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Model specific boards => Golf mk2 => Golf mk2 gallery => Topic started by: jv on 27 December 2005, 19:04

Title: Lewy - 16v OG
Post by: jv on 27 December 2005, 19:04

Original Gangster? ah - Oak Green  :tongue:

Title: Re: Lewy - 16v OG
Post by: Lewy on 28 December 2005, 17:46

Quote from: jv on 27 December 2005, 19:04

Original Gangster? ah - Oak Green  :tongue:

Not me Jon, I don't like guns!! :wink:



Bit of History:

Bought the car from a colleague in January of 2005 after getting rid of a Type-r Civic in September 2004 - Huh I hear you say, but I have a tendency to spend a few months abroad a year so having the Type-r sat on the drive doing nowt is a bit of a waste of time, as my wife had a Mk3 Polo she ragged around.

I bought the car completely standard with 124k on the clock for the paltry sum of £1100. The previous owner was still abroad, so I managed to bung his wife the cash, and needless to say she was happy!!

(http://img411.imageshack.us/img411/4465/dscf00564cg.jpg)

Exterior:
The car didn't stay standard for too long, a quick chat to Richard at Venom supplied me with the crystal front end set-up. But un-beknown to Richard FK had supplied him with LHD units, and I had to wait another couple of weeks for the RHD ones. I've used the edition38 Auto Jumble for alot of bits and pieces, so when a set of all red rear lenses came up I got them for £40 delivered from Darren at G-Werks, colour coded the large plastic side and top panel, and hey presto! One of Dizzies fine looms and 100/90w bulbs late and all at the front end was cushty. I also managed to pick up a set of BBS RM's from the illustrious Ebay for only £300, and ran them for the summer - typical crap tyre fitter had whacked the balance weights on the outside of the rim, therefore leaving a mark when I removed them and balanced them properly! The wheels have now been stripped, acid dipped and powdercoated to an excellent finish in Anthracite Grey by Dav (Lowvento) ready for 2006, along with shiny new 2" BBS rims supplied by Mark (Myxa) Dzus of Juswheels. I also dabbled with a single lamp front end, but decided to bin it as I wasn't happy with it and went with a chrome badge on the front instead of the black

(http://img359.imageshack.us/img359/814/20050731image01832op.jpg)

(http://img505.imageshack.us/img505/8500/20051222image02065yw.jpg)

Interior:

I've been a mechanic now for roughly 15 years so nearly all of the work carried out on the car has been by my fair hand, but alarms and MDF work are not my forte, so I entrusted Sextons to fit my Clifford Concept 650 all singing and dancing alarm. They also fabricated the rear panels which house the sub and amps. The whole boot floor, doors and bootlid are covered in Dynamat Extreme, and the whole system is made up of:-

Headunit - Alpine 9831
Door Speaker Amp - Genesis Profile 4
Subwoofer Amp - Genesis Profile Sub
Sub - JL Audio 12w6 in 1" MDF custom enclosure
Front Door Speakers - Focal Polyglass 165v2 in Audioscape pods
Pheonix Gold ARX-750tln RCA's
All 0 gauge power and earth, and Directed Audio 8 gauge speaker cable
90 amp alternator to power the bugger

(http://img359.imageshack.us/img359/8859/20050731image01945sv.jpg)

(http://img359.imageshack.us/img359/8871/20050731image01955vu.jpg)

(http://img359.imageshack.us/img359/1922/20050731image01875ed.jpg)

The rest of the interior is very good condition Rainbow, but is due for an upgrade in 2006. I've also managed to get hold of 1" thick wool fire retardant matting, so I lined the floor and side panels, again to aid the soundproofing.

Under The Bonnet:

I've done next to nothing under the bonnet except a full service, cambelt, and K&N panel filter. At the moment the engine bay looks like this:-

(http://img394.imageshack.us/img394/6876/20051222image01800yb.jpg)

And probably will do for a little while whilst I clean the bay, box, and lump, add a new clutch and a few little tweaks to give a fresh new look. The suspension is fully adjustable AVO coilovers, this is how I get a look like this

(http://img243.imageshack.us/img243/3232/119sv.jpg)

And every conceivable bush has been replaced by the polyurethane Powerflex variety, something I would recommend to everyone as it stiffens up the front end no-end.

I'm off into work this Friday and weekend so I'll update some more then

Title: Re: Lewy - 16v OG
Post by: Lewy on 29 December 2005, 19:37

Right here is a list of jobs I've got to do before the start of the show season:-


Very light smoke tint the windows, including Happich!
fit G60 arches!
Smooth rear bumper
Polish amplifier casings
Change disc's all round
Replace bee-sting
Jiggle rear box to accomodate rear bumper

The list goes on, but is predominately filled with replacing trim clips, and poxy plastic parts, bot if you want OEM+ then thats the price you have to pay!

A few more pitures of it's current carnation

(http://img394.imageshack.us/img394/6927/20051222image01824de.jpg)

(http://img528.imageshack.us/img528/6121/20051222image01985hn.jpg)

(http://img207.imageshack.us/img207/4420/20051222image01865ec.jpg)

(http://img411.imageshack.us/img411/7663/20051222image01849wi.jpg)

The masking tape is there to stop my nads scratching the wings!!

Title: Re: Lewy - 16v OG
Post by: Lewy on 09 February 2006, 20:41

Righty ho here goes the next and long awaited instalment.

I have nearly completed the painting of the block and ancillaries in a mixture of satin black, silver and the best colour, Oak Green.

(http://img137.imageshack.us/img137/8027/20060209image01711hf.jpg)

The red Samco’s are the only thing I’m still not too sure about, but they’ll do for now and as I only paid £60 for them (new!) I’m not too out of pocket.

(http://img345.imageshack.us/img345/7832/20060209image01699xp.jpg)

The BBS centres are with AC Auto Refinishers of Thame as they offer a ‘chrome’ paint effect, and I wanted to keep the original depth instead of the shallow versions available out there.

(http://img345.imageshack.us/img345/6630/20060209image01838el.jpg)

My lippage!!

(http://img327.imageshack.us/img327/9509/20060209image01868og.jpg)

As my Mk4 got rear-ended just before Chrimbo the body shop which has undertaken the repairs is a TVR specialist and whilst they are wielding their magic with my Mk4, theyÂ’ve taken on the task of plastic welding my rear bumper tow-eye cover and shortening the rear No plate plinth, so it can smarten up the rear end with a smoothed tailgate and tiny No plate!

Thanks to me olÂ’ mucker Joe, he has got me a solid front engine mount, and thanks to the Queen (for paying me every month) I have just taken delivery of two Vibratechnics mounts, of course they are now painted and waiting to get in, as IÂ’m yet to start the engine bay clean up. IÂ’ve decided not to go too far with the engine bay as IÂ’ve got plans for next year, perhaps a complete re-shell in a new shell, or just a strip and go, in two minds at the mo but IÂ’ll get there, I always do.

(http://img308.imageshack.us/img308/1795/20060209image01776bd.jpg)

HereÂ’s just a few of the things I need to fit before the start of the sea

(http://img327.imageshack.us/img327/4752/20060209image01807mt.jpg)

(http://img308.imageshack.us/img308/3097/20051222image02029hh.jpg)

Bloody hell, they look like they'll need a clean!!

(http://img345.imageshack.us/img345/7818/20060209image01768ap.jpg)

(http://img345.imageshack.us/img345/4854/20060209image01813ne.jpg)

I'll try and get some more info and picture up soon, as no doubt Simon will pester me more!!

Title: Re: Lewy - 16v OG
Post by: Lewy on 12 February 2006, 14:15

Spent another 9 hours in work yesterday, removed all of the brakelines, re-painted them and now ready to go back on. The master cylinder also received a coat of paint in preperation for the cleaned and colour coded servo, which is still attatched to the car. Both parts of the inlet are now painted and waiting to go back on, all I've got to do is get the new fuel pipes done and Bobs your uncle, but that'll probably be next month as they are £35 each, and I need 6  :shocked: !

I tried one of the wheels on the car yesterday also, just to see how much they'll stick out, and be Jeesus, they stick out. I think I'll run them on standard arches for now for the fat look, and then when it goes for the MOT I'll whack the steelies on.

What do you think, I think they look the shizzle, and as the boots will be here this wek I'll plonk another photo up with the them on, I managed to get Goodyear Eagle F1's for £42 a trye delivered, not bad I thought.

(http://img484.imageshack.us/img484/9745/20060211image00084pp.jpg)

(http://img484.imageshack.us/img484/700/20060211image00066lo.jpg)

Title: Re: Lewy - 16v OG
Post by: Lewy on 18 February 2006, 17:50

Over the last few weeks I've been spending every weekend Saturday and sunday doing the car, and with a nearly 6 month pregnant wife in tow, you can tell she's bound to be a bit narky. So this weekend I've decided to not go into work, but instead I went into VW to get some bits, and boy did this start an argument!

My rubber got delivered on Tuesday, 4x Goodyear Eagle F1's (http://www.genial-guenstig-shop.de/shop/Sommerreifen/Details/Goodyear%20eAGLE%20f1%20GS-D3.jpg) not bad price either at £42 a corner as I've sorted out a contract with Dunlop.

Hopefully if I get my finger out of my jacksie this week I'll get the gearbox cleaned up and painted ready to go back in once I've got the front engine mount off of Joe, as he decided to leave it at his house when we met at No-rice, something about cutting his finger on it, and not having enough plasters!!

The next jobs on the agenda are to clean and paint the servo and master cylinder, also the bulkhead could do with a clean and polish ready to re-fit the brake pipes and servo shizzle.

I've got my tailgate with a welder friend of mine at the mo, so hopefully that'll be a bit smoother come the end of this week, ready for a lick of paint and a smoked window.

Fit Samco's
Fit SFS breather kit
Very light smoke tint the windows, including Happich!
Fit tyres, and then the wheels, then if the wheels are too wide, then fit G60 arches!
Replace interior - rainbow for Recaro
Smooth rear bumper
Fit single wiper kit
Polish amplifier casings
Change disc's all round
Replace bee-sting
Fit TSR manifold
Replace exhaust.

The list is slowly getting shorter. :rolleyes:

Title: Re: Lewy - 16v OG
Post by: Lewy on 26 February 2006, 15:35

Well yesterday turned out to be a pain in the butt. Workmates wanting a hand with they're cars and people just asking daft questions, and along with the Mk4 messing me around, it was not a very productive day. But I still managed to take a few piccies of my wheels and my 'minter than mint' Recaro seat bases, that were expertly re-bolstered by the man of the hour, my shizzle Joe. I'm still waiting on the BBS centre caps to come back from being 'chrome painted', and the minute I get them back I'll get some pictures up, as I'm assured they'll look the buisness.

The tyre 'stretch'.

(http://img503.imageshack.us/img503/7528/20060226image00141ct.jpg)

(http://img130.imageshack.us/img130/7055/20060226image00241jr.jpg)

Most of the guys in work were like ' how did you get them to seal?', and 'are you sure thats illegal?'
Well to seal them I left them over my lunch hour to re-form after being manipulated to go on the rim initially, and then whipped out the valve to increase air-flow into the tyre. It only took 2-3 attempts and hey presto 'POP' on they went.

And I couldn't give a monkeys if they're not legal, I'm no saint. :evil:

This what they look like on the car

(http://img503.imageshack.us/img503/7646/20060226image00234yk.jpg)

Might stick out a bit, but as I've said before I might change to G60 arches, and I've a very good mate who's an MOT tester  :wink:

And the seats.

(http://img130.imageshack.us/img130/268/20060226image00355in.jpg)

(http://img503.imageshack.us/img503/5274/20060226image00347od.jpg)

Gotta say Joe is a very good man, and very articulate about his work (his second job, not his first!). He's even taken a mates' dash away to trim in leather.

Hopefully this week will be a little bit more productive, so an update and more photos will be sorted.

Title: Re: Lewy - 16v OG
Post by: Lewy on 09 April 2006, 09:50

Righty ho, I'm without camera at the mo, but I'll do a little update none-the-less.

The gear box is finally clean and covered in paint, it took a total of 5 hours to prep, and was a bloody nightmare, but looks completely factory finish - even if I do say that myself! The selector is rebuilt with all new parts and looking rather nice, along with the ball and socket from under neath.

(http://img422.imageshack.us/img422/1886/2006050500210sd.jpg)

(http://img177.imageshack.us/img177/8992/2006050500221ew.jpg)

The rear of the car has been extensively cleaned and undersealed, and looks utterly factory. It took me a while as I had to remove the rear shocks and clean them up, but if you look at my boot install, you'll know why it took so long, as I had to remove the boxes first  :evil: !

(http://img325.imageshack.us/img325/1451/2006050500315lu.jpg)

I've got the centre caps back from the 'chrome painter', and they look the buisness. They're not completely perfect (how I like things), buth they'll do for now until I think of something else. I stumbled across a set of Eibach anti-roll bars last week that just need a quick clean and they'll be on the newly undersealed axle. They were an absolute bargain - 40 big uns, and that came with a set of koni top adjustables, eibach springs, and a sparco strut brace - which won't be going on!

Next weekend sees the interuption of a bank holiday, so no doubt her indoors will be wanting to go somewhere, so low production is what I see there, but I have the following week off, so the engine and box will be going back in  :smiley: and I can't bloody wait. All I've got left to do is finish the undersealing and paint the two front chassis legs, and it's a new happy home for the 16v.

Once I get the camera back I'll get some photo's up and re-fresh this page.

Lewy

Title: Re: Lewy - 16v OG
Post by: Lewy on 20 April 2006, 10:32

Ok still no camera but I'll try and sort that out tomorrow. This week has consisted of stripping the front subframe off and replacing it with the Seat one.

It was shotblasted and coated in stonechip protection and then a few coats of satin black. I also re-cond the front wishbones, which were more-or-less new anyway as I'd replaced them when I did the poly bushes, but I decided they looked gash alongside the subframe. I also removed the shocks in order for me to underseal the front end

(http://img417.imageshack.us/img417/7962/2006050500121vt.jpg)

I also stripped off the front calipers and mounts to paint them a nice shiney red, just to compliment the red hoses and the red GTI badges on the sides and rear. The next job is to get the front cross member stripped and resprayed in satin black (again!!) and re-fit the engine mount. The clutch turned up yesterday also, so I need to take it off of the stand and fit the crankshaft seal before I can fit the clutch and the flywheel, but before any of that can be done I need to paint the front inner wings, so thats a tomorrow job.

(http://img417.imageshack.us/img417/3944/2006050500153iq.jpg)

I've decided now that I will get it ready for the Edition38 show instead of Stonor, as it'll not be done to my spec in time, so it'll be in the show'n'shine for 2006, hopefully get the 'dog of the show' award!

Here's a few more as a bit of a taster.

Inner wings - paint complete!

(http://img417.imageshack.us/img417/9886/2006050500142hf.jpg)

(http://img417.imageshack.us/img417/8676/2006050500133bu.jpg)

Engine, not quite complete, but still looking good.

(http://img417.imageshack.us/img417/723/2006050500178yh.jpg)

(http://img177.imageshack.us/img177/1011/2006050500168dz.jpg)

Servo

(http://img325.imageshack.us/img325/1156/2006050500373cq.jpg)

And the now clean Recaro's, which took ages to get clean!

(http://img417.imageshack.us/img417/1781/2006050500055uc.jpg)

And now what the car looks like, not bad hey :cool: :embarassed: :embarassed: :embarassed: :huh: :laugh:

(http://img422.imageshack.us/img422/8827/2006050500281nv.jpg)

More to follow tomorrow.

Title: Re: Lewy - 16v OG
Post by: Lewy on 05 May 2006, 20:39

Just remembered that I'd heat wrapped the exhaust manifold, thanks to Haribo for the wrap.

(http://img417.imageshack.us/img417/9798/2006050500092sh.jpg)

Oh and I forgot this one of the inlet manifold :cool:

(http://img417.imageshack.us/img417/3062/2006050500181hu.jpg)

Title: Re: Lewy - 16v OG
Post by: Lewy on 07 May 2006, 00:00

Right, today was quite a sucessful day, managed to get a bit done.

The wiring loom has now been completely taped up, it looks like a new one, as I managed to get hold of a roll of fabric tape from Glyn (vr6rallye) on Ed38 and an hour later after de-greasing the loom, the job was done.

(http://img152.imageshack.us/img152/673/2006050600054gg.jpg)

My original idea was to run the loom through the chassis legs, but as the paint job I did on the legs wasn't 'the best', I thought I'd run the wiring in the original position, and as it's now looking really pretty and OE, I think it'll look the buisness.

I also managed to fit the servo today along with the resevoir (which has got new seals), along with the expansion tank mount. I've got a new tank but I'll wait untill the engine is in place before I fit that. I also moved the MFA temerature sensor, it used to come from the back of the dash, down the bulkhead, along the chassis leg and down to the front part of the front wing. What a palava!! So I pulled it backwards, through the bulkhead and down through the indicator wiring hole. It now goes over the arch liner and down to the sensor.

The other job I did today was remove the rear anti-roll bar - again :rolleyes:  as I'm going to get them both off for powdercaoting on Monday, hopefully they'll be back by Friday, so the rear end will be sorted and I'll not have remove the bloody amp box ever again!!! :angry:

(http://img327.imageshack.us/img327/2709/2006050600138zw.jpg)

Once the front one is back I'll be ready for the engine to go back in as it's a pain in the butt trying to drop the freshly painted subframe with the engine on, just to whack the ARB in.

Some more shots.

Freshly undersealed

(http://img152.imageshack.us/img152/5669/2006050600112hd.jpg)


(http://img152.imageshack.us/img152/1581/2006050600164eq.jpg)

I've got to do the ali heat shield next, on the inside, as the Milltek might be a bit on the noisy side.

Heres the wiring loom secured around the servo

(http://img327.imageshack.us/img327/1502/2006050600092ac.jpg)

And I whacked a spot ofpolish and wax on the bulkhead, so the inner wings and servo didn't look too out of place.


But...... these are my favourite pictures of the moment, sorry it took so long to get them up, but this is what my centre caps look like, and the wheels with the tyres on. I know they 'look' like the shallow type, but believe me they look the shizzle as they are phat!!

(http://img327.imageshack.us/img327/8862/2006050600015uo.jpg)

(http://img152.imageshack.us/img152/6499/2006050600030jc.jpg)

Title: Re: Lewy - 16v OG
Post by: Lewy on 09 May 2006, 10:04

Okay yesterday saw me getting up at 6 and going straight into work.

The engine and box is nearly ready to go back in but I popped the ARB's off to the powdercoaters, and as soon as they are back and fitted, the engine bay should be 90% complete.

I went about fitting the Recaro wiring loom in preperation of the seats going in

(http://img139.imageshack.us/img139/1245/2006050800029dz.jpg)

and replaced the old rainbow rear door cards with my spanking ed1 ones. I didn't realise the difference between the old and the new untill I'd got them side by side - it's quite a bit. When I stripped the interior out last year for the stereo install, I lined the inner rear wings and back of the door cards with some extra thick wool matting, the kind you find in your footwell. It's really good stuff, and it was free, so billy bonus all round.

Inner wing

(http://img65.imageshack.us/img65/9135/2006050800057ye.jpg)

Back of door card

(http://img139.imageshack.us/img139/2295/2006050800045jp.jpg)

Door card fitted - yum yum.

(http://img65.imageshack.us/img65/262/2006050800085yw.jpg)

I then popped into my garage at home and grabbed the Recaros and fitted them - to say I was impressed was a bit of an understatement, I even sat there for 5 minutes going up and down in them - DIV KID!

(http://img139.imageshack.us/img139/1029/2006050800151uy.jpg)

(http://img139.imageshack.us/img139/266/2006050800167ba.jpg)

The seats look more-or-less brand new, and after my main slice Joe re-bolstered them they feel new now. It's amazing that something so small as an interior can give you a right kick up the ass!

Other interior jobs consisted of replacing the dash fascia as the old one had a few cracks in it, albeit behind the stereo and switches, but it cheesed me off. It only takes a few minutes to change, but looks great. I did think for all of a nanosecond to colour code it, but I'm glad that my bag of crack was not that strong!!

(http://img139.imageshack.us/img139/4334/2006050800125ob.jpg)

(http://img139.imageshack.us/img139/6126/2006050800143mc.jpg)

Oh and another tiny job was a bit of bling for you shiny people. :wink:

(http://img157.imageshack.us/img157/2217/2006050800208gc.jpg)

I also replaced the selector ball in the bottom of the gear selector, bit of a bum job, but with a bit of patience and a swear box, you too can be richer and have a better selector! There wasn't that much wrong with the old one, but because I had one I replaced it anyway.

(http://img65.imageshack.us/img65/4940/2006050800078gg.jpg)

Should have some more photo's by the end of today.

Title: Re: Lewy - 16v OG
Post by: Lewy on 20 May 2006, 23:40

I've had the clutch sat in it's box for a few weeks, so yesterday I thought it was about time I fitted it. So I took the enigne off of the stand and laid it onto some thick foam so as not to scratch it. I replaced the crankshaft oil seal, and then proceeded to change the clutch. It was a piece of wee wee, and as there were a few lads working tonight I grabbed one just to help me fit the box. It went together so well I thought there must be something wrong, but I went through all the gears whilst turning the crank, and found everything was fine. I then went about fitting the new clutch release bearing, re-con'd starter, front mount, new alternator and a few more bit's and pieces

But at the moment this is what it looks like, albeit sat on my toolbox

(http://img108.imageshack.us/img108/9796/20060520tuesday08050600239iu.jpg)

(http://img167.imageshack.us/img167/3042/20060520tuesday08050600228id.jpg)

(http://img167.imageshack.us/img167/4070/20060520tuesday08050600215ms.jpg)

(http://img108.imageshack.us/img108/9052/20060520tuesday08050600246nb.jpg)

The engine and box should be in by Thursday, as I'm being messed about by my powdercoater, (he's got too many gates to do!!) he said they'll be ready for Monday, so fingers crossed they'll be fitted by Wednesday night along with the exhaust and rear calipers, as I'm waiting on the ARB eyelet bushes.

(http://img235.imageshack.us/img235/9160/20060516tuesday08050600037ik.jpg)

I've also finished the undersealing as a mate of mine had noticed a few spots that I'd forgotten :rolleyes: so I masked it all up again and got covered in it, not too much though as it was only a few spots.

(http://img207.imageshack.us/img207/4071/20060516tuesday08050600044hp.jpg)

(http://img235.imageshack.us/img235/5433/20060516tuesday08050600054ex.jpg)

I think you'll agree it looks good.

My deadline is getting closer and closer as the wee one is due next month, and Jo is taking it for paint sometime in July, so I'd better get my finger out and start cleaning some stuff

Title: Re: Lewy - 16v OG
Post by: Lewy on 23 May 2006, 23:10

After the joy of getting the new clutch fitted and the gearbox on, the reality set in. I'd forgotten that in order to get the engine and box re-fitted it would be advantageous to get the Eibach ARB's back from my lazy powdercoater, and fit the most important one - the front. So yesterday I decided to knob off early from work and get them. I only paid 20 quid for the job so I was quite pleased at the outcome. I fitted the rear one last night (thanks to Reuben at Tuningwerkes for the fitting kit) and decided to finish off the rear end for good.

(http://img308.imageshack.us/img308/9338/20060523tuesday08050600049qo.jpg)

(http://img308.imageshack.us/img308/7235/20060523tuesday08050600055lu.jpg)

I re-fitted the rear calipers, carriers, and handbrake cables and adjusted them up. Hopefully, if my memory serves me right, that means the rear end is now complete!

(http://img287.imageshack.us/img287/2205/20060523tuesday08050600022cw.jpg)

Whilst the car was on the ramp I tightened all the front brake pipes, and secured them to the bulkhead with some 'adapted' clips.

I then went onto fitting the rear silencer. Some of you may know that I went for a full Milltek system as it has an OE type tailpipe design, and again thanks to Tuningwerkes it turned up 18 hours after ordering at the cheapest price.

This is how it 'hangs out the back'  :shocked: :rolleyes:

(http://img287.imageshack.us/img287/4430/20060523tuesday08050600093hg.jpg)

(http://img308.imageshack.us/img308/9321/20060523tuesday08050600101hf.jpg)

(http://img287.imageshack.us/img287/826/20060523tuesday08050600129if.jpg)

To say I'm pleased is a bit of an understatement, it fills the cavity a treat, and hopefully will sound nice along with the 4 branch.

Title: Re: Lewy - 16v OG
Post by: Lewy on 26 May 2006, 12:48

Bummer - the wife wants to go away this weekend so unfortunately 'ol fat one' must be obeyed, and we're off.

To be honest I could do with a break away from the car, so Tuesday morning the engine will be back in and hopefully wired up as far as I can go.

Title: Re: Lewy - 16v OG
Post by: Lewy on 12 June 2006, 00:30

Sup fools - well the last few days have been quite fruitful, I've managed to get the engine and box back in, fit the manifold, get the driveshafts fitted, fit the front anti-roll bar, replaced the front wheel bearings, fit the whole exhaust system, fit the power steering pipes, expansion tank, washer jet resevoir, servo vacuum pipe, and wire up most of the engine - I'm too knackered to write any more, so let the pictures do the talking.

(http://img209.imageshack.us/img209/2158/20060611tuesday08050600437ll.jpg)

(http://img209.imageshack.us/img209/6582/20060611tuesday08050600460at.jpg)

(http://img209.imageshack.us/img209/2019/20060611tuesday08050600429hw.jpg)

(http://img154.imageshack.us/img154/4677/20060611tuesday08050600401ga.jpg)

(http://img147.imageshack.us/img147/7115/20060611tuesday08050600473rn.jpg)

(http://img147.imageshack.us/img147/5059/20060611tuesday08050600494mv.jpg)

(http://img147.imageshack.us/img147/6751/20060611tuesday08050600505ml.jpg)

(http://img154.imageshack.us/img154/6416/20060611tuesday08050600382xl.jpg)

Lewy

Title: Re: Lewy - 16v OG
Post by: Lewy on 18 June 2006, 00:14

It's getting closer - she's gonna blow!!!!!

Well I have 4 days left before the little one could turn up, but so far he's a bit of a no-show, so I can get some more work done on the car.

The inlet manifold minus the throttle body are fitted, the radiator is now fully plumbed and topped up with coolant, and the p/s pipework all fitted and filled with fluid. I have double checked every nut and bolt of the whole car now, as I know what I'm like for going off on a tangent, so this labourious task was a bit of a good idea, luckily nothing was loose, after all my son and wife 'may' travel in it :wink: .

(http://img143.imageshack.us/img143/1854/20060617tuesday08050600209do.jpg)

As I don't require much access to the bottom or the front of the car I fitted the front end back on. The slam panel I've fitted for now is just to get the car through the MOT, the other on I have which is genuine and mint, will be colourcoded and fitted by Jo next month.

(http://img148.imageshack.us/img148/6966/20060617tuesday08050600048gy.jpg)

All the fuel pipes and the metering head are stripped ready to clean and paint

Jobs Left:

MOT
Paint
Fit arches
Fit tinted glass
Lower suspension

Hoover and Polish!! :smiley:

I got narked a bit off with the state of it, after all it hasn't been washed in nearly 9 months, I thought I'd give it a once over and to say I was as happy as a sand boy after washing it would be an understatement.

Before

(http://img148.imageshack.us/img148/940/20060617tuesday08050600078yh.jpg)

(http://img143.imageshack.us/img143/121/20060617tuesday08050600086li.jpg)

(http://img111.imageshack.us/img111/7638/20060617tuesday08050600125sr.jpg)

After

(http://img143.imageshack.us/img143/8944/20060617tuesday08050600171ve.jpg)

(http://img143.imageshack.us/img143/2226/20060617tuesday08050600167at.jpg)

(http://img148.imageshack.us/img148/7987/20060617tuesday08050600218es.jpg)

I'll bring some more progress pictures tomorrow, hopefully I'll have some cleaned and painted metering head pictures and sundries.

Title: Re: Lewy - 16v OG
Post by: Lewy on 28 June 2006, 22:52

*******UPDATE UPDATE UPDATE*******

Anna decided to pop out my son last week, so the car will have to wait for a while. I was hoping to get it ready for painting next month, but my fantastic employers have put me on a course over the days that I was hoping to get it shipped off -  :evil: !

It looks like I might be pushing it to make it to ED38, but by hook or by crook............

Title: Re: Lewy - 16v OG
Post by: Lewy on 15 July 2006, 23:52

Ok, I've been 'allowed' to do a bit on the car the last few days, so I went about timing the engine up - but alas no :angry: !

The flywheel was fouling the bellhousing and not allowing the engine to turn over, so back to square one, and out with the engine and box again! It turns out the new pressure plate was too big and instead of seating inside the flywheel, it sat on the edge, thus still being able to be torqued up, but it sat wrong. I've now gone back to using the old clutch as it looked like it had done only 10k, and the new EBC one will be going back to the w8nkers that supplied me with it 215mm doesn't go itn 210mm - b'stards!

I'm away for a week now with work, but I'll be putting the engine and box back in next week

Title: Re: Lewy - 16v OG
Post by: Lewy on 17 August 2006, 23:12

Well as last reported I had replace the clutch and plonked the box back on and started to get back to where I was before. Everything was going well, but it must be said I haven't put much effort into it lately as A, I've been extremely tired with my 8 week old son, B, I've advertised the Mk4, C, picked up a VR, and D, I've been as busy as hell with my son. :cry: 

So over the last few days I was allowed to play with the car on an evening. The fuel pipes were on, the battery was hooked up, the stereo was all wired in and playing and it was 95% away from firing up. I had to get a replacement throttle body as some of the dimwits I work with think it's funny to mess around with things that don't concern them, hence my carefully laid out stripped body was a mish-mash of bits! :angry: After I had painted it I fitted it with new gaskets and placed it on this morning along with the air intake pipe from the metering head.

So there I am key poised at the ready, I turn the key to the start position, get a click and a whoooooomph - AAAAAAAAAAAAAARRRRRRRRRRRRRRRRRGGGGGGGGGGGGGHHHHHHHHHHHHHHHHH, MY F**KING CAR IS ON FIRE!!!!!

In my tiredness I had not quite done one of the fuel pipes up on the WUR and it had spilled fuel all over the starter, and when I put 12 volts down it had created a spark and up it went. I sh*t myself, and luckily enough we have to comply with very very stringent H+S so I had a foam extinguisher at the ready, my mate Ben just froze, poor lad didn't know what to do. Luckily enough he was on hand to clean all the foam up, and change his pants.

All the fire did was singe a few cables, but didn't completely wreck them, but the petrol has ruined the paint on the starter and box -  :cry:. At the time I didn't feel too down, but the more I think about it the more I feel cheesed off about it. I even went throught the 'how much would I get for it if I stripped it' thinking, but it's got to be an onwards and upwards from here on.

If I get it sorted for ed38 then I'll be there, but if not, then I'll be in the 'Dog' with a few extras fitted  :wink: , but I have faith in my ability so it should be with OG.

As soon as I got home tonight my son gave me the biggest smile, and that made me re-think my whole game plan, and put me in a different frame of mind, check the 'Parts For Sale' Section soon!

Title: Re: Lewy - 16v OG
Post by: Lewy on 20 August 2006, 23:42

Well after the bush fire of 2006 I've finally got it going (sorry Joe if I sounded excited - but I was!!) and boy does it sound good. At first there was a bit of tappet noise but that soon went away to give me the throaty sound of the Milltek. I nearly created a fire zone after I got the engine nice and hot and the heat wrap started to heat up - boy does that stuff smoke!

It's running a bit lumpy at the moment as the timing is out, only very slightly but still needs attention. The list of jobs is now down to just a few, but this is by far a finished article as there is plenty of jobs in the pipeline.

I even managed to take it for a little spin around the block, something it hasn't done in nearly 9 months.

(http://img80.imageshack.us/img80/9127/0021bt0.jpg)

(http://img80.imageshack.us/img80/7429/0020tj3.jpg)

(http://img124.imageshack.us/img124/6278/0016ru8.jpg)

(http://img388.imageshack.us/img388/1640/0018km8.jpg)

And heres the fire damage, nothing a lick of paint won't sort out.

(http://img92.imageshack.us/img92/9052/0003vc6.jpg)

(http://img201.imageshack.us/img201/4702/0001ab6.jpg)

(http://img201.imageshack.us/img201/7924/0002eg3.jpg)

(http://img201.imageshack.us/img201/3971/0006ku9.jpg)

All being well the car will be off for a tune-up, an MOT and 4 wheel laser tracking this week as ed38 is looming

Title: Re: Lewy - 16v OG
Post by: Lewy on 09 December 2006, 00:14

Righty ho, it's been a while.

The car made it to Edition as some of you may know, and as far as I was concerned it was ok, not quite right but still drew quite a bit of attention, and nearly caught fire prior to going on stage!! :shocked:

(http://img224.imageshack.us/img224/1310/img0991hf6.jpg)

(http://img294.imageshack.us/img294/769/medgallery420016621wi1.jpg)
Bit of a chop by Joe, but don't worry, it ain't happening!

As I'm due to go away soon for a few months (no, not prison!) I'm doing my damnest to acquire new Genuine parts to do the car with when I return. So this is what I got:-

The RM's are now sold in favour of some other splits that only a few people know the type and future size  :wink:
2.0 6A bottom end from and Audi - to be blue-printed
Brand new  :shocked:  Mk2 dash
New chrome bonnet, boot and door catches
US Passat steering wheel
More Dynamat for the whole floor
New sunroof seal
Tarox Monza Discs - front and rear
etc etc etc

My plans for the car are to turn it into the car that VW should've built in the first place, a few tweeks here, a few tweeks there, everything subtle, but in your face in the same breath. I plan on keeping it off the road for 18months to 2 years, but don't worry, I'll keep my page updated (well sort of!) and keep you guys in the know!

Title: Re: Lewy - 16v OG
Post by: Lewy on 17 April 2007, 23:29

As I'm off for a 4 month summer holiday on Sunday, I thought I would post a few pictures of how the car looks now. As my wife said earlier, 'your green car looks sh1t now doesn't it?' How right she is (for once!), it's been sorn now nearly 2 months as I've been busy buying spares and getting together most of the bits I need to get it ready for the 2008 season.

Enough talking as these kinds of posts are useless without pictures

(http://img413.imageshack.us/img413/4501/0704160029hg6.jpg)

(http://img413.imageshack.us/img413/3236/0704160030tf6.jpg)
Fat BBS's are sooo last year, it's all about the space savers!!

(http://img413.imageshack.us/img413/3781/0704160031co4.jpg)

(http://img413.imageshack.us/img413/1149/0704160032em2.jpg)
Jesus, I've been robbed!

(http://img413.imageshack.us/img413/1051/0704160036ti5.jpg)

(http://img413.imageshack.us/img413/9572/0704160039uc4.jpg)
Auto jumble or what!?!

(http://img413.imageshack.us/img413/3497/0704160041ej4.jpg)
Koni fully adjustable stainless coilovers

(http://img413.imageshack.us/img413/8041/0704160043ff5.jpg)
Now which one do I use, the new Momo, the perforated leather re-trimmed one, or the US Passat one??

(http://img413.imageshack.us/img413/3947/0704160045od8.jpg)
Eye eye, what's hiding in there!!


When I return the car will be getting a full re-spray, a full retrim, wheels built, and a new engine! :cool:

Just hope I come back - know what I mean! :wink:

Title: Re: Lewy - 16v OG
Post by: Lewy on 17 October 2007, 21:02

Holla!

Well it's off for it's MOT on Saturday, and once it's done I'll be driving it to my week day home where I'll pull it apart again (cos I can) and try my hardest to get it how I want it.

That is unless a certain Wife or Mr Vickers decide otherwise!

I'll get some pictures up soon, just to prove I've still got it!

Title: Re: Lewy - 16v OG
Post by: Lewy on 22 May 2008, 23:41

Ok here we go, 7 months on and I'll try and see if I can still write!!

Well the car has been sitting at work since the last post due to me being too tight to insure it, and I've been all over the place lately with work, and so I've had no time to spend on the car, which is a bloody shame as I've been hoarding bits and pieces like a squirrel collecting nuts!

The wheels are now 8.5" on the front and 9's on the rear. Bit of a crappy photo but thats a cheap Nokia for you.

(http://img529.imageshack.us/img529/6532/image032yf2.jpg)

(http://img529.imageshack.us/img529/8053/098cf0.jpg)

The front

(http://img529.imageshack.us/img529/5812/image031uo7.jpg)

(http://img529.imageshack.us/img529/8900/095iu6.jpg)

I've collected so many bits of late I'd forgotten about bothering to get it painted. The paint is terrible! When I bought it I was happy with it, but after 2 and a bit years (much of that off the road!) it looks bloody awful as the lacquer is peeling all over the place, so.....

(http://img529.imageshack.us/img529/2872/dscf1142nc1.jpg)

(http://img529.imageshack.us/img529/7199/dscf1143ae8.jpg)

........And the best thing about the strip down is that when we exposed the metal under the windscreens and the rear side windows, there wasn't a spot of rust that Brad my painter had to sort out - no all the scabby parts are in the rear panel!!! :laugh: :laugh: Hopefully the car will be back with me in time for me to fit back up again, lower it, and do some stuff ( :shocked: ) to it for Bug Jam.

All being well Mr Trimdeluxe will delivering some nice bits and pieces this weekend, so the interior will be just as nice as the outside.

I also got hold of this humble 9A to plonk in next year, after it's been made a bit bigger (2.1) and £2k's worth of throttle bodies!

(http://img529.imageshack.us/img529/3809/011kw0.jpg)

Toot toot!

Title: Re: Lewy - 16v OG
Post by: Lewy on 11 December 2008, 01:46

Well after serious consideration the OG was broken up and sold off.

I'll probably never ever will go down this route again. I have wasted too much spent alot of time and money and I enjoyed it too.