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Model specific boards => Golf mk2 => Golf mk2 gallery => Topic started by: jv on 27 March 2006, 18:56
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I bought this very tidy Edition One 8v as a daily runaround but it was just too good a project base to waste. Seeing as it has taken me forever to get anything much done to my Rallye, I was persuaded to sell the Ed1 to Dizzie rather than have 2 unfinished cars!
I look forward to seeing this one complete. Aubergine is a stunning mk2 colour plus 20v power should make for a :cool: car
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28th March 2006
Right then! Suppose I bettered explain myself for purchasing this car when I already have the blue 20vT. The bodywork on the blue one is bad in places which are difficult to fix. Namely under the dash, in the gap when you open the door, around the fuel flap, tailgate, rear arches and around the windscreen. Basically it would of cost me more to sort all those problems out than it would to buy another car and transfer my engine into it. so that's what I did. Lots of persuading and 4hrs on a train later I was at JVs :D
Right then. This is the car
(http://www.tripwyre.co.uk/dizzie.biz/edition1/e1kmarch.jpg)
You can't really see how lush the colour is in this pic because it was such a gloomy day, but in the sunlight it's a really gorgeous purple. The official colour isn't actually Aubergine as a lot of people say but it's "deep burgundy pearl". Originally the edition one's came with loads of lush little touches that the other golfs lacked. These included Blue electric recaro seats with matching door cards, plush blue carpet, blue parcel shelf (try finding a mint of those!) and chromlux glass. It also has a leather G60 steering wheel, gearbox and hand brake handle which make driving that little bit nicer. Most of the edition ones are G60 engined, but there are a small number of 8v and 16v versions. This is one of the 8v models.
The plan! I'd spent a lot of money on my blue golf in the engine department and it still wasn't finished. As the edition one's all came in LHD I wanted to convert it to RHD using the power steering setup off the blue one. I'm also going to install the 20vT engine out of the blue one into this car. The brakes are are currently on the car are the 8v standard 239mm ones so I shall also move my 280mm ones off the blue car onto this one to improve the braking! I will also be putting all those little luxuries like electric mirrors and windows :smug:
So far I haven't really done much to the car. The blue carpet wouldn't look right with the non-blue seats so I've sold that. removed it all today. Also the carpet is different for RHD. Here's a few pics of what I've been up today.
(http://www.tripwyre.co.uk/dizzie.biz/edition1/nocarpet.jpg)
Most of the original VAG soundproofing is still there are in VGC!
(http://www.tripwyre.co.uk/dizzie.biz/edition1/bootfullofbits.jpg)
All the bits and bobs removed to let me remove the carpet!
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2nd April 2006
"Déjà Vu"
Right then. During a normal boring sunday I decided to crack on with the conversion of LHD to RHD. Here's what I got up to!
I want to get the car back running again once I've made it RHD and then move onto installing the 20vT engine aswell as the mk3 dash. The mk2 dash obviously bolts straight in which I can do a lot quicker than a mk3 one which will require welding and fabricating to get it in there perfectly.
During the week I'd removed the blue carpet sections which have now been sold on aswell as my beloved electric recaro seats. All in the name of this car! During removal of the carpet I had to remove the lower section of the dash so the boot was full of that already. I set to work removing the surround housing all the switches. Off came the steering wheel and stalks. I then started removing peices of loom which went from the fusebox to the switches and stalks. These bits of loom won't need modifing due to the distance staying the same.
(http://www.tripwyre.co.uk/dizzie.biz/edition1/lhdtorhd/dashout.jpg)
The dash was easily removed. a site which I'd seen before when I installed the mk3 dash into my other golf and one I'll see again in the future no doubt.
next I started to remove the steering column and pedal box. I knew how to do the column as I had to modify it during the mk3 dash swap to clear the dash. The pedal box was a different kettle of fish. I'd removed all the visible bolts which held the pedals to the car's bulkhead but still it wouldn't come clear. The cables and brake servo had also been disconnected, but this made no improvement to my situation. It turned out to be the hole where the clutch cable went through into the engine bay that held the pedals in now which was quickly solved by removing a clip under the bonnet. Unfortunally my original idea of what was involved had all the points where the pedal box, etc mounted ready there so I could just bolt it all back on. Unfortunally this isn't the case. All the grommets I had been hoping for weren't there. :cry: This means I will have to make these holes. The though of cutting a 10cm hole into an edition one is a little un-nerving!
(http://www.tripwyre.co.uk/dizzie.biz/edition1/lhdtorhd/pedalboxout.jpg)
Still trying to remove the column from the rack which is tricky. I need a really big screwdriver and then I'll be able to lever it free.
As for the loom... I've got a cat 1 alarm installed on this car which I would like to remove in a way it can be reinstalled on another car later on. So far I've managed to remove it without cutting any wires to this plan is still going smoothly. I've also fed through 1 of the main engine harnesses. There are 2 in total. Both of these will need to be replaced with RHD versions to save me severly modifying the original one. As for the large bunch of wires which feed the rear lights, etc I shall be reusing the original one and swapping over the indicators so they flash the right side when I move the stalk. Easily done.
(http://www.tripwyre.co.uk/dizzie.biz/edition1/lhdtorhd/bootfull.jpg)
This is now the state of the rear of my car housing all the parts I've removed from the dash area aswell as the spare set of wheels from my grey runabout.
Next task is to further remove the remaining section of loom which is under the bonnet aswell as work on removing the alarm system without cutting too many wires and having no idea where they joined to making the alarm useless!
Plus I'm f**king knackered now from all this work :grin:
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3rd April 2006
After speaking with Gareth @ DUBusiness today he informs me I must fully remove the nut and bolt which hold the steering column to the small knuckle system which goes through the hole. There's a small cutout which prevents the 2 coming apart unless the bolt is completely removed. To add further humiliation once I'd removed said bolt the whole setup just fell apart! And there was me pulling with all my might holding it down with 1 foot yesterday trying to get the bloody thing apart :rolleyes:
(http://www.tripwyre.co.uk/dizzie.biz/edition1/lhdtorhd/lhdgone.jpg)
So that was that. The steering column was now free and moved accross to the other side of the car where it will now live. Luckily the threads where it bolts to the bulkhead were there so I bolted that in :smug:
The remaining loom section which I didn't remove yesterday was stuck because of the alarm's siren and bonnet pin. As these wires were all different colours I decided to cut them leaving the engine harness free to remove. So that's all the loom completely removed in the front of the car. The only section that remains is the main bunch that run the rear lights. I shall be modifying this section and reusing it once it's moved to the opposite side of the car.
Next came the brake servo. This was easy to separate from the master cylinder as it was a 2 bolt job and a bit of manouvering to get it past the brake hoses etc and free. That was the servo out of the car fairly straight forward. I also wanted to give the engine bay a nice wash before the loom goes back in so I removed the washer tank and header tank out of the way and cleared up the n/s wing as much as possible.
(http://www.tripwyre.co.uk/dizzie.biz/edition1/lhdtorhd/servogone.jpg)
now onto the steering rack. This is held in by 4 bolts through the subframe and secured with 4 nuts on top. pretty straight forward enough to pop a spanner on the top nuts and use the ratchet underneath the car to loosen it all off. I then drained the PAS fluid (into a bucket, not onto the drive!) as I will need to swap over 2 of the 3 PAS hose sections when I reinstall the RHD steering rack. Now I've looked at the PAS hoses most of them are crimped on which is annoying. I guess the whole PAS system will have to be removed at this stage and I shall have a rethink on what my attack plan will be once I've removed the steering setup from my blue mk2.
At the moment the rack is loose and can be moved around, but not removed from the car just yet. I've also removed the bolts securing the rod gear change setup from the rack aswell as the trackrod ends from the hub carriers.
Tomorrow's tasks:
Completely remove steering rack
remove brake master cylinder
I've also bartered a RHD 90 spec 8v engine harness and other RHD parts in exchange for some work out at DUBusiness so project £0 continues :shocked:
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5th, 6th and 7th April 2006
I've been so busy with working the last 3 days I haven't had a chance to get onto the PC to update!
Well as was trying to remove the subframe from the car in order to drop it down to remove the rack the bolts were giving me a bit of resistance. I then put all my strength into undoing this one front bolt with the breaker bar attached when I thought I'd got it. Unfortunally I had just sheered the head off the bolt so the subframe was no longer bolted in there. nuts.
I gave Gareth @ DUBusiness another call and he said if I brought the car up to his workshop I could work on it outside there and have access to all the tools and advice I needed. Also he would get the remains of the bolt out of the chassis and sort all that out for me. So on Thursday night we nipped back to my place and picked up the car to tow it up to his.
I have been working out with him for the last 3 days installing a VR6 lump into a once 2.0 8v mk3 which has gone well. learnt a fair bit about other engines and golfs other than the mk2 with a 4 cylinder engine! As I haven't been getting paid for this work he has been paying me in parts I have needed for this conversion I'm doing on the edition one. Sounds alright to me.
As I'd wired up the mk3 ready for it's engine and swapped the pedal boxes over and installed the cable shifter it was ready for it's engine to be installed. Since there was another car in the workshop I wouldn't be able to get the VR6 engine past on the crane so there was nothing else I could do to the conversion I was given the remaining half of the day to work on my car. :D
I managed to install the pedal box from the RHD mk2 I have parked next to the edition one which is being broken aswell as the fuse box hanger. I then bolted in my steering column support and attached the column aswell. It was starting to look more like a RHD mk2 now - yay :D I have also installed a new heater matrix into my RHD heating system, but haven't bolted it to the car yet as there isn't a hole for the air to enter the car yet above the fan. Once I've cut this hole I shall install the heating system.
(http://www.tripwyre.co.uk/dizzie.biz/edition1/lhdtorhd/lookinglikearhdnow.jpg)
As the car I took the fusebox hanger turned out to be a G plate '89 instead of a G plate '90 spec mk2 this caused a few problems. Firstly the loom I was planning on having has the older style plugs on the fuse box so there was no chance I could just plug it straight in. Arse. Secondly the lugs on the sides of the fuse boxes were slightly different between the '89 and '90 so I had the cut new guides for the lugs to rest in. This then gave me more problems as the fuse box wouldn't sit securely in the hanger even with the 2 white clips on both sides. I'm still looking into this problem and more than likely I shall hunt down a 90 spec hanger and avoid further problems with boxes not fitting right. grrr.
I haven't cut any new holes in my bulkhead yet, but I think I'll be getting on with that during tomorrow as there is no work booked in. I have also removed the old brake master cylinder ready to install the one removed from my blue 20v mk2 which we collected from my mum's house tonight so I can start transfering the goodies from that.
After talking with Gareth tonight during the drive there's a good chance I'll be installing the 20vT into the edition one sooner than I first thought :D
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8th April 2006
Didn't really get much done to the car today, but I thought it was worth an update on what's happening. I've decided I'm going to drop the 20vT in now instead of wiring up the 8v and getting it running again. I've also decided to rebuild the engine while it's between cars and install the k04 turbo setup. I've got a buyer for my k03s downpipe so that'll provide me with some money to get the new one made up.
All I did to the edition one today was remove the rad and intake ready to lift the engine out.
(http://www.tripwyre.co.uk/dizzie.biz/edition1/radout.jpg)
I also stripped most of the blue mk2 out ready to sell all the little bits and get rid of the shell.
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14th April 2006
"Removing the 8v"
With the whole interior bar the headlining removed to make way for the mk3 dash and RHD conversion next on the list was the engine bay. I had also removed the entire LHD loom as with the fusebox relocating to the opposite side of the 'cabin' the engine bay harness no longer reached and would have to be a) modified to reach or b) replaced with a complete RHD version. I opted for option b in this case so the entire RHD 90 spec loom has been agreed @ £48. I haven't paid for it yet so I haven't fitted it either! Once I purchase the new loom it'll all be fitted into the car. I will be removing some parts of the engine harness as I won't be running the 8v engine in the car anymore, but I want to retain the original sensors so that my clocks still function perfectly unlike before.
This is how the day started. I'd removed the radicator and intake eariler and drained all fluids apart from oil from it.
(http://www.tripwyre.co.uk/dizzie.biz/edition1/frontoff.jpg)
With the gorgeous welsh weather truely coming out it was a lovely day to work outside on the car. Also it showed off the true colour of my car - IT'S NOT BLACK! After removing the front of the car it became obvious why the side parts of the bumper which cover the lower front of the wings were so far away from the wings. Some donut in the past had fitted the guide peices that attach to the wings upside down putting the guide further away from the wing. They had then spaced the bottom section out with rubber washers holding it all together with a nut and bolt. :rolleyes: I rectified this little annoyance ready for when I refit my bumper.
Next was to remove the driveshafts so that the engine could be lifted out. After separating the hub housing from the wishbone aswell as the trackrod end and shock the driveshaft refused to part company with the hub leaving my no option than to remove the 2 together and attend to that problem in the workshop. I have G60 280mm brakes replacing the original 239mm GTi ones aswell as the driveshafts I removed from my blue mk2 so I wasn't that fused. Ali is having the GTi ones for her car so I best separate them later on. My shocks are also being replaced with the KW setup I bought a few months ago, but they're at Voodoo's workshop so i can't swap those over just yet.
(http://www.tripwyre.co.uk/dizzie.biz/edition1/8vbrakesgone.jpg)
With both driveshafts and hub assembley removed it was ready to lift the 8v free of the engine bay. The exhaust was causing more problems in the fact it had rusted itself together and I couldn't get the downpipe to separate from the cat. I guess this was coming out together then. I did split the exhaust after the cat though. With the remaining subframe bolts giving me loads of trouble, but no more sheering off it dropped to the floor. luckily I had already got the engine on the hoist so that didn't crash to the floor with the subframe :grin:
(http://www.tripwyre.co.uk/dizzie.biz/edition1/readytolift.jpg)
1, 2, 3....
(http://www.tripwyre.co.uk/dizzie.biz/edition1/8voncrane.jpg)
I shall be removing the sellable parts such as the alternator and starter motor and moving the HT leads and Dizzy cap onto my daily 8v runabout and scrapping the rest. If anyone is interested in this engine PM me and I'll leave it as it is!
(http://www.tripwyre.co.uk/dizzie.biz/edition1/subframeout.jpg)
With the subframe removed from the car you can see the remains of the bolt I sheered the head off sticking down. It's on the left just next to the row of sockets on the floor. I will need to weld a bar to that to try and remove it from the car. With the cross member, subframe and radiator supports all removed from the car I dowsed them in cleaner and pressure washed them off ready to recieve a nice coat of black paint so they should be looking like new when they go back into the car. not covered in oil and grim. :smug: I will also remove the LHD PAS rack and fit the RHD one I removed from my blue mk2 before refitting commences.
When it came to replacing the original rod shifter with my cable one I needed to slightly modify the mk3 shifter to allow me to bolt it to the bottom of the car. This was only as the housing was slightly too wide for the bolt holes. Using the angle grinder I cut 4 half moons into the housing which lined up with the bolts perfectly.
(http://www.tripwyre.co.uk/dizzie.biz/edition1/modtocableshifter.jpg)
All that was left for me to do then was slide back under the car and fix the shifter in place and replace the heat shield. voila :cool:
(http://www.tripwyre.co.uk/dizzie.biz/edition1/cablesfitted.jpg)
I'm now waiting for the tools to rehone my bottom end so I can fit the new low compression pistons and rebuild the 20v engine back up and bolt on my k04 turbo. As funds are still very tight I won't be able to buy the DTA management loom or get it remapped so it could be a while before she's putting 280bhp to the floor.
Tomorrow I shall be working on fitting the mk3 dash in and more than likely replacing the headlining as it's just getting battered in the back of the car. Might even drill the holes needed to fit the steering and brake servo if we get some tank cutters.
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23rd April 2006
"Putting it back on it's own 4 wheels..."
After some carefull pushing and pulling while the front of the car was on 2 jacks we managed to get the car inside the workshop and back down onto axle stands.
(http://www.tripwyre.co.uk/dizzie.biz/edition1/outsidedubusiness.jpg)
Ready for Gareth to weld on a bar to the remains of the bolt and remove it. I dunno how people see what they're doing with a welding mask on. I couldn't see a thing, but at least I avoided arc eye!
(http://www.tripwyre.co.uk/dizzie.biz/edition1/inworkshop.jpg)
Once the bolt was removed it was over to me to refit my freshly painted subframe. I removed the 2 rear engine mounts from it before fitting as both of these were showing signs of wear. Best to pop 2 new ones in at this point than later down the line when the engine is in the bay. I managed to refit the subframe nicely under the car and bolted the ARB back down onto it when I realised I haddn't fitted the sodding RHD PAS rack to it. Grrr. :angry:
I then decided I wasn't removing the subframe again and I would do it with it still on the car. After removing the one side tie rod I wiggled and pushed and got it back on the car and the tie rod refitted with the rubber boot secured over it as it was before. Subframe done. PAS tank was popped in it's little holder and the pipes secured in the hook on the chassis leg. The rad support needs a lick of black paint soon.
(http://www.tripwyre.co.uk/dizzie.biz/edition1/subframeon.jpg)
I then went onto refitting the radiator support and cross member to the front of the car and then tried to fit the front bumper back on the car. this proved to be impossible as the rad support bar haddn't lined up so the bumper bolts were never going to go through to secure it! :angry: So I removed it all and started again making sure all the holes were lined up this time! I had also made slight repairs to the guide peice on the bumper as the previous one had broken at the top allowing it to sag. some monkey who owned the car before JV and myself had held it up with 2 screws through the splitter and into the plastic arch. what is the dubworld coming to! I tried again to refit the bumper, but it was still giving me grief. With 1 bolt in that was enough to hold it secure. I broke the opposite guide peice now so I'll have replace that one to get it sitting perfect.
With the slam panel and grill on I refitted the hubs from the blue car which had the G60 280mm brake setup attached. with the hubs on the G60 15" steelies were fitted. There's no a lot of room between the brakes and the wheel, but enough not to catch! The car was then dropped back down onto it's own 4 wheels for the first time since the last post so we can move it around again. There's still no steering column connected as I haven't cut the hole for it to go through, but at least the rack is there now! That'll be next week's task. I can then start to fit the heater matix and braking system.
It's amazing how much the engine lowers the front of the car LOLÂ :laugh:
(http://www.tripwyre.co.uk/dizzie.biz/edition1/needslowering.jpg)
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25th April 2005
"Engine rebuild begins..."
I did do some work on the car yesterday, but nothing really worth writing a separate post about. All I did was install the leccy window mechs and leccy mirrors in both doors. this gives me enough room to work on installing the dash better without the manual mirror adjusters hitting the dash.
Today I started to strip down the 20vT block ready for it to be rebuilt with the lower compression pistons and a few other little tricks here and there to get a healthy and reliable 280bhp once it's been remapped by Vince @ Stealth. There's so many little hoses and bits that need to be removed. I decided to remove everything bit of the engine so it can be throughly cleaned ready for paint. Hopefully it'll look like new once this is complete and I can reinstall it back into the engine bay. I also need to install the engine loom under the bonnet really really tidy seeing as I have loads of room to get that done.
First I lifted it up using the crane and drained most of the fluids from it while it was on there. One of the flywheel bolts didn't come off easy so we had to get the bolt remover to get that one out. the rest were easy.
(http://www.tripwyre.co.uk/dizzie.biz/edition1/stripdown.jpg)
Then onto the engine stand so it's easier to work on hopefully!
(http://www.tripwyre.co.uk/dizzie.biz/edition1/onstand.jpg)
After all that the bits where rounded up and popped in a box so I wouldn't loose any of them! I have another inlet manifold which I plan to polish up aswell as the spare rocker cover I have. This should make under bonnet viewing very pleasing. :smug:
(http://www.tripwyre.co.uk/dizzie.biz/edition1/boxofbits.jpg)
I shall remove the head tomorrow and see what condition the bores are in. if they're ok I'll install the new pistons and start to rebuild the engine up. Should have it done this week :D
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26/27th April 2006
"More engine work"
Continuing over the next couple of days I stripped the engine down further to the point there I removed the pistons and rods. I still can't remove the bolt from the end of the crank so I left it in the bottom end! I will be removing the pins soon and fitting my new lower compression pistons. I need to get the honing tool to slightly do the block before refitting can happen.
(http://www.tripwyre.co.uk/dizzie.biz/edition1/head.jpg)
(http://www.tripwyre.co.uk/dizzie.biz/edition1/block.jpg)
(http://www.tripwyre.co.uk/dizzie.biz/edition1/pistonsout.jpg)
It's been reconmended I replace the big end bearing shells at this point so those will have to be ordered from VW aswell as a huge array of gaskets and bolts. There are too many bolts that can't be re-used! :angry:
With various bits now removed from the engine I gave them a thorough clean in the parafin parts washer and then once dry gave them a lovely coat of my favorite paint - Hammerite :cool: The plan is to paint the block black and all the little bits that bolt onto it a nice silver colour. I've made a start with the sump, oil cooler and the alternator and PAS pump bracket.
(http://www.tripwyre.co.uk/dizzie.biz/edition1/paintedsump.jpg)
The day was ended with the tidy up as usual leaving my engine in about 100 peices :undecided:
(http://www.tripwyre.co.uk/dizzie.biz/edition1/100peices.jpg)
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28th April 2006
"Making holes..."
As with a lot of parts being replaced during the conversion to RHD I need to cut some new holes in the bulkhead for bits to come through into the engine bay. Before I had cut these the only way to move the car was to steer by adjusting the wheels and pushing some more. First hole I needed to make was lower down which would allow me to connect the steering column from inside the car to the steering rack on the otherside. The cutter of choice was a borrowed 'nibbler' from my friends @ Sextons.
Using the nibbler requires a little skill. if you're not carefull it'll run away from the area you want to cut and just go mad eating everything. I'd drawn a rough circle where I needed the hole so I tried to say within the line! After the nibbler had done it's duty I went round the edges with a hand file to tidy the edge up.
(http://www.tripwyre.co.uk/dizzie.biz/edition1/steeringhole.jpg)
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30th April 2006
"The wiring nightmare begins"
I wasn't sure how long I'd be up at work today as it was a sunday, but it turned out I had enough time to get a fair wedge of tasks completed. :grin:
Before the engine is installed into the car I needed to mount the brake servo which also requires new holes to be cut and the brake lines which I'll be making up soon. Of course the servo will be receiving a nice new coat of black paint before it's bolted in. It required slightly modifing to get it to clear the turret, but that didn't take long and it was in the bay.
Tasks that don't require much in the way of tools or electricity was installing the wiring loom which I bought for a RHD 90 spec golf. First of all was the loom for the rear of the car. I had removed the LHD version of this part of the loom eariler in the week. The main difference between the 2 is the side of the car that the loom runs down. I wanted to keep the loom as tidy as possible so every single little plastic clip that holes the loom along the back of the car was sought out and used.
(http://www.tripwyre.co.uk/dizzie.biz/edition1/reardone.jpg)
Aswell as the whole back of the car being tidy as possible I then routed it nicely down the side of the car again using the clips to hold it in place.
(http://www.tripwyre.co.uk/dizzie.biz/edition1/rearloom.jpg)
I've always been a fan of cars where the loom is as hidden as possible under the bonnet so this was one of the main issues I had to address. The new loom I had bought had been wrapped with the kind of wrap that new golfs are done in. some of which had to be removed for what I had in mind, but I plan to rewrap any parts that are under the bonnet. There are 2 large clumps of loom that run across the top of the bay on the edge of the raintray which I didn't want on show. I laid the loom into the engine bay to see which bits can be hidden. There are also a number of bits of the loom which won't be used due to the DTA engine management taking care of running the 20vT lump. I only managed to get the 1 large peice routed back into the bulkhead and routed between the matrix and the bulkhead. I decided it was best to plug a few things into the fusebox to make sure it all reached before finalising it's resting place. Everything was fine as it was :smiley: You can also see where I've made the hole for the brake servo here too. The hole currently covered in gaffer tape will be welded up soon sealing it from the outside.
(http://www.tripwyre.co.uk/dizzie.biz/edition1/loominside.jpg)
I also drilled the holes I needed to ready to mount the mk3 matrix and fan system. There were 2 holes I needed to make in order to bolt this in which with some carefull messurements I did 1st time instead of 3rd time like on the blue mk2. I haven't made the hole yet for the fresh air to enter the car, but this shouldn't be a problem.
(http://www.tripwyre.co.uk/dizzie.biz/edition1/matrixin.jpg)
I made a few more little cuts to the mk3 dash to get that fitting more flush and sat back to think of how it'll all look once the work is done. :drool:
(http://www.tripwyre.co.uk/dizzie.biz/edition1/mk3dash.jpg)
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14th May 2006
God it's been like 2 weeks and I haven't updated!
Spend the 7th of May (last sunday) working purely on the dash. I made a lot of new cuts to get it sitting better without gaps aswell as a lot higher so I can use audioscape door pods once I get some. I got it in there and very high by tilting it to bring clearance up at the bottom. This was all going good until I realised there was now a huge gap at the bottom where the peices that meet the door vertical's were about an inch away! grrr. Time for a rethink.
I tilted it back down so they were touching the door verticals again and began working on just moving the dash up instead of tilting. This has been going well apart from I have another gap where I made it fit before. I'll fill these soon when I retrim the whole dash. At a guess I'd say the dash is now about 2 inches higher than it sat in the blue car. The steering column hasn't been lowered like before and the dash is a good inch at least off the standard position so I should have gained some more room lower down to clear pockets.
Then yesterday I had the car washed, dried and into the workshop for what I hoped was a day were I could get the dash support bar welded into the car and I could start building up the dash, but no welding took place. Instead I worked on the wiring a bit more and tiding things up under the bonnet. I've decided that the battery is now going in the boot aswell as the washer bottle. I removed a couple of bits of the loom from the peices that run down the n/s chassis. with these gone I started to route it through the leg peice by peice. The original big red wire that goes to the battery now pops out the chassis leg halfway down and will connect to the starter motor. I shall connect the huge 0 gauge power cable from the battery to the start also aswell as a big peice of 4 gauge from the alternator to the starter so power levels should be as high as possible.
(http://img.photobucket.com/albums/v106/essee/enginebay.jpg)
I will now remove a bit more from the dash support bar so that can be welded in soon. other than that I'm almost at a stop until I can rebuild my engine which should be taking place this week. that after I've made up brake lines and go new rear engine mounts the engine can be installed. I'm not planning on getting the wings smoothed off just yet. that's a future plan as I just want the car running for now!
pics to follow!
****Edit****
Right, here's a pic of my work from saturday. The light is too low in the workshop to take a pic with the flash off so I had to take one when the car was outside in the daylight. It looks like I've gone backwards since the last pic! The only traces of wires that can be hidden are right close to the bulkhead where they enter the chassis legs. after that they only amerge at the end where they meet the headlights, horn, indicators, etc. Really please with how that little opperation went. :)
(http://www.tripwyre.co.uk/dizzie.biz/edition1/enginebaymay14.jpg)
The wires you see hanging around the middle of the engine bay are the ones that connect to the engine for the sensors, etc.
I plan to make up some plates to weld onto the tops of the chassis legs which when smoothed down will give the engine bay a lot better look. I will also be removing and smoothing down all the little bits that are in the turrets and eventually removing the scuttle panel and all the holes which have grommets in them at the mo. I'm not going to do that right now even though the engine is out of the car because I just want to get it back in 1 peice and ready to show off at VW Action :cool:
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3rd June 2006
"work continues"
So the project has been sort of put on hold for the last couple of weeks due to work and waiting for parts from America to arrive. I managed to installed a 20vT lump into a corrado yesterday. It went from engineless at 9am to engine in and mostly connected at lunch and then running and driven out of the workshop at 6pm. Not bad for a day's work :smug:
The parts I've been waiting on for ages have been the new con rods now available from SCAT. SCAT are a company mostly associated with the air cooled side of the VW range, but recently released engine parts for us water cooled peeps. After hearing good reports about them and impressive numbers on both the BHP handling (150 per rod!) and the price! After converting to pounds they set me back £166 for the rods, £40 postage and £27 import tax. Not bad seeing as VAG want twice that for their rods which are no where near as strong. The SCAT rods are also lighter than the standard ones so my engine should rev up slightly better. See the pic to see how much the SCAT ones (on the left) are phatter than the VAG ones.
(http://www.dizzie.biz/edition1/rodssidebyside.jpg)
So I attached the new S3 lower compression pistons to the SCAT 'rods ready to be fitted into my bottom end. I couldn't get the clips into the small ends so I left them until tomorrow when I'll have some help. The new rods also came with ARP bolts so with these babies in the bottom end is pretty much bomb proof which is nice to know when you're knocking on the door of 300bhp. My flywheel should be back next week lightened and balanced :grin:
(http://www.dizzie.biz/edition1/4pistons4rods.jpg)
With the corrado out of the workshop I could finally get my car in there instead of it being outside the unit so it was straight onto the ramp for me to remove the digi fuel pump and get the higher pressure K-jet one installed which was donated by the blue car. I had to make up a small peice of the fuel line as 1 of the pipes came off the pump differently, but that wasn't hard to do.
(http://www.tripwyre.co.uk/dizzie.biz/edition1/fuelpumpgone.jpg)
Making sure the line from the tank was clamped off! There's a full tank of super I didn't want on the workshop floor!
(http://www.tripwyre.co.uk/dizzie.biz/edition1/fuelpumpinstalled.jpg)
The underside of the car is looking pretty good anyway, but I'll give it a fresh coat of undersealant just to make sure everything is good there!
next I moved on to fitting the corrado pedal box. This will allow me to run a Hydraulic clutch setup. After driving the G60 I can't go back to a cable one. It just feels horrible now! Aswell as simpley changing over the pedal boxes I needed to drill 3 more holes in the bulkhead to mount the clutch cylinder. It also dawned on me why the brake servo 'fork' was so tight up against the pedal. I had used the one from when the car was LHD which had a longer fork due to the servo being further away from the bulkhead. Not to worry as Gareth has another I can have which should sort that problem out. I'll move my 22mm master cylinder over onto it and bolt that one back in with the new pedals once I'll sorted the holes out for the clutch.
Whilst I was under the bonnet I ran the fog light peice of loom. This is detattachable from the rest of the car so I missed it earlier when I was routing cables through the chassis legs. not a problem though. Then I installed the 0 gauge cable which I would be running from the starter motor to the battery which now lives in the boot. I was having doubts about getting this into the leg due to it's size and thinking new holes would be needed, but it all went in there just about! I then did all the laying of the cable nicely inside the car where it ends in the boot.
(http://www.tripwyre.co.uk/dizzie.biz/edition1/0gaugerun.jpg)
I also put the washer bottle in the boot and installed 1 side of the parcel shelf supports. Not a bad day's work. I'll rebuilt the engine tomorrow or next week once i've ordered up headbolts and gaskets :D
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4th June 2006
"bottom end rebuild"
With the promise of a BBQ at the unit on the cards and the glorious welsh sunshine set to full power I popped into work to find Gareth and Kins sat on my seats from the edition one inside the door of the workshop with the paper and glasses of coke while burgers and bacon sizzled on the smallest BBQ you've ever seen...
Anyway, not a lot to write about really in this update. In a nutshell I fitted my pistons and rods into the bottom end without breaking any piston rings (although piston no2 tried twice not to go in!)
With the pistons and rods installed, bolted to the crank and torqued up I slung on the sump once again and took some pics. Head bolts, gaskets, water pump and oil pump will be ordered up this week and the whole engine will be back in 1 peice ready to install into the car once I've fitted rear engine mounts and made up the brake lines. :laugh:
(http://www.tripwyre.co.uk/dizzie.biz/edition1/pistonsin.jpg)
Pistons in
(http://www.tripwyre.co.uk/dizzie.biz/edition1/arpbolts.jpg)
Lovely ARP bolts :cool:
(http://www.tripwyre.co.uk/dizzie.biz/edition1/blockpainted.jpg)
Everything looks so much better with a bit of paint. Almost brand new :drool:
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21st June 2006
"slow, but steady progress"
About time for an update ain't it?! First of all there isn't a chance in hell the car will be making it's debut on the weekend at VW Action. The costs in getting it running aswell as the spare time I have to complete the car were heavily against me so I decided a more realistic debut show would be Edition 38 at the end of the year. This gives me a lot more time to sort out all the little niggles aswell as take more time over everything making sure there are no corners cut just to get something finished.
Anyways, what have I bought in the last 2 weeks? Firstly I won a set of mk3 clocks on ebay for £19.98 (inc the P&P), but they were lost in the post by ANC, grrrr. The seller was very understanding and issued a refund on the item so everything was good there. There was another set of clocks listed a few days later taken from a Seat Ibiza GTi. Physically the same as the mk3 Golf ones, but they have silver dials and red needles :smug: they also only set me back £16.50 (inc P&P). Bargin :grin:
(http://www.tripwyre.co.uk/dizzie.biz/edition1/mk3clocks.jpg)
Secondly I purchased the new water pump to go into my engine. The plastic impellar ones are prone to breaking their blades so I decided one of the metal impellar ones is a better investment. They're only a couple of quid more at the end of the day so it's silly not to if your original one has died. Another visit to the local GSF and £21.74 later...
(http://www.tripwyre.co.uk/dizzie.biz/edition1/waterpump.jpg)
Seeing as I haven't bought the new oil pump yet the sump remains unsealed, but temporaryly bolted to the bottom end for photo purposes. Once I get said oil pump I will seal the sump on for the final time and the bottom half of the engine will be complete. I will be getting this from VAG aswell as 10 headbolts and every gasket for the engine (about 8 of them). The VAG headgaskets are better quality than GSF ones so I don't really want to risk it for the sake of a few quid in this department! I've reattached the crank pulley, installed the timing belt onto the crank and reinstalled the cambelt covers for the bottom end.
(http://www.tripwyre.co.uk/dizzie.biz/edition1/waterpumpinstalled.jpg)
After my amazing find of Aubergine hammerite something had to be painted in it. The colour isn't a complete match as that would be asking too much, but after a quick mix with some black we got it slightly closer to the car's colour. It seems every other alternator these days is polished so I decided to colour code mine :cool: I also painted the aux belt tensioner which will be installed soon as the paint is still drying. that means I can install the aux belt too :)
(http://www.tripwyre.co.uk/dizzie.biz/edition1/engine210606.jpg)
I'm hoping I can get the head bolts and head gasket next week so I can bolt the head back onto the engine. my inlet manifold is currently away being polished. I'm going to have the rocker cover polished also when Chi says he has the time to get that done. I can't wait to bolt the head back on and stand back to see the engine well on it's way to being back in one peice :)
I still need a rear engine mount. preferabley a G60 one so it can take a little more abuse, but until I can install the brake lines under the bonnet it would be silly to install the engine just yet. I also need my flywheel back from being lightened and balanced and then a clutch to go on it before I can attach the recently rebuilt G60 gearbox.
It's all coming together slowly :laugh:
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12th July 2006
"interior progress"
As funds are extremely tight at the moment I've been working on doing things that won't cost me a penny! A few weeks ago I made the hole for the hydraulic clutch cylinder to mount to. As the hole was on a ridge in the bulkhead the cylinder didn't sit flush and when connected to the pedal was very very low. After a quick look at a friend's RHD G60 saw I needed to flatten the bulkhead in that section to allow it to sit flush and hopefully bring the pedal up... 2 brave pills later and with Dan holding a peice of wood inside the car and me in the engine bay I started to hammer away... You can see where I've had to flatten the bulkhead to get it in there. I'll give that a lick of hammerite in as close as I can get the right colour soon!
(http://www.tripwyre.co.uk/dizzie.biz/edition1/clutchcylinder.jpg)
With the pedal box bolted in for now and the steering column secure I wanted to get the mk3 dash support bar finally welded into the car so I could build up the dash and reduce the number of dash bits that are in the rear of the car cluttering things up! with some small alterations to the areas of the car that hold a mk2 dash in it was time to get the welder out and make those spot welds to hold it in position. After 2 small spots it was held in there pretty solid, but I want to remove the actual dash soon and put in a good few inches of strong weld that will hold it as solid and hopefully stiffen up the car a little bit. sort of like a strut brace (ish). With the dash secure in the car it was time to step back and have a look at the fit. After all it was a bit late to decide it needed to move now we'd welded it in! Luckily the fit was as I wanted and it's nice and flush against the windscreen line and sits nice against the door verticals. the overcuts on the edges will be filled in with fibreglass soon and once I've retrimmed the dash in alcantara you'll never know they were there! Also I need to build up the remaining air vents with fibreglass so there are no gaps or holes allowing the warm air from the blower to leak. In the blue car this was a major issue, but something no one else knew about :grin:
(http://www.tripwyre.co.uk/dizzie.biz/edition1/mk3dashin.jpg)
Still got a hole where the LHD steering coloum went into the engine bay. this will also be covered up hopefully this week if I get a chance to get some more work done on her :)
(http://www.tripwyre.co.uk/dizzie.biz/edition1/stillgotahole.jpg)
As I'm still waiting on the fusebox hanger from a certain forum member... my fusebox remains on the floor with all that loom lol! I managed to wire in the driver's side electric window and mirror also yesterday so I could build the door back up temporaryly. It'll all be coming off again to install the cable for the speaker and central locking, but for now at least there isn't a door car without a door inside the car making it look messy. It's starting to look like a car now inside. So pleased I've got the dash in there finally! I've hit a slight problem concerning the clocks. they don't fit. My steering column is in the way. I'll be having a think about this problem over the next few days. I may have to cut most of it away and build another support peice which will be welded or bolted to the car giving the original support back to the column. I don't want to pull on the wheel when getting out of the car and find it dropping on my knees!
(http://www.tripwyre.co.uk/dizzie.biz/edition1/wiringmess.jpg)
After my little session with the quik clay and major Zymöl waxing sesh it was only fair to put a pic of it in the daylight. I should of taken a pic when the sun was out, which wasn't for long! The purple looks gorgeous :smug:
(http://www.tripwyre.co.uk/dizzie.biz/edition1/outside120706.jpg)
What's in the white bag? PAS lines, that are still leaking 3 months after I drained the system :angry:
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25th July 2006
"Brake lines done - yay"
We had a F plate gti in work that was being broken for parts. The original plan was to build up my brake lines using the new copper pipes we have, but with a lack of tool to do the ends the chances of me actually doing this sometime soon were slim to none. Anyway, with the other mk2 going I decided to liberate it of it's brake lines and transfer them onto my car. that way I know they're perfected sorted for the task. After about 20 mins of carefully removing them off the bottom of the car and moving them around the engine so I didn't bend them out of shape they were off the car. The original LHD setup was removed too and folded up ready to be binned.
I removed the lines from the compensator under the n/s wheel forward. The compensator is the common place were the LHD and RHD lines are at the same point on the car. Refitting the lines to the unside fo the car is so much easier than removing them without breaking anything! After using the daily driver as a referance they were fitted to the edition one as if VAG had done them :D
(http://www.tripwyre.co.uk/dizzie.biz/edition1/brakeline.jpg)
I still need to mount the proper servo with the master cylinder on before I can attach the lines to it making the braking system pretty much finished. Getting this done has really recharged my inspiration towards the project! I've got the front calipers and carriers setup removed off the car and gave them a bit of a shotblast to remove the previous paint before giving them a fresh lick of black paint. After 15 mins of shotblasting the 1st caliper I gave up. It's hard work lol. so decided if the paint isn't coming off like that it's hardly going to come off when they're on the car!
I'll be painting them this week ready to refit to the car.
As for what was going on inside the car. I also took the carpet from the breaker so I now had a complete carpet set that was in very good condition. the patch under the driver's heals wasn't worn at all. I guess the mats that were in the breaker when we got it had been in there a long time and that shows with these carpets :). The downside was I think someone has spilt a mcd coke or something in the back. When I lifted the carpet out the smell that hit me can only be described as raw sewage!
I completely soaked them in truck wash before turning the pressure washer up to the highest heat setting and giving them the cleaning of their lives! Now they look brand new again and don't smell!
I also got a rear bench for the car in the same pattern as the front seats so that was put in there to make the car a little more complete. all the parts and bits still to put on the car now fit in the boot so the car doesn't look like it's had the interior ripped out of it! I'll be installing the carpet's once I've changed the roof seals. No point in doing them without swaping the seals else as soon as it rains I'll have a puddle in the back again!
(http://www.tripwyre.co.uk/dizzie.biz/edition1/inside.jpg)
As the car has been sat outside for the last couple of weeks it was getting really dusty so I gave it a wash. It's all about the purple eh JV!
(http://www.tripwyre.co.uk/dizzie.biz/edition1/washed.jpg)
The little update didn't cost me a penny which was nice :smug:
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6th August 2006
"Engine gets rebuilt and installed"
I had a little surprise this week in work. The boss had bought all the gaskets and bolts I needed to complete my engine and get it back into the engine bay. With the whole Saturday to work on my engine I cracked on! I'll pretty much leave the pictures to do the talking :)
Let's start at the bottom and work up. First of all I needed to install the new oil pump and windage tray. The sump on the 20v doesn't have a gasket like a 8v from a mk2 so you have to use a special sealer. it's a bit like icing a cake lol!
(http://www.tripwyre.co.uk/dizzie.biz/edition1/newoilpump.jpg)
Next up was to pop on the lovely genuine VAG metal head gasket and bolt on the head.
(http://www.tripwyre.co.uk/dizzie.biz/edition1/headgasket.jpg)
(http://www.tripwyre.co.uk/dizzie.biz/edition1/headon.jpg)
As money is still very very tight at the moment and I haven't got the other rocker cover polished up I decided to give the old one a quick spray to see what that comes out like. I'm quite impressed really. looks good :)
(http://www.tripwyre.co.uk/dizzie.biz/edition1/blackrocker.jpg)
After spending several hours reattaching water pipes and getting all the oil and water feeds for the turbo sorted it was time to bolt on the gearbox. this was pretty much the last thing I had to do. My flywheel had been lightened and balanced last month so that was bolted onto the crank. I think a lot has been taken off it because there's a lot of space between it and the block :D
Hopefully that'll allow my engine to spin up nicely. With everything bolted on it was time to load it onto the crane ready to install into the car
(http://www.tripwyre.co.uk/dizzie.biz/edition1/20vtoncrane1.jpg)
I'll be having a new intake pipe made up when it goes for the downpipe and boost pipes. the standard one is so bendy it can't be good for airflow! As soon as my polished inlet manifold arrives from voodoo that'll be going on which will make the engine viewing a lot more pleasant. Kinda lets down the look now :( I'm probably going to move the PAS tank so it's flush against the chassis let. sort of sticks out a bit!
I did have a solid front engine mount, but it doesn't line up and I was getting really annoyed so popped in a standard 16v one for now.
(http://www.tripwyre.co.uk/dizzie.biz/edition1/20vtinbay1.jpg)
(http://www.tripwyre.co.uk/dizzie.biz/edition1/20vtinbay2.jpg)
(http://www.tripwyre.co.uk/dizzie.biz/edition1/20vtinbay3.jpg)
had to put this pic in :grin:
(http://www.tripwyre.co.uk/dizzie.biz/edition1/hardatwork.jpg)
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16th August 2006
"Brakes are done - almost"
Only a little update, but I thought I should do one anyway. The hydraulic clutch was now installed and ready to bleed and the brakes weren't far off being bled themselves. Managed to get a cheap set of goodridge braided brake lines for the car so that was the final peice of the hydraulics completed. Now all I need to do it put it all together.
The fronts were extremely easy as I didn't have flexi lines on there anyway so it was a simple case of just popping them on. The middle peice which goes between the ridgid lines on the car to the rear beam were little buggers. The one on the n/s was pretty much unaccessable due to the brake compenstator being in the way. After I'd removed that it was easy enough to remove and replace with the new line.
(http://www.tripwyre.co.uk/dizzie.biz/edition1/braidedfront.jpg)
The n/s rear was again easy enough. I decided to install my new green stuff pads at the same time. I think the person that installed the last set of pads didn't really know how to fit them right as there was no copper slip on them so removal was more difficult than I had of hoped. After much pry barage they were off the car. I will be removing them again soon to install my sexy drilled rear discs purely cos they look nicer than the solid ones. After the car is running the discs won't look like they're off a scrapper and they'll be back to their shiney state.
Annoyingly the o/s rear caliper is seized and no matter how much I hammered it it wouldn't free up so it's time for another one :( Either that or time to pop on mk3 ones :smug:
(http://www.tripwyre.co.uk/dizzie.biz/edition1/greenstuff.jpg)
I also installed the shorter of the 2 driveshafts while the car was up in the air. I need a CV boot before I can install the longer one.
(http://www.tripwyre.co.uk/dizzie.biz/edition1/onramps.jpg)
We're going to see if we can make up a downpipe using the original TT one and my old k03S one. That'll save me a few more quid and then I just need the management loom before I can turn the key. Well, that's providing I've done the rest of the electrics lol :D
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20th August 2006
"Major air assault on the interior and wiring!"
After the daily driver had packed up and had been broken for parts and then the mk3 I was using to get to work being sold it was an all out assault on the edition one to get it completed as soon as possible!
I started off by laying all the cables I wanted under the carpet. As the carpet was now under feet in the unit and getting more dirty everyday it had to be installed this weekend! I ran the 2 sets of cables down the drivers side of the car which were for my Alpine DVD screen. I then ran 4 lengths of 12 gauge speaker cable for the mids in the doors and the tweeters in the dash. Previously I had my crossovers in the dash, but I wanted them to be tidy in the boot this time so 4 lengths were needed. With these all gaffer tapped to the floor it was time to install the middle section of the carpet. this went as smoothly as possible which the carpet fitting perfectly. I kept all the little clips and grommets from other cars so it's all secured down nicely :)
(http://www.tripwyre.co.uk/dizzie.biz/edition1/neatcables.jpg)
After i'd installed the rear bench and bolted that into the car aswell as replacing the rear 1/4 panel door cards it was time to tackle the front carpet section. As I had so many wires under the carpet now this prooved to be quite a task annoying me for the best part of half an hour where it wouldn't go any further into the car and the fit was terrible. After much pushing and pulling I managed to get it somewhere near. it's still not 100% perfect in the driver's footwell, but I'm putting that down to everything under the carpet. Once it's got a nice mat on top it'll be fine :)
(http://www.tripwyre.co.uk/dizzie.biz/edition1/carpet.jpg)
It's hard to take a good picture when it's in the workshop because of the low light levels, but you can see everything just about!
Next I moved onto the dash. Everything was routed as neatly as possible so it should be fairly easy to install the alarm when the time comes.
I installed the main heater vents which feed the dash, but as the dash is now further into the car everything was a lot tighter. I think I need to cut some off and reseal the vents up as I can't fit the middle vents and radio section at the moment. Basically I got it looking half presentable for now. I'll start with the cutting soon!
(http://www.tripwyre.co.uk/dizzie.biz/edition1/dashaug.jpg)
Someone in the past had made a right pig's ear of repairing the roof seal as JV knows using foam and god know's what else to try and seal it. I used the roof seal from the grey car and replaced it nicely so it should be water tight now. I also sealed both door membranes so no water should be able to get in and wet my carpets now. I haven't tested this yet!
(http://www.tripwyre.co.uk/dizzie.biz/edition1/roofseal.jpg)
That's it! A productive day's work I feel. I shall be connecting the battery up soon to do a lights check and see what happens there.
I need the downpipe and boost pipes making up aswell as the DTA management loom before I can turn the key! it's getting close now!
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9th September 2006
Only a little update really. I fitted the mk3 rear calipers only to find I have a f**k load of travel on the handbrake cables meaning I have no handbrake at all. I will have to look into this problem.
I also need a mk3 steering column so I can fit the mk3 clocks. If I can't find one cheap enough i'll remove the dash and secure them ontop of the mk2 column for the time being so I can get it running and MOT'd. AFAIK you don't need a dash for the MOT test :D
Next job is to remove the dash and front carpet section and cheak everything is connected where it's suppose to be. I'll connect up the lights, etc and battery and see what happens.
I also fitted my polished AGU inlet manifold that I collected from e38 last weekend only to find out my injectors no longer fit. I will need blue TT injector seats apparently which should cure this problem.
Not long until I get the loom and downpipe done and she'll be on the road providing nothing else goes wrong!
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16th September 2006
Managed to get a little bit more done on the old golf today which makes a change! This is as she spends most of her days. :grin:
(http://www.tripwyre.co.uk/dizzie.biz/edition1/assheis.jpg)
First of all there was the matter of a split CV boot to address. 5 mins later...
(http://www.tripwyre.co.uk/dizzie.biz/edition1/cvboot.jpg)
As the front bumper hasn't been bolted onto the car in probably 6 months it was about time I sorted the intercooler out and got that mounted so I could finally bolt on the front bumper! I knew from the blue car that the intercooler never fitted as good as an original G60 one would and some cutting was needed. During the original conversion the lower section of the o/s slam panel had been completely removed to make way for the intercooler... I had a few plans to try and retain this and avoid cutting and making sharp edges!
Firstly I needed to trial fit the intercooler behind the rad and see how much room I had, or didn't have whichever way you want to look at it!
(http://www.tripwyre.co.uk/dizzie.biz/edition1/intercoolernofit.jpg)
As you can see on the edge it's right up against the slam panel meaning if I left it like that it would more than likely rub during driving making a horrible metal on metal noise! Not good :( Also because it was pushed right up against the slam panel the rad couldn't sit in the little holes on the rad support bar and also couldn't be secured at the top to the slam panel so a rethink was needed. I'd removed the fan and cowling to give me more access. this also ment the rad could easily be installed and removed without knocking the engine and my new inlet manifold!
(http://www.tripwyre.co.uk/dizzie.biz/edition1/radnofit.jpg)
I marked out where I needed to cut on the lower section of slam panel and removed that small amount with the cutting tool. Refitted the intercooler and volia! :smug:
(http://www.tripwyre.co.uk/dizzie.biz/edition1/moddedslam.jpg)
With the increased room gained by my cuts it ment the intercooler was further forward and the rad would be mounted in it's original place. Nice and secure :)
On the G60 cars the intercooler is bolted directly to the rad (obviously with nice holes) I wanted to take this approach with mine too. Previously it was secured using crude L shapped brackets which weren't very good at all meaning the intercooler had a fair bit of wiggle in it. I messured where I needed to put the bolts through and made them... All was well. After threading the rad I managed to get some bolts though the cooling fins and avoiding damaging the pipes that carry the air so it was nicely bolted together. Now when my rad is secure like it is the intercooler will be too :cool:
No modding needed to the chassis leg like we had to when fitting a sprinter intercooler here!
(http://www.tripwyre.co.uk/dizzie.biz/edition1/intercooler.jpg)
I also installed the speed sensor into the gearbox. You can't really see it, but it's there! The oil breather pipes have now gone. I shall be using 2 of those small green stuff air filters instead. :)
(http://www.tripwyre.co.uk/dizzie.biz/edition1/hydroslave.jpg)
1 last pic of it all bolted back together :laugh:
(http://www.tripwyre.co.uk/dizzie.biz/edition1/enginewithic.jpg)
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10th February 2007
"OMG he's done an update!"
Hrmm. almost 5 months since I last updated... (2 fast 2 furious quote) "Do I even want to know where the Edition one is?" :D
She's safe and sound. It's been living outside my house since it left the workshop, but nothing has been done to it since. The brakes and (hydraulic) clutch were completed before I moved it which made light work of getting it off the back of the recovery truck without sailing off down the street in an unstopable manner :D The Steering was connected and ready to rock. I could probably put PAS fluid in the resevoir, but I haven't. The departments that still require attention are: The exhaust, boost pipes, water pipes and engine management. There are still a couple of small things I also need to do to the wiring, but nothing major - I hope!
So the exhaust. I already had the full 2.5" system made up from the other car, but as I'd changed the turbo now the original downpipe was no longer useable. The original k03s setup had the outlet pointing towards the back of the car so the downpipe was simple. Now I'm using the k04 setup the outlet comes off towards the side. Quantum Performance Engineering (http://"http://www.qpeng.com/") (Qpeng) make downpipes for easily converting a mk1/2/3/corrado to the 20vT engine, but the price wasn't far off £300 when you added VAT on :(. Last year funds were a bit tight so I couldn't afford to get the downpipe I needed. This week after deciding this car had to be finished I checked again on their website not only to find that you can now order on it, but the price had been reduced to £200+vat which with the postage costs came to a nicer £242. One was promptly ordered up :D
(http://www.tripwyre.co.uk/dizzie.biz/edition1/downpipepeices.jpg)
The downpipe comes in 2 peices which makes fitting so much easier. the first section can be attached to the turbo and once the engine is installed the section with the flexi can be connected and cut to fit the existing exhaust.
(http://www.tripwyre.co.uk/dizzie.biz/edition1/downpipetogether.jpg)
I haven't got round to fitting the new shiney gifts yet as I'm not lying on the floor outside my house when there is snow all around me! I also found an eBay shop by a company called Pipe Werx which sells shiney intercooler pipes in various bore sizes and in varrying bends making the larger pipe easy to sort out without having to goto an exhaust shop to get built on the car. These pipes don't come with the outlets for the dump valve or boost control valve so I'll have to get those welded on beforehand else I won't be able to drive the car.
I also need a couple of Samco hoses to connect my throttle body to the intercooler and the intercooler to the boost pipe. I've messured the bore on all the parts I need to connect to so out came the Demon Tweeks catalogue to find out which sizes Samco do. All my hoses will be in Black rather than the usual Samco Blue everyone else has :D
The problem I now face is bridging this gap...
(http://www.tripwyre.co.uk/dizzie.biz/edition1/ictbgap.jpg)
Originally I was thinking a 90° 70-63mm reducing elbow off the throttle body into a 90° 63-51mm reducing elbow onto the intercooler, but after looking at the car again this won't work. The 90° bend off the intercooler would point the pipe straight up and miss connecting to the thottle body hose. Hrmm. so I need to think about this one. a 45° hose would be perfect for this connection... but Samco don't make 45° reducing bends! :angry: I think the way it has to be done is a 63-51mm straight reducer off the intercooler into a small 45° metal bend and then into the 70-63mm 90° reducing elbow onto the throttle body. I'm going to order up those hoses this week coming and see where I stand then. It might require cutting of the hoses to get them closer to the intercooler and pipe, but I'm pretty confident this idea will get the job done.
As for the other side of the intercooler. Another 63-51mm straight reducer will go onto the intercooler and a peice of pipe will then connect that to the pipe which is already connected to the turbo. The only thing I need to work out now is how I'm going to route this pipe and how much of a bend I need in it! I was original thinking of making a new intake pipe from a straight peice of metal which would cut out the sharp and tight bends the original intake pipe makes. This will still be done, but I think I'll be using the original pipe for now until I have a few more pennies to get that done :)
My ECU needs to be posted to Steath Racing (http://"http://www.stealthracing.co.uk/") so that Vince can upload a base map for my engine onto it and order a wiring loom from DTA for my engine. Once he's modified that loom to accept my plugs I'll be paying for it + a map sensor which will let the ECU know how much boost the engine is recieving.
With all those things attached I think I can fill it up with oil and water and turn the key!
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15th February 2006
Oh. Look what arrived the other day!
(http://www.tripwyre.co.uk/dizzie.biz/edition1/fan.jpg)
Due to the fact I can't run a standard fan anymore because the engine hits the cowling I had to go for a slimline fan. these fans are known throughout motorsport so this was the way to go really. it was a bit pricey, but had to have it to run the car. Also ordered a mounting kit which are like cable ties and go through the rad securing the fan to it. I went for a 9" fan with the plan to add another later down the line when funds allow. due to the 8v wiring it'll turn on the 2nd one if I wire it that way. I may even have a switch in the car to manually turn them on.
(http://www.tripwyre.co.uk/dizzie.biz/edition1/fanmounting.jpg)
Small rubber grommets are fitted too so the rad fins aren't damaged. Once it's all secured to the rad I bolted the intercooler back to it. It's nice that the rad and intercooler can be lifted out as one really easily.
(http://www.tripwyre.co.uk/dizzie.biz/edition1/radandicwithfan.jpg)
With it all bolted back into the engine bay it looks a bit like this
(http://www.tripwyre.co.uk/dizzie.biz/edition1/fanbehind.jpg)
Next to do is get the downpipe mounted, modify my engine mount on the back and fit the longer driveshaft. with the downpipe on I can install the rest of the exhaust. Hopefully hardcor3 has hoooked me up with some mk3 bits so I can complete the dash and get the clocks mounted. Finish the electrics while I wait for my DTA loom. get that fitted. Got boost pipes to do too and it's not far off running then!
Getting excited now :D
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23rd March 2007
Time for another update I think!
Started off earlier in the week by building up my new boost pipes. My black samco's were finally here! only took a month for those! With the Samcos attacked to the intercooler I could set about making educated guesses where I needed to cut my pipes. I'd also made educated guesses to what angle my pipes needed to be to get from the turbo at the back of the bay to the intercooler which is just in front of the radiator. I had settled on 2 60° bends for this. I found a shop on eBay by a company called Pipewerx. They sell various things for exhausts, etc for you to make up your own pipes. The intercooler pipes they sell are all mandrel bends so don't get thinner in the bend increasing air flow :)
I'd ordered 3 60° bends as I plan to make a free flowing intake pipe later down the line and also if I bugger this up I've got another to use.
First of all it was working out where these pipes were going to run aswell as positioning my intake pipe and air filter around things so it all worked well. I'd looked at a lot of pictures of other people's 20vT conversions in mk2's so going by these pics I settled on the layout you see below. After putting them up as they came I got a fair idea how much I needed to take off in order for the 2 pipes to meet in the middle and get joined.
Several cuts later I was left with this. I used a small offcut of samco just to hold them in place. I need to order up a longer peice so I don't run the risk of blowing the pipes apart the first time I boot it :evil:
(http://www.tripwyre.co.uk/dizzie.biz/edition1/newboostpipe1.jpg)
(http://www.tripwyre.co.uk/dizzie.biz/edition1/newboostpipe2.jpg)
(http://www.tripwyre.co.uk/dizzie.biz/edition1/newboostpipe3.jpg)
I think that's nice and free flowing. I wanted to avoid reducing the bore of the pipes aswell as keeping it as smooth as possible. I think I've done this as best I could :)
With all the new bits going on under the bonnet it would be rude not to replace the old header tank. :grin:
1 quick call to VW and this arrived and was promptly fitted.
(http://www.tripwyre.co.uk/dizzie.biz/edition1/newtank.jpg)
(http://www.tripwyre.co.uk/dizzie.biz/edition1/newtankfitted.jpg)
Next up was to connect the new Qpeng k04 downpipe onto my existing Prospeed built exhaust system taken from my blue mk2. Qpeng give you loads of excess on the downpipe for you to join it so first of all I needed to fit the exhaust and work out where I needed to lop it off. More sawing needed! I hate having the exhaust blowing from the joins so decided to weld this to the system eliminating another join. It was a small enough peice to not hindle future removal. It only needs joining to the downpipe and the backbox now which are all ready to be done once I've got a couple of new clamps. This will happen very soon.
(http://www.tripwyre.co.uk/dizzie.biz/edition1/weldedzorst.jpg)
(http://www.tripwyre.co.uk/dizzie.biz/edition1/zorst.jpg)
Yes that's a space saver on there! Still waiting for my new Azev wheel and I'd removed the other 3 for a good clean so they look like new just like the actual new one :)
That's the update for now. I moved on to tackle the interior briefly before calling it a night on that. The dash is out now so I'll be working on it tomorrow after work. Took 1 more pic of under the engine though :D Also filled it with oil and turned it over a few times. Turns over really nice and smooth so confident on my rebuild :) Can't wait for the management to arrive now so I can wire that up and turn the key to see what happens!
(http://www.tripwyre.co.uk/dizzie.biz/edition1/underengine.jpg)
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27th March 2007
Only a little pictureless update tonight.
Powered up the car using the booster pack as I haven't mounted the battery yet or got the cables run to link it, but on the whole the electrics test was very good. Had a slight issue with the indicators. they wouldn't work at all and then after a quick look at the daily's fuse box I realised I was missing relay 21. with that installed they worked perfectly.
plugged in the mk3 clocks to be greeted with the temp and fuel gauges swining left and right and the oil light dimmly flashing... hrmm. after some playing around I got them in a stable condition. the oil buzzer is constantly on and the oil light is flashing. I'm putting this down to the engine having no oil in it. the sensors not connected properly and the engine hasn't been properly earthed to the chassis. can't see that being a problem. also the right turning arrow is constantly lit. when I indicate it flashes as it should... need to look into that. but the fuel gauge shot straight to the right as it's been full of fuel for a year now lol.
Got everything else just about working. wipers, lights, horn, heaters blowing. got a few small things to sort out. nothing major and then a really good tidy so everything is nicely routed.
DTA management loom should be arriving this week. might even be able to start her up as the exhaust just needs clamping together. it's fitted now, but not clamped. Boost pipes are together, but not clamped either so it should idle, but won't take boost.
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19th April 2007
About time I did another update really!
Since I haven't updated for a while I've lost track of what order this lot happened in lol. I'll try my best to remember.
The DTA loom finally arrived from Stealth. the quality of it is fantastic. everything has a new rubber seal on it. the workmanship is A+. Really pleased with it. Also it came with a shift light which I didn't expect. I'll be mounting a small LED in the rev counter which will do this job. You get a larger 8mm one in the box. The feed for my rev counter is really obvious so shouldn't have much of a problem getting that to work with the mk3 clocks :)
(http://www.tripwyre.co.uk/dizzie.biz/edition1/dtaloom.jpg)
I still has the problem of the mk2 steering column being in the way of my clocks when they're fitted. the only option here was to fit a mk3 steering column which supports from underneath rather than holding from above. As we're breaking a mk3 vr6 at work I got one from there. I also got a couple of other little bits like heater controls, wiring looms so I can get it all working properly. With the column swapped and bolted in it's all back and functional again. I also have height adjustment now :smug:
The clocks now fit a treat so I'm happy about that. I didn't have to cable tie them to the column for the MOT :laugh:
(http://www.tripwyre.co.uk/dizzie.biz/edition1/clocksin.jpg)
So what was next... I laid the DTA loom onto the engine and started plugging things in and routing everything nicely around the engine into the scuttle to where the ECU will live. Unfortunally the loom isn't long enough to go inside the car so I'll put it inside a little water proof box under there. should be ok. When I got to plugging in the throttle body and air sensor I hit a small issue with the loom. When I was ordering it I told Stealth that purely for the map side of things my engine was a BAM 225 lump. My engine was originally a AUQ 180 lump that now has a k04 turbo setup and BAM pistons and forged rods. so it made sense to say it was BAM for the map until I get the final map. anyways. as the BAM engine is a 225 the throttle body is on the right. the AUQ being a 180 has the throttle body on the left... you can guess the rest. the loom wasn't loom enough!
I now had 3 issues that were stressing me out. 1) I had boost pipes that needed outlets welding onto them. 2) the BAM injectors on the AGU manifold weren't going together so wouldnt' work and needed major surgery to get them in there. and 3) my new loom wasn't going to fit without lengthing the wires. I didnt' really want to cut my loom because if there was a problem and it had to go back I'm sure they would tell me where to go seeing that I'd chopped it up!
My problem with the injectors ment the only way to get those in to work was to enlarge the seats. slim up the injectors and modify the fuel rail to lower the injectors into the seats. Hardly ideal.
The Boost pipe wasnt' really hard to fix, but time consuming and I didn't really want to do that part. Anyways. the solution? If I fitted the BAM 225 inlet manifold and boost pipe that comes around the top and down the side I curely all 3 of those problems. So that was it. Hopped on eBay and posted a couple of wanteds around the net and less than a week later and I had said items. Manifold I paid a little more than I would of liked off DUBsport through ebay which came in at £82. the boost pipe was from a local guy for £30.
The downside or sad bit about doing this was the boost pipes I had spent money on and the samco's to join them where now redundant. also the AGU manifold I had bought and then paid to have polished was also redundant :cry: ohwell. manifold will be for sale and samco's can be reused.
so now the engine looks like this. I'll be ordering up more samco's soon. probably blue this time as I cba to wait another month for black ones :angry:
(http://www.tripwyre.co.uk/dizzie.biz/edition1/225middle.jpg)
(http://www.tripwyre.co.uk/dizzie.biz/edition1/225left.jpg)
(http://www.tripwyre.co.uk/dizzie.biz/edition1/225right.jpg)
I can use the redundant black samco's to build a free flowing intake pipe which will replace the black rubber one. should make it spin up a little better. I'll work on that soon.
I also moved my rad over 1 set of holes which made all my water pipes line up again so they don't need to be modified now. water ways are almost done now :)
Other than little bits and bobs I've done around the car, but other than that I washed her :cool:
(http://www.tripwyre.co.uk/dizzie.biz/edition1/washed1.jpg)
(http://www.tripwyre.co.uk/dizzie.biz/edition1/washed2.jpg)
(http://www.tripwyre.co.uk/dizzie.biz/edition1/washed3.jpg)
I haven't waxed the car or anything in about 9 months now. I only gave it a quick once over with the wash mit and shampoo. Still got a nice shine to it :smug:
(http://www.tripwyre.co.uk/dizzie.biz/edition1/shineroof.jpg)
Next job is to get the little wiring issues done. the DTA wired up to the fuse box. the shift light done. those boost pipes done. mount the battery in the boot and wire that in. fit the other driveshaft after modding the engine mount slightly. seal and clamp down the exhaust.
Almost there!
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26th May 2007
IT RUNS!
Finally got it to fire up today after a few weekends spent headscratching. Loads of silly little things I had done weren't helping matters either. When I finally got the fuel to the rail for the 2nd time and primed it with all the lines connected it blew the fuel pressure regulator out of the rail lol. always remember to put that little clip in to hold it down!
Still loads to do. the exhaust isn't connected yet so it was very loud when running and I have a water leak on the back of the block. nothing a good day can't fix :D
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17th August 2007
This project is for sale
I don't have the time to finish it and I'd rather have the money to do other things with :)
Selling the 20vt setup here http://www.edition38.com/forums/index.php?showtopic=104455
anything else you want PM or or call/text 07816 895164 at sensible hours!
Gareth