the box. I put the terminal on later but no pic of that
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/2011-10-03164052.jpg)
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/2011-10-03164103.jpg)
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/2011-10-03164109.jpg)
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/2011-10-03164143.jpg)
Also uncovered this thing, anyone know what is it? :P
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/2011-10-03164119.jpg)
Next up was the negative wire. I pulled back the carpet around the box and wheel arch looking for a good spot. not really many options tbh, basically either through the arch which would mean having to bolt through the exterior of the arch which I didn't want to do, or just behind the arch as shown in the pic where I could get behind and so have both nut and bolt on the interior
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/2011-10-04151313.jpg)
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/2011-10-04155519.jpg)
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/2011-10-04162240.jpg)
and here it is in the box with the terminal attached
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/2011-10-04180746.jpg)
so that's all the new wiring routed and ready. Next up was fitting the junction box and fitting the new 8mm terminals onto the old wiring. original trminals are something like 6 or 7mm, just to small for the junction box which was a bit annoying :angry: So I set to cutting the ends off and fitting the new terminals. I didnt get any pics as almost as soon as I cut the first wire it started to lightly rain and I started panicing as I now had a car that couldn't be moved :laugh:
Pretty straight forward, cut the old terminals off, crimp on the new ones. Also as the old battery terminal was grounding the engine block to the bodywork, I had to cut the negative terminal off and ground the engine directly to the body. I used the original grounding points under the battery tray, there are 2 under there but I only used 1 and used to other one to bolt the junction box to. I mounted it onto a block of wood so I could angle it the right way without the other wiring getting in the way
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/2011-10-05171431.jpg)
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/2011-10-05171443.jpg)
and thats pretty much it for the battery, tidied a few things up but thats all the work done. here it is sitting it ins nice new cosy home in the boot away from the cold :grin:
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/2011-10-05171406.jpg)
next up catch can install
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OK, catch can install!
in addition to the bits already posted before I purchased some 15mm id hose, a plastic 19mm T piece, and a box of jubilee clips, so I now have this lot
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/2011-09-23224005.jpg)
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/2011-10-04145210.jpg)
First job pull out the old pcv pipework.
It runs from this outlet in the oil filter housing held in with a clip that you just pull out towards you (don't lose the O ring),
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/2011-10-02162726.jpg)
up to the notorious for breaking Y pipe pictured here (mines broken as you can see)
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/2011-10-02162958.jpg)
then that leads to the 'hockey puck'
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/2011-10-02165904.jpg)
There is also a small outlet just behind and to the right of the dipstick held on with a pain in the arse one time use clip. Pull this off and cap it as its just a vacum source for the pcv system. If you have no caps just cut the hose and cable tie a bolt into the end of it.
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/2011-10-02163113.jpg)
Undo all these connections and pull it all out. you need to keep the 2 pieces in the following picture, forget the T piece and the copper pipe, that plan backfired :grin: just keep the filter housing L shaped pipe and the hockey puck
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/2011-10-02163654.jpg)
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/2011-10-02165941.jpg)
keep these bits
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/2011-10-02171139.jpg)
Pictures for the rest of the install are not great as this is the same time like in the above post that it started to rain, so I was moving fast.
Its a pretty simple install, You want to use the the original L pipe from the filter housing and fit a length of 19mm pipe onto it, this then runs to the T piece. From here the pipe splits, one way goes to the can and the other goes to where the original Y pipe was fitted. that's one side of the can install done. the other end is even easier, just run the pipe from the can to the hockey puck, and fit the puck back into its original location
The reason for the 15mm id pipe and reducers is that my can only has 15mm inlets so I had to reduce the 19mm down to 15mm (I actually used 16mm reducers and pipe as I couldnt find 15mm, but meh it has the same affect)
Hopefully you can make sense of that from the final install pics
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/2011-10-05171638.jpg)
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/2011-10-05171708.jpg)
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/2011-10-05171631.jpg)
All I did after this when the rain stopped was push the last few pipes on properly and stick some clamps on them. I'll probably lengthen some of the pipes at a later date so they can be run under some of the other stuff and not look such a mess, but until after the mot im not gonn throw any more money at it :grin:
cheers :)
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That thing you were asking about is the seat belt pre-tensioner. Its attached to the buckle and on impact, fires a clip through the hole in the buckle to stop it ripping out. Good work so far, be good to see the finished article!
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Passed MOT yesterday woohoo, had to buy another lambda as the wires were rubbing on the driveshaft which caused a fail on the lambda reading :( all good now though
I've decided to remove the cold side dv kit as its gains are next to nothing go gonna flog it for some cash :grin:
Just gonna be tinkering now probably untill the new year, cant really afford to throw any more money at it for a while :(
I've been getting a pressure drop code pop up every now and then so gonna be looking for a boost leak, may take this opportunity to redo some of the pipework especially the passenger side now the battery is gone, make it more conventional routing. Also read the T bolt clamps are a bit sh!t and can cause leaks so will replace them with jubilee clips (there cheap enough :laugh:)
Writing all this is making me wanna spend money lol so I'm gonna stop
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Great progress now will look sweet once all tidied up :cool:
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Started fitting the new TIP today from creation motorsport, didnt go so well though as it gets dark so goddam early now. managed to get it on while nearly crushing my hand in the process, dunno how most mk4 people do it but I'm guessing there's a lot more space than there is in the mk3! Hoping to finish it off tomorrow along with some other bits and pieces so should be a pic update tomorrow with a relatively tidy engine bay and also how the exterior looks atm as I haven't had any outside pics for a while
also going to fit some boot struts to the bonnet and get rid of the awful rusty lifters I have fitted now, and fit some new rear bump stops. Exhaust needs looking at as well as it hangs real low and wonky at the back
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You could have at least chose a better way of getting the cable from the bay to the cabin. There are better access point to choose from without cutting into the side of that bellows. :undecided: You could also do with soldering those crimped connectors for extra strength and conductivity. :wink:
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You might be better to get a vented battery at a later date.
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wires, wires, wires everywhere :laugh: what do they all do ?
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Thought the idea if moving the battery was to tidy up the bay? Does look a bit hectic tbh.
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Its a work in progress we're not all blessed with garages and/or cover from the rain and dark :laugh:
Bits and pieces are slowly getting done, just hard up for time especially as it gets dark so early now and this is my only car so I need to finish whatever I start :sad:
It does look better now just need time for an update
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Getting close to the bay being finished now, thinking I'm gonna be getting a 42DD stealth catch can at some point as its the only one I can find with 19mm inlets. Does seem a lot of money for what it is though :undecided:
I've sorted out the boost piping now and it looks much better, tomorrow gonna play around with the catch can at a last attempt of making it look half decent before I give in buy some new pipe and stealh can. Also gonna move the washer tank to drivers side.
Fingers crossed for pictures!
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If you want the can out of the way, put it where the carbon canistor went. Just has the pipes showing.
(http://img.photobucket.com/albums/v458/tshirt2k/16vt%20project/DSC00749.jpg)
Comes out behind drivers side light.
(http://img.photobucket.com/albums/v458/tshirt2k/16vt%20project/Catchcaninposition.jpg)
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great minds think alike :p this is what I've decided I'm going to do, just ordered another length of pipe :) also ordered a load of water washer pipe so as soon as that comes I'll do it all together. Going to get a new can as well, seems to fill quite quickly and this ones a pain in the arse to empty
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If it fills quick, your engine may be breathing heavy. Are you sure its being circulated back into the engine right?
That should stop it filling quick.
My can has a drain plug underneath, that you can get to by putting your hand under the bumper. I just don't like the fact that it isnt sealed very well
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how would I know if it was circulating right? pretty much all I've done is take out the pcv valve and put a can in its place, and made the hoses longer
When I say it fills quick, it's never actually filled but I'd say it fills maybe a 1/4 up the indicator tube in just over a month (iirc thats the last time I checked it) My can looks the same as yours, just has a different brand name on the top, thinking about it if I move it so I can get access to the underneith it would be much easier to empty and I may not need a new one :smiley:
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A quarter a month is nothing. have you filled it with scourers? cant remeber reason why. but think it helps vapour condense easier
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Nothing inside it just empty can. I thought1/4 was a lot, I've read of only half being filled in 6 months
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Fill it with some stainless scourers.
(http://img.photobucket.com/albums/v458/tshirt2k/16vt%20project/Catchcanscourers.jpg)
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That looks very clean! The stuff my can picks up is gunky with oil, wouldn't it get blocked being that full?
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Its clean because that was before it was used. :wink:
That doesnt take up much liquid space, it help the vapour condense.
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I'd worry about the gunk getting stuck at the top and not draining, I pulled a fair bit of gunk out of the pipes as well when messing with it the other day. I'll give it a go though and see what happens :cool:
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It should be mainly water that comes out anyway, but with an oily film.
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One of these days I need to get a whole day to go over everything and make sure its all ok, everything been so rushed recently I've had no chance to double check everything is as it should be. Bit of a leak coming from the filter housing that I need to take a closer look at, maybe thats something to do with the gunk building up
This weekend is looking good time wise, I may even get a whole day to myself! :smiley:
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This thread is great and just gives me too many bad ideas.
Keep up the good wrk!
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Nice build mate just had a quick read though, like the idea of putting the battery in the boot, i know the earth cable would then go onto the chassis but how did you join the live cable from where it went from old cable to new cable under the bonnet?
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I used a junction box. the old battery terminal was basically 4 or 5 wires bolted to the terminal, one of them fixed. I cut them all off the terminal and crimped ring terminals onto them, then fixed them to the junction box along with the new cable that runs to the boot. Soldering the connections would be best, but I haven't got round to that yet :p
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Still haven't got round to anythign in the engine bay, but I did fit some late mk4 GTi seats :cool:
(http://i147.photobucket.com/albums/r309/Danuk100/mk4%20Seats/2011-12-09160844.jpg)
(http://i147.photobucket.com/albums/r309/Danuk100/mk4%20Seats/2011-12-09161009.jpg)
(http://i147.photobucket.com/albums/r309/Danuk100/mk4%20Seats/2011-12-09161031.jpg)
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maybe time for a small update I think
Engine bay is pretty much finished now I think, at least until the summer. Will get a pic when I'm next outside
exterior is nearly there now too, just need some smoked fogs, side repeaters, and a new painted grill as my current one has lost some of the retaining clips with all the times its been on and off. Playing with the idea of black alloys but will get a pic up of how it is now for opinions, I do like all black cars though :)
Also recently fitted a Toad AI606 and after some teething problems its now all setup and no longer waking me up in the middle of the night or making me crawl in through the boot with the siren going off, not sure what the problem was but the fob was only working at REAL short range. All working now though :)
Next on the cards is fitting a new gearbox, nothing wrong with the DPA except all the gears are a bit too short, the idea of MOAR POWER! is slowly going away and giving in to better economy and a nicer drive, so will be looking at fitting a mk4 shifter and a mk3 diesel ASD box
updated pics to follow hopefully tomorrow after a trip to the scrappy :)
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Sounds like good progress :afro:
Look forward to the pics!
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delay on the pics, my dads gone on holiday for a week and so I cant get into the garage. nobody bloody told me!
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Wow your excuses for lack of pictures are getting more imaginative :grin: :grin: :grin:
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I'm not posting pics of a dirty car! :laugh:
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Wow your excuses for lack of pictures are getting more imaginative :grin: :grin: :grin:
Classic haha
I wanna see some piccies of this! :D
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Gearbox arrived yesterday plan is to fit it early next week, also found problems with my cooling system, bottom radiator hose isn't getting warm not sure what the problem is but I have a new neuspeed low temp rad fan switch and thermostat to fit so if it isn't the thermostat a new water pump could be on the cards
I'll have access to the garage again sometime on Monday so I'll try and get the car clean for some updated pics as well
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Hi mate brilliant read this has inspired me to put a 1.8t in my golf!
Did some one on here do the mods for the engine harness?
Tried to pm you but my pc is being a turd!
Thanks dazfx
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you cant pm until you have 10 posts :) a guy called Rubjonny over on clubgti did mine for me, hes a member on here also but dont think hes too active over here. He did it for £100 you just need to supply the mk4 and mk3 looms though in my case I didnt have a mk3 loom to give him so he got me one for £25. drop him a pm hes the most helpful guy I've ever met it seems nothing is too much to ask :)
regarding my lack of thread updates, theres a big one coming soon trust me :wink: I've just been very busy with other things. I'm soon to be moving into the world of home ownership! offers been accepted and in the process of getting a mortgage sorted, it wont be the end of the golf though just means I need to get it sorted before the repayments start :evil:
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Thanks for the help dan :wink:
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Dan one more question mate!
when converted yours did you change to mk4 clocks or keep the standard mk3
Ones?
Cheers bud
Daz
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Everything inside including clocks is standard mk3, though if running anything below a 16v/vr6 it may be a good idea to use their clocks for a higher speedo (not that I go over 140mph or anything :wink:)
depending on the engine you use and the mk3 loom though some things may need changing, for example I have an AUM which is electronic throttle so I had to fit an electronic throttle pedal, also as mine was an 8v I had to change the 8v 020 rod gear change to a 16v 02a (soon to be 02j mk4) cable change and change the 8v cable clutch to a 16v hydraulic clutch, which is a pain in the arse! highly recommend starting with a valver!
with the loom if you have a lower spec mk3 and use a 16v loom for example you may have to add some stuff to the fusebox but afaik nothing is compulsory from the higher spec cars :)
hope you decide to go ahead with the conversion, nothing puts a smile on your face like a 20vt mk3 :evil:
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thanks for the info dude. I have a 2.0 8v cabriolet, been doing my research so i know i gotta change the clutch over and maybe the throttle pedal but i'm willing to do that! :grin:
i would love to have a valver mate but really enjoying the cabriolet, so a 1.8t is going in it early next year just need to start gathering the parts!!
thanks again mate
dazfx
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20vt cab is gonna be my next project once i get my own garage to keep it in :cool:
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I've been ever so slightly slacking in the recent months with updates mainly because I forget to take pictures or simply cant be arsed, but I managed to get a few the other day in the sun. Nothing much but its looking a bit different to last update
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/2012-05-25124336.jpg)
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/2012-05-25124246.jpg)
engine bay while I was doing a bit of tinkering
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/2012-05-12132841.jpg)
and how my gearstick looks with the 02j shifter before I out the knob on
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/2012-03-26141847.jpg)
next mission is removing the gti trim (again) and sorting out all the rust then refitting the cl trim, not sure what to do after that think im almost there
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looks good mate
like that porsche in the background :cool:
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cheers, yeah thats my Dads current mid life crisis motor, so far hes been through a Porsche carrera softtop, forget which model it was, a 52 plate audi TT, and now he has this, Porsche 911 Turbo 930 :cool: In the coming months that's going to be getting a new exhaust and rebuilt engine should be a beast when finished
Also has an MG BGT that we're restoring hopefully in time for le man classic in July, bodywork has been done enough to get the mot done, now it just needs the paintwork seeing to and hoping to rebuild the engine in time where it should put out around 130bhp. only 80 from standard so its quite an improvement especially in what is essentially a tin can on wheels!
On to my car then :P
Taken the arches off and fitted the CL trim, now have some horrible lines from where the arches have scratched the paintwork and a few rust bubbles. started fixing the rust today, not happy with the finish though so it will be redone sometime next week. Was fine up to the lacquer but the 2nd coat bubbled and my attempts to sort it out were a failure :(
Here are the pics I got today
Didn't get a before pic so this is a similar but smaller bubble on the other side
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/2012-05-29183959.jpg)
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/2012-05-29183931.jpg)
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/2012-05-29183939.jpg)
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/2012-05-29194709.jpg)
Engine bay, bit tidier and cleaner now :) still a work in progress though
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/2012-05-29161054.jpg)
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/2012-05-29161103.jpg)
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/2012-05-29161110.jpg)
Interior progress
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/2012-05-29184043.jpg)
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/2012-05-29194637.jpg)
Exterior, new indicators/fogs, smoked repeaters, black powder coated new beetle 16s, and the cause of my recurring nightmares, the exhaust that no matter what I do wont stop knocking! At least its hanging straight now though
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/2012-05-29195157.jpg)
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/2012-05-29195205.jpg)
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/2012-05-29195221.jpg)
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/2012-05-29195237.jpg)
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/2012-05-29195253.jpg)
That's it for now almost there :)
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Looking good! Did you fit those rear seat mounts alright?
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No I didn't mate :( Only tried to fit them last week but they are too long I can only guess that there are different types of mk4 mounts? No big deal though I can cut them down and re-weld they are the right shape and everything just too long. Thinking I'm gonna leave it for now though as I'll eventually get a leather mk4 interior and knowing my luck I'll cut the mounts down then they will be too short for the leathers :grin:
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What exhaust is it?
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Its a jetex, I bought it second hand though and didn't know until I received it that the previous owner has cut off the middle hanger which should be on the top of the pipework, and welded on some bodge job hanger onto the bottom, so when you hang it it sits very close to the floor almost touching and when it vibrates it knocks sending vibrations and loud noises all through the car.
Its so very annoying!
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No I didn't mate :( Only tried to fit them last week but they are too long I can only guess that there are different types of mk4 mounts? No big deal though I can cut them down and re-weld they are the right shape and everything just too long. Thinking I'm gonna leave it for now though as I'll eventually get a leather mk4 interior and knowing my luck I'll cut the mounts down then they will be too short for the leathers :grin:
O right sorry bud. It might be bcoz I made mine for a 5 door golf and then copyd mine to make yours. I wanna get a set of cream mk4 leathers but I don't think thatll happen anytime soon
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Its a jetex, I bought it second hand though and didn't know until I received it that the previous owner has cut off the middle hanger which should be on the top of the pipework, and welded on some bodge job hanger onto the bottom, so when you hang it it sits very close to the floor almost touching and when it vibrates it knocks sending vibrations and loud noises all through the car.
Its so very annoying!
Middle hanger? It doesn't have one in the middle. There is a double hanger before the rear beam. Do you have that?
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that's the one I mean
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You can get a new pipe from jetex. They should fit perectly.
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I dont think you can get a resonated section I checked their site before and only found the non res piece :(
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I dont think you can get a resonated section I checked their site before and only found the non res piece :(
Get a non res bit and swap with me if you like. :wink: :cool:
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mine is non res, and the exhaust is Quiet as f**k, just has a really nice Grunt under load (engine sound)
id hate to think i had the Resonated one on their...
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I actually want mine quieter! :p
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Doing a bit more repairs on the arch, sanded down and started again on the first bit I did and this time went for the whole thing. Didnt get time to finish up so no more pics but I'll probably continue this on Thursday
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/2012-06-04184854.jpg)
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I would have at least took the wing off the car to do as its not that hard to do
interested to see the final result tho
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What laquer are you using? :undecided:
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http://www.paints4u.com/ProductDetails.aspx?productID=3166
Thought about taking the wing off but then decided I'm eventually gonna get new wings when I respray anyway so not too bothered about the finish. That and I'm lazy
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I've got all the paint and everything ready now just waiting for some time to get started. It's gonna take a loooong time before its all finished!
found some pics of a rattle canned mk3 on ed38 looks pretty good imo
(http://i52.photobucket.com/albums/g19/wyatt_adam_/VR6/IMG_0979.jpg)
(http://i52.photobucket.com/albums/g19/wyatt_adam_/VR6/602990_10151839184240204_174433408_n.jpg)
(http://i52.photobucket.com/albums/g19/wyatt_adam_/VR6/IMG_1218.jpg)
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Rattle can job was a fail lol started off well but I got lazy and it started to show in the finish so I've scrapped that idea new idea is this
(http://www.sealey.co.uk/Images/Products/175/HVLP2000.V2.png)
everything needed should be here next week, exciting stuff!
Also fitted a boost gauge and will be fitting new drivers door hinges. pics will follow as it gets done :smiley:
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any pics so far pal ?
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nothing yet man I didn't finish till late wednesday and working since then so not had a chance, on nights now so pics are first on my list tomorrow :smiley:
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Had a rough night shift friday so was in no state for anything on saturday! Today wasn't too bad though in between the rain
put the new wings on
(http://i147.photobucket.com/albums/r309/Danuk100/2012-07-29141633.jpg)
(http://i147.photobucket.com/albums/r309/Danuk100/2012-07-29161211.jpg)
(http://i147.photobucket.com/albums/r309/Danuk100/2012-07-29173501.jpg)
also took the chance to check my sills. Was pleasantly surprised by the passenger side
(http://i147.photobucket.com/albums/r309/Danuk100/2012-07-29141704.jpg)
Solid as a rock!
not so much the drivers side though, will need attention soon :(
(http://i147.photobucket.com/albums/r309/Danuk100/2012-07-29200207.jpg)
Also fitted new ARB droplinks
old and new
(http://i147.photobucket.com/albums/r309/Danuk100/2012-07-29194904.jpg)
(http://i147.photobucket.com/albums/r309/Danuk100/2012-07-29172459.jpg)
Sorted my door as well no pics but basically all it needed was a bit of teflon tape and tightening of the grub screw
Thats it for today, will continue tomorrow weather permitting!
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Didn't do as much as I'd liked today, spent a while on the bane of my existence aka my exhaust think its sorted now :lipsrsealed:
What I did do was fit the boost gauge and paint the trim around it. I went for a pillar mounted one as I don't fancy the steering column one. It measures from -6 (vac) up to 2 bar which should be more than enough for the future
Before
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/2012-07-30173717.jpg)
plastic primered
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/2012-07-30174958.jpg)
Finished
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/2012-07-30182018.jpg)
Mounted
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/2012-07-30183635.jpg)
Need proper fixing but I'm fairly pleased with it. Also need to wire it up for illumination and cut a piece out of the trim so it doesn't squash the pipe too much.
On testing my boost I'm running just under 1.5 bar so I'm please with the results and now I know I'm boosting properly :)
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Was that a pattern wing? How well did it fit?
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Yeah pattern, fits ok kinda crap in places but I'll probably adjust them a bit before painting. Meant to get pics but it got late and I forgot :P I'd definitely advise getting genuine over new pattern panels but I got these cheap from a guy who never fitted them
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No progress yet waiting for time and space to start the paint, should be doing my rear axle bushes over the weekend weather permitting. Got some pics of the new toys but that's all for now :tongue:
Sealy electric spray gun
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/2012-08-02135457.jpg)
Paint and other goodies (the engine here is from the mini seen in some previous pics and is the reason I have no space :angry:)
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/2012-08-02134937.jpg)
and some new febi bushes and a VW tool for fitting them. Its made for the mk4 so will need a bit of creativity to make it work but will no doubt make the job easier
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/2012-08-02135244.jpg)
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Did you get those bushes in mate? Was that mk4 tool any help
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I haven't yet mate, the misses' contract just got sorted finally so we been house hunting not much time for the golf this weekend, the plan was to start spraying it up tomorrow but will see what happens now I may end up doing the bushes instead.
Good news is I think we found somewhere though and will be making an offer tomorrow morning, if it gets excepted and all goes well I will finally have a garage! :smug:
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Good luck mate! Where did you get your febi bushes from?
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Ebay :afro:
changed one side yesterday, time was short so I thought I'd get one side done to see what it was like and then get pics on the other side. Turned out a good idea because it was a f**king mission!
Doing the other side tomorrow so I'll get pics up along with whats involved, to use the tool I bought a bit of ingenuity is required :laugh:
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Oh and also we got the house with 2 garages :cool: so respray is on hold until we're moved in so I have a nice dry and wind free environment :smug:
no more stone driveway fun for me!
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here's what happened on Tuesday then....
started off like this, looking pretty worn and perished
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/2012-08-21133837.jpg)
dropped the beam
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/2012-08-21135053.jpg)
decided to drill the rubber through rather than burn it out and it came out quite easy, drilled through in 4 or 5 different places then prised the middle out with a screw driver
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/2012-08-21140736.jpg)
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/2012-08-21140959.jpg)
Now comes the fun part. Getting the metal sleeve out is a royal pain in the arse an took the best part of 2 hours of hammering chiseling cutting and lots and lots of swearing!
The other side I did the day before came out a lot easier than this side but was still a big job
Started by cutting a groove in the sleeve then chiseling along the cut about halfway and finishing off with a hammer. This is what I did to get the driver side one out no problem, took around 35-40 minuites. Passenger side was a different story! the sleeve had somehow for lack of technical terms expanded in the beam so I couldn't cut it without also cutting the beam. I didnt know this which is why it took so long to get it out. I cut as much as I could then when chiseling along the cut failed to show any results I resorted to brute force :evil:
This is how it looke with a lip hammered into it before cutting
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/2012-08-21141206.jpg)
After a good hour of smashing it with a hammer it finally came out and I was left with this nice hole and a pile of scrap metal and perished rubber
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/2012-08-21160210.jpg)
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/2012-08-21140952.jpg)
Putting the new ones in was surprisingly easy with the tool, I just had to use various sockets so the tool sat flush against the bush and the pressure was applied to the metal case rather than the rubber when I tightened it up. Also on the last part I had to add 2 sockets to the other side as the thread on the tool runs out before the bush is all the way in.
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/2012-08-21162520.jpg)
(http://i147.photobucket.com/albums/r309/Danuk100/18t%20conversion/2012-08-21163347.jpg)
and thats it! no pics of the finished product as I was running late for work, but its pretty simple stuff just jack the beam back into place and f**k about with it until the bolt holes line up
I now have a non squeaking rear beam :cool:
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nice job bud i had a mare with the gti gutted now as its in bits looks like i will be doing the vr next spring not looking forward to it one bit :grin:
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nice build mate, i think im going down the same route, i own a mk4 20v t and love the power but prefer the mk3 shape, were the mk4 seats easy to fit? im hoping to put my recaros from the mk4 into the mk3, also does the left hand side engine mount just bolt down onto the chassis rail?