GolfGTIforum.co.uk
Model specific boards => Golf mk2 => Golf mk2 gallery => Topic started by: jv on 11 February 2008, 18:48
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:)
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Thanks JV,
Ok here we go, this is going to be lengthy, but I'm going to keep the words as few as possible.
Its the story of my track slag, a £400 impulse buy off ebay when i was pi$$ed.
Here it is, the day I picked it up. Modifications included electric windows that fell down, non working door locks, three bent BBS rims, a gear change so baggy each gear selection was a random guess and various dents incl one in the roof :huh:
(http://i130.photobucket.com/albums/p271/20vt_project/The%20original%20build/golf2.jpg)
Some people think I'm a lucky bugger: I used to instruct at Goodwood
(http://i15.photobucket.com/albums/a397/leavingeasy/cars189.jpg)
I have a cool job
(http://i15.photobucket.com/albums/a397/leavingeasy/croatiaaugust06198.jpg)
Nice toys
(http://i15.photobucket.com/albums/a397/leavingeasy/T7D_2333S.jpg)
And get to do some fun stuff
(http://i15.photobucket.com/albums/a397/leavingeasy/CIMG4121.jpg)
But by the end of this project, you will know I'm the unluckiest bloke around!!
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It started innocently enough....
Few years ago my best mate and I decided we needed to go to the Nurburgring, to scratch that itch and tick it off the list.
I decided I needed a decent car to go in, so bought myself an E39 M5. What was I thinking??
8 laps later and we were doing ok, but the M5 was doing 6mpg and I was constantly worried about bruising my £20k pride and joy (and the loan still had six years to run!!)
In the car park I started chatting to a few guys that had DRT (dedicated ring tools). These were typically 80's and 90's hot hatches that had been lightly modded to meet the needs of the Ring. They were cheap, fun and fast.
A plan was hatched.
My best mate promptly returned home, I sold the M5, bought a 20VT Passat estate and we decided to build our own DRTs.
I'd had mk2's and 3's in the past and loved them, it was a no brainer.
We gave ourselves a budget of £1500 plus the car and set to work.
My mate built a stormer- it's been developed over the years and is now a 195bhp 9A engined dream car. Sure it owes him a few quid now, but anybody who has been in it knows what a fabulous car it is, laps 8:30 at the Ring all day long but is quiet, civilised and very easy to drive.
(http://i15.photobucket.com/albums/a397/leavingeasy/Picture017.jpg)
Of course I couldnt do anything that easy! :embarassed:
First things first:
Having got the car back, I took it to my friends workshop to see what a shed I'd bought. I'm really lucky to have a great mate who has his own garage business and without him I could never have done this.
The good news was, no rust!
The bad news was the entire car was baggy, old and was going to put strain on the budget.
I had two months before we headed back to the Ring.
So I stripped the car out and we fitted an OMP six point cage
(http://i130.photobucket.com/albums/p271/20vt_project/The%20original%20build/Cagefitting.jpg)
Then some cheap bucket seats
(http://i130.photobucket.com/albums/p271/20vt_project/The%20original%20build/golfat12.jpg)
Some dodgy 5 spoke rims with 888's off ebay
(http://i130.photobucket.com/albums/p271/20vt_project/The%20original%20build/golfat12-2.jpg)
And three pieces of perspex from another bloke on ebay
(http://i130.photobucket.com/albums/p271/20vt_project/The%20original%20build/golfat12-1.jpg)
The I had my flywheel skimmed
(http://i130.photobucket.com/albums/p271/20vt_project/The%20original%20build/CIMG2544.jpg)
Bought a new clutch plate (that didnt fit for some reason) and we ready to roll!
Nurburgring here we come!!!
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First lap on the Ring was pretty good, it handled well despite the nasty cheap KONI suspension I had bought.
Spec at this point:
Standard 16v, with drilled airbox.
Scorpion back box.
polybushed all round
KONI non adjustable suspension
239mm brakes with DS2500 pads
28mm rear ARB
OMP cage
three point harnesses
Monaco S buckets
perspex rear windows
We fixed the gear shift, made a short shifter and gave it a service.
Second lap was pretty good too, it was lifting an inside rear wheel and the brakes were rubbish but it was easy to drive, bit soft, but controllable and fun.
Third lap sawing me following another mate in his 205 GTi DRT. Half way round the track I lost all the gears. I thought the clutch cable had snapped as the pedal went to the floor. I waggled the gearstick about and eventually found third so carried on with the intention nursing the car the rest of the lap.
I didnt make it!!
(http://i15.photobucket.com/albums/a397/leavingeasy/CIMG1965.jpg)
There was oil all over the gearbox so I thought the worst.
160 euros lighter and the car was recovered to a local garage. They pulled the gearbox out and found the centre of the clutch had spun out. I was so annoyed- I'd bought a new clutch but it hadnt fitted so we had put the old one back in. Now I knew why it didnt fit, the gearbox was from an 8v and had less splines.
Fun over after just two and a half laps.
I went to the bar and sulked whilst my mates kept lapping. Here is Jason in his mk2 lapping
http://video.google.co.uk/videoplay?docid=-5781126425731273815
I continued to drink then bummed a lift home, the car couldnt be fixed and I would need to send the parts from the UK (can you believe it- they couldnt get a 16v clutch for a German car in Germany as it didnt have the right TUV papers!!)
I picked the car up a month later and headed home.
With the R888's in the back the Golf handled rather badly, not helped by the rain and nearly bald nankang ditchfinders on my road wheels.
Just approaching the Belgium border and madman in an A4 came around the bend towards me, backwards! I skidded to avoid him, escaped down a side road, got on the verge and hit the armco. Bloody brilliant- 2.5 laps on the Ring and crash avoiding some bloke who never even stopped!
Damage wasnt too bad- a bet valance and dinked wing. The car still got me home!
Here it is, home at last after a month in Germany.
(http://i15.photobucket.com/albums/a397/leavingeasy/GolfOct05.jpg)
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The season was over at the Ring so I had an entire winter to work on the car.
I hated the fact Jasons mk2 was so much better than mine so i set about improvements.
I got carried away and blew the budget. BADLY!
I bought a 6A and started making it special.
(http://i130.photobucket.com/albums/p271/20vt_project/The%20original%20build/CIMG2496.jpg)
I stripped it, had it all balanced, re-honed it, new rings, steel head gasket, new water pump, oil pump, steel headgasket.....
(http://i15.photobucket.com/albums/a397/leavingeasy/Golfengine.jpg)
The head was ported and polished and I fitted piper 258 cams
Variable cam sprocket, 50mm induction manifold
(http://i15.photobucket.com/albums/a397/leavingeasy/CIMG2495.jpg)
And a new 4-2-1 SS magnex manifold and system. Lovely :tongue:
(http://i130.photobucket.com/albums/p271/20vt_project/The%20original%20build/golfApr0612.jpg)
(http://i130.photobucket.com/albums/p271/20vt_project/The%20original%20build/GolfJune0616.jpg)
Then I decided to beat Jason good and proper I needed a Quaiffe ATB differential. So I stole my kids pocket money and bought one and a 16v 02Y was rebuilt with new second gear and syncros at the same time. A Helix clutch was also fitted. Ouch, kerrrrr-ching!
(http://i130.photobucket.com/albums/p271/20vt_project/The%20original%20build/golfApr063.jpg)
I baffled the sump, fitted silicone hoses and an oil cooler
(http://i130.photobucket.com/albums/p271/20vt_project/The%20original%20build/golfApr0615.jpg)
The old 16v was pulled out- along with the dented wing
(http://i15.photobucket.com/albums/a397/leavingeasy/CIMG2492.jpg)
(http://i15.photobucket.com/albums/a397/leavingeasy/CIMG2491.jpg)
And the new engine and gearbox were fitted.
(http://i130.photobucket.com/albums/p271/20vt_project/The%20original%20build/GolfJune066.jpg)
So up to this point I had owned the car less than a year, the gearbox had already been out three times and I had learned to hate taking out the drive shafts!
But I didnt stop there:
I sold the BBS rims and bought some TSW's with TOYO T1Rs as my wet weather wheels. At the same time I changed the cheap KONIs for some SPAX RSX coilovers (same as on Jasons car and simply the best available for the budget)
(http://i130.photobucket.com/albums/p271/20vt_project/The%20original%20build/GolfDec05afterRSXsfitted5.jpg)
The dreadful 239mm brakes were binned and a set of G60 hubs and calipers sourced from ebay. I fitted Pagid 16 groove 280 discs and DS2500's again. The hoses were braided x6 and I hoped it would be able stand a chance of slowing for Adenau bridge this time!
(http://i130.photobucket.com/albums/p271/20vt_project/The%20original%20build/CIMG2811.jpg)
Gauges were fitted to monitor the health of my new motor
(http://i130.photobucket.com/albums/p271/20vt_project/The%20original%20build/CIMG2817.jpg)
I made up some door cards from 0.6mm aluminium (and got carried away with the stickers)
(http://i130.photobucket.com/albums/p271/20vt_project/The%20original%20build/GolfJune0613.jpg)
stuck my private plate on it and a Ring forum sticker in the back window and it was ready!
(http://i130.photobucket.com/albums/p271/20vt_project/The%20original%20build/GolfJune0622.jpg)
Nurburging here we come again!!
(http://i15.photobucket.com/albums/a397/leavingeasy/CIMG2901.jpg)
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The drive to the Ring was hell. Really hot and the traffic was terrible, but the engine performed brilliantly all the way, I was confident I would be kicking arse.
(http://i130.photobucket.com/albums/p271/20vt_project/The%20original%20build/IMG_7204.jpg)
The fuelling had been set up my Stealth racing and the rolling road showed 185bhp
(http://i15.photobucket.com/albums/a397/leavingeasy/CIMG2798.jpg)
I'd run the car in very carefully and aside of a strange noise when pulling away the car performed brilliantly.
The first two laps can be seen here- I really must get round to editing this vid sorry for the first few minutes of fumbling around!!
http://video.google.co.uk/videoplay?docid=9094328091870563345
On the third lap I met up with a mate in his 350bhp Scoob. He's a Ring regular and we decided to go out and do a few laps together.
Given my car's meagre 185bhp I knew that to keep ahead of him I'd need to be fast through the twisties. I soon stretched a small gap between me and him and was making great progress. At the power sections he quickly caught me up, and by the time we had got up the hill to the famous Karrussel he was all over me again. The next section of track is technical and down hill, suiting my lighter car, so I pushed out more of a gap.
Entering Bruunchen (a famous spectator spot) Simon the Scoob driver saw a puff of smoke. He thought I'd locked up a rear wheel. He was wrong.
That puff of smoke was the final gasp of my beautifully and lovingly crafted 6A. It had lasted precisely 2 2/3rds laps. About 3km more than the first time I went there.
Yet again my car was put on a 160 euro low loader and taken to Ollie, the local garage.
At first I thought the cambelt had snapped as there was no compression. Sadly this was not the case.
It was Friday, we were staying until Monday and my car was fooked. Game over.
I went to the pub.
Next day we needed to get the car down from the circuit to Adenau where I could store it until I collected it the following month. Its a 7km drive so we set about towing it there. Then we thought it might be more fun to see how far we can roll it, after all its nearly all down hill. We set up the video cameras and set off.
(http://i15.photobucket.com/albums/a397/leavingeasy/IMG_7879.jpg)
I cant find the video right now, but I must post it up soon. That drive was legendary. For those who havent done it, there are a few hairpins as you descend Eifel mountains towards Adenau- I needed the speed to make it all the way so refused to slow too much, lifting a wheel on the corners whilst over coming the lack of pas or brake servo. Brilliant!
We made it too- passing the crowds at Adenau bridge as the ate their lunch, in the quietest car of the season!!
I picked up the car a month later and took my 20VT for three cheeky laps whilst I was there. Was pretty good actually- 9:15 BTG on road tyres and not pushing too hard was impressive I thought!
(http://i15.photobucket.com/albums/a397/leavingeasy/CIMG3820.jpg)
(http://i15.photobucket.com/albums/a397/leavingeasy/CIMG3821.jpg)
By now I hated this damn car! :sick:
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For the rest of the season at the Ring I used my other car. I was lucky enough to also own a Caterham 7. I hadnt wanted to use it at the Ring as it was getting on a bit and had already covered about 15,000 track miles without a rebuild.
I didnt realise it was to do another 3000km at the Ring before I would finally finish the Golf!
(http://i15.photobucket.com/albums/a397/leavingeasy/DSC_0893.jpg)
Not that it was always reliable- here the throttle cable snapped- same spot as I broke down the first time in the Golf (another 160 euro lorry ride required!!)
(http://i15.photobucket.com/albums/a397/leavingeasy/CIMG5126.jpg)
(http://i15.photobucket.com/albums/a397/leavingeasy/CIMG5130.jpg)
Anyways, having got the car home it was time to find out what had gone wrong
(http://i15.photobucket.com/albums/a397/leavingeasy/CIMG2809.jpg)
My good friend Gareth started lifting the head at his workshop
(http://i15.photobucket.com/albums/a397/leavingeasy/CIMG3831.jpg)
We found this in the inlet manifold :sick:
(http://i15.photobucket.com/albums/a397/leavingeasy/CIMG3832.jpg)
I held my breath as the head was removed
(http://i15.photobucket.com/albums/a397/leavingeasy/CIMG3833.jpg)
It didnt look pretty- my beautiful polished head was scrap
(http://i15.photobucket.com/albums/a397/leavingeasy/CIMG3838.jpg)
And the block was no better
(http://i15.photobucket.com/albums/a397/leavingeasy/CIMG3835.jpg)
Here is number three piston
(http://i15.photobucket.com/albums/a397/leavingeasy/Cars22.jpg)
And here is the culprit- a dropped exhaust valve. I found this in the sump, along with large chunks of piston.
(http://i15.photobucket.com/albums/a397/leavingeasy/Cars25.jpg)
I can not tell you how terribly sick I felt after that. I was soooo sad, I just wanted to cry.
But life goes on and out came the engine and gearbox and I undid those bloody driveshafts again!!
(http://i15.photobucket.com/albums/a397/leavingeasy/Cars28.jpg)
Again the car was abandoned at Gareths yard.
From this:
(http://i15.photobucket.com/albums/a397/leavingeasy/GolfJune0618.jpg)
to this in two and a bit laps :cry:
(http://i15.photobucket.com/albums/a397/leavingeasy/Cars32.jpg)
That piston was mounted and now sits on my shelf. I'll come onto the bent con-rod and piston later.
(http://i130.photobucket.com/albums/p271/20vt_project/080907.jpg)
See I told you that you would feel pity for me eventually.
Hang on-
(http://i15.photobucket.com/albums/a397/leavingeasy/anothertoughday.jpg)
Bet you don't anymore!!
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I decided to build another engine.
I sourced a 9A and the guy who built my first head sent me another FOC once they had seen what happened to the first one.
Same spec as the first, new oil pump, new water pump, new head gasket, bling bling 50mm inlets
(http://i15.photobucket.com/albums/a397/leavingeasy/CIMG4354.jpg)
Put it all together and then read an article in PVW about putting a 20VT in your car in a weekend. Hmmmmm :drool: sounds like a plan.
The 9A never made it into my car and sold on pistonheads for a grand. The hunt for a mk4 Golf 20VT AGU began.
I needed to store the car somewhere and a work mate had an old chicken shed. It was cold, badly lit and leaked, it was November, the place stank but I was eager to press on and build a 200bhp 20VT. I just knew a more modern engine would be more reliable. :huh:
Yet again, the plan changed.
Jasons car was by now nearly 200bhp from his n/a 9A and a serious tool. To beat it I needed to lose some weight and gain some power.
I stripped the engine bay
(http://i130.photobucket.com/albums/p271/20vt_project/2-5.jpg)
and the subframe
(http://i130.photobucket.com/albums/p271/20vt_project/2-2.jpg)
Out came the PAS- no need for that anymore, weighs too much!!
(http://i130.photobucket.com/albums/p271/20vt_project/2-4.jpg)
I bought an AGU of ebay for £600. It had supposedly done 85,000miles. I think they must have been HARD miles
(http://i130.photobucket.com/albums/p271/20vt_project/2-12.jpg)
The trim was stripped
(http://i130.photobucket.com/albums/p271/20vt_project/2-13.jpg)
The interior removed
(http://i130.photobucket.com/albums/p271/20vt_project/2-14.jpg)
And the area known as "the plane crash" grew
(http://i130.photobucket.com/albums/p271/20vt_project/2-15.jpg)
It was December. I was pretty low- everybody told me I was an arse.
The project was looking impossible, so cheer myself up, I changed my mind again!!!
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Why build a K03 200bhp car, when all I need to do is strap a K04 turbo on and I will have 270bhp???
How bloody naive was I??
(http://i130.photobucket.com/albums/p271/20vt_project/11-2.jpg)
So I bought a K04 from a APY S3, the injectors, manifold a few pipes.
The test fit was fine
(http://i130.photobucket.com/albums/p271/20vt_project/11-6.jpg)
Oil piped seemed to fit
(http://i130.photobucket.com/albums/p271/20vt_project/11-7.jpg)
Then after Christmas, QPEng sent me a present
(http://i130.photobucket.com/albums/p271/20vt_project/04-1.jpg)
My ECU and downpipe had arrived :grin:
(http://i130.photobucket.com/albums/p271/20vt_project/04-2.jpg)
(http://i130.photobucket.com/albums/p271/20vt_project/04-3.jpg)
But my plan was still changing. Now my car would potentially be producing 300lbft of torque, the 02Y box was only rated to about 200lbft max, it would never be able to take it- I needed to uprate the gearbox before I could even think about fitting the engine.
Bugger- this wasnt as easy as the article suggested.
I swapped some bits for an unknown 02A box from a 16V Corrado and set about working out the best way to adapt the hydraulic change to a cable mechanism.
(http://i130.photobucket.com/albums/p271/20vt_project/06-6.jpg)
I also needed to work out how to get the oil return pipe under the engine mount (attempt number one seen here)
(http://i130.photobucket.com/albums/p271/20vt_project/15-1.jpg)
Get the new bigger flywheel lightened
(http://i130.photobucket.com/albums/p271/20vt_project/15.jpg)
Work out where to put the new cable shift
(http://i130.photobucket.com/albums/p271/20vt_project/06-2.jpg)
And mock up the new pipe work for the K04
(http://i130.photobucket.com/albums/p271/20vt_project/06-4.jpg)
Still least the shiny bits looked good!
I decided to start with the easy stuff and vibratech engine mounts were fitted in each corner
(http://i130.photobucket.com/albums/p271/20vt_project/15-6.jpg)
(http://i130.photobucket.com/albums/p271/20vt_project/15-7.jpg)
Ben at QPEng adapted the throttle body to work with the 1.3 mk2 Golf throttle cable I had bought
(http://i130.photobucket.com/albums/p271/20vt_project/15-5.jpg)
And I took the opportunity whilst the engine was out to re-route the brake pipes so that the fronts now work as a pair. Orginally the wheels work in a diagonal pairs for safety reasons- fitting them this way makes it easier to get the balance right for a track car, but does mean condition must be monitored carefully!
(http://i130.photobucket.com/albums/p271/20vt_project/15-9.jpg)
Next I needed to decide what to do about the hydraulic clutch. Whilst i could use SEAT parts and maintain the cable operation I decided to go fully hydraulic as I wanted to use a paddle clutch. That put me back a few more weeks.......
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So this is how you fit a hydraulic clutch to a a mk2- (this might make a useful sticky???)
Why do you need to do this?
If you want a stronger gearbox than the standard 02Y it is possible to fit the cable shift 02A box from the mk3 (cables, clutch choice and all that jazz is an entirely different thread).
I got an 02A from a 16v Corrado
(http://i130.photobucket.com/albums/p271/20vt_project/06-6.jpg)
originally the plan had been to convert this to a cable shift and forgoe the hydr operation, but I was advised against this as I am using a paddle clutch and it would be so heavy it would be undriveable.
So you need a few parts, the first of which is a Corrado 16v pedal box which has the bracket for the clutch master cylinder. Here we can see the original and the new side by side.
(http://i130.photobucket.com/albums/p271/20vt_project/06-8.jpg)
Using the pedal box as a template it is then necessary to mark the holes in the bulkhead for the clutch master cylinder
(http://i130.photobucket.com/albums/p271/20vt_project/06-11.jpg)
On the engine side it looks like this:
(http://i130.photobucket.com/albums/p271/20vt_project/06-9.jpg)
Next it is necessary to remove the brake servo
(http://i130.photobucket.com/albums/p271/20vt_project/06-10.jpg)
As you can see the bulkhead is not flat and it is necessary to fit the clutch mc between the two red dots. The m/c must be perfectly aligned for smooth action with the clutch pedal otherwise it may wear and result in failure. Which is bad.
Therefore- using sophisticated tooling, it is necessary to reshape the bulkhead. I chose a large hammer.
I smacked seven loads of pooh out of it until it looked like this:
(http://i130.photobucket.com/albums/p271/20vt_project/06-12.jpg)
Then I fitted the m/c against it and cut a template from the inside:
(http://i130.photobucket.com/albums/p271/20vt_project/06-13.jpg)
(http://i130.photobucket.com/albums/p271/20vt_project/06-14.jpg)
Amazingly the cluch m/c fitted perfectly
(http://i130.photobucket.com/albums/p271/20vt_project/06-15.jpg)
Trouble is that doesnt look too good and I figured probably wasnt the best job:
(http://i130.photobucket.com/albums/p271/20vt_project/06-14.jpg)
so I treated it to a little rustproofing
(http://i130.photobucket.com/albums/p271/20vt_project/06-16.jpg)
then painted it in a random silver colour that almost matched the car
(http://i130.photobucket.com/albums/p271/20vt_project/06-17.jpg)
Next the pedal box is fitted
(http://i130.photobucket.com/albums/p271/20vt_project/26-1.jpg)
And the servo and clutch m/c fitted
(http://i130.photobucket.com/albums/p271/20vt_project/26.jpg)
The more Golf anally retentive amongst you may notice that hydraulic reservoir has an extra spout- this is to feed the clutch m/c and was robbed from another Corrado:
(http://i130.photobucket.com/albums/p271/20vt_project/26-4.jpg)
A dying E30 BMW donated the necessary hosing
(http://i130.photobucket.com/albums/p271/20vt_project/26-5.jpg)
You can also see a new copper pipe that routes from the cluch mc to the slave cylinder on the side of the gearbox.
Et voila- would have been so much easier if someone had posted a thread on how to do it!! :smug:
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Eventually the engine was finished and ready for gearbox fitting
(http://i130.photobucket.com/albums/p271/20vt_project/CIMG4581.jpg)
I make that sound easy. Actually there is a shed load of stuff that needs changing to go from a K03 to K04. The oil lines are different, water pipes need adapting and all the air hoses are entirely different. I didnt realise most of that at the time and just blindly carried on!
(http://i130.photobucket.com/albums/p271/20vt_project/CIMG4582.jpg)
The down pipe was wrapped as it proximity to the bulkhead was causing me some concern!
Having cleaned the surface newly lightened flywheel
(http://i130.photobucket.com/albums/p271/20vt_project/CIMG4594.jpg)
the gearbox was fitted
(http://i130.photobucket.com/albums/p271/20vt_project/06-18.jpg)
Subframe was painted
(http://i130.photobucket.com/albums/p271/20vt_project/CIMG4598.jpg)
And engine bay tidied up
(http://i130.photobucket.com/albums/p271/20vt_project/CIMG4595.jpg)
(http://i130.photobucket.com/albums/p271/20vt_project/CIMG4604.jpg)
My car has no heater so some ali sheet was made up to fill the holes in the bulkhead
(http://i130.photobucket.com/albums/p271/20vt_project/15-12.jpg)
A manual rack was fitted (and polybushed)
(http://i130.photobucket.com/albums/p271/20vt_project/06-22.jpg)
Finally the engine and subframe were reunited
(http://i130.photobucket.com/albums/p271/20vt_project/06-23.jpg)
(http://i130.photobucket.com/albums/p271/20vt_project/06-24.jpg)
And slowly the whole lot was put back in the car
(http://i130.photobucket.com/albums/p271/20vt_project/10.jpg)
(http://i130.photobucket.com/albums/p271/20vt_project/10-1.jpg)
(http://i130.photobucket.com/albums/p271/20vt_project/10-2.jpg)
(http://i130.photobucket.com/albums/p271/20vt_project/10-4.jpg)
By now my workmate had had enough of the plane crash and wanted me out. So I begged Gareth to let me bring the car back to his workshop and rent a bay in his building.
Yet again the Golf was back in his yard!
(http://i130.photobucket.com/albums/p271/20vt_project/CIMG5003.jpg)
-
By now it was Spring and with the bay made available to me, progress speeded up!!! :smiley:
First job was to join up the 16v Magnex exhaust system with the QPEng turbo downpipe.
This was done by cutting out the centre box and welding in a 2.5" stainless section
(http://i130.photobucket.com/albums/p271/20vt_project/CIMG5062.jpg)
(http://i130.photobucket.com/albums/p271/20vt_project/CIMG5065.jpg)
(http://i130.photobucket.com/albums/p271/20vt_project/CIMG5073.jpg)
I fitted the correct clutch slave cylinder and routed the hydraulic pipe
(http://i130.photobucket.com/albums/p271/20vt_project/CIMG5075.jpg)
then out came the engine again- I was getting good at this by now and could have it in and out in minutes
(http://i130.photobucket.com/albums/p271/20vt_project/CIMG5079.jpg)
My biggest concern was the intercooler pipework. The K04 was not compatible with the K03 set up. Luckily I had a bit of a result when a broken APY engine arrived in the yard. Manifold and pipework were promptly commandeered and modded to suit the big valve AGU head.
(http://i130.photobucket.com/albums/p271/20vt_project/CIMG5083.jpg)
A throttle cable bracket was welded onto the new manifold
(http://i130.photobucket.com/albums/p271/20vt_project/CIMG5091.jpg)
The water bottle and header tank were removed from the n/s turret and the header welded onto the o/s
(http://i130.photobucket.com/albums/p271/20vt_project/CIMG5092.jpg)
(http://i130.photobucket.com/albums/p271/20vt_project/IMG_7706.jpg)
Heaps of heat protection was added to the bulkhead
(http://i130.photobucket.com/albums/p271/20vt_project/CIMG5100.jpg)
but still something was missing
(http://i130.photobucket.com/albums/p271/20vt_project/IMG_7651.jpg)
so in it when for the last time (i hoped :tongue:)
(http://i130.photobucket.com/albums/p271/20vt_project/IMG_7717.jpg)
I made up a new top hose to accomodate the mk3 TDi rad
(http://i130.photobucket.com/albums/p271/20vt_project/IMG_7767.jpg)
And changed the recirc valve for a forge one as the orig was buggered
(http://i130.photobucket.com/albums/p271/20vt_project/IMG_7769.jpg)
-
Next I started work on the inside.
That bloody evil sealant was stripped out :sick:
(http://i130.photobucket.com/albums/p271/20vt_project/CIMG5086.jpg)
A centre dash was mocked up
(http://i130.photobucket.com/albums/p271/20vt_project/IMG_7772.jpg)
and the dashboard wiring was routed (another horrible horrible job)
(http://i130.photobucket.com/albums/p271/20vt_project/IMG_7771.jpg)
the battery box was fitted behind the passenger seat
(http://i130.photobucket.com/albums/p271/20vt_project/IMG_7773.jpg)
and a through panel installed to feed the starter
(http://i130.photobucket.com/albums/p271/20vt_project/IMG_7774.jpg)
holes were made for the gearbox cables
(http://i130.photobucket.com/albums/p271/20vt_project/IMG_7775.jpg)
and slowly the wiring took shape
(http://i130.photobucket.com/albums/p271/20vt_project/IMG_7776.jpg)
we cut out the towing eye to give anough room to fit the Mercedes Sprinter intercooler
(http://i130.photobucket.com/albums/p271/20vt_project/CIMG5227.jpg)
with the TDi rad fitting neatly behind it
(http://i130.photobucket.com/albums/p271/20vt_project/CIMG5231.jpg)
Finally some oil cooler brackets were made (yes I know its upside down but it was the only way it would fit!)
(http://i130.photobucket.com/albums/p271/20vt_project/CIMG5255.jpg)
-
I bought some new wheels from a mate c/w new 888's
(http://i130.photobucket.com/albums/p271/20vt_project/CIMG5256.jpg)
Wiring was still an issue
(http://i130.photobucket.com/albums/p271/20vt_project/CIMG5252.jpg)
But finally the engine was in and fitted. The cooler pipes were bodged together until something more long term could be produced.
(http://i130.photobucket.com/albums/p271/20vt_project/CIMG5258.jpg)
The digidash was wired in and we were ready to go
(http://i130.photobucket.com/albums/p271/20vt_project/17090712.jpg)
First impressions of the car up and down the private road outside the workshops were mixed.
It sounded fab, looks of wooshing and hissing but didnt seem very fast. A quick check of the boost pipes revealed one had popped off!
Few more jubilee clips and another attempt and it was incredible. There was a huge rush of boost upto 1.5 bar, the wheels span, it torque steered all over the place, it wooooooooooshed, hissed and was uncontrollable on the damp concrete.
Both Gareth and I parked up and looked at each other.
We had made a monster!!!!
With a few more tweaks over the following few days it was ready to take home.
I managed to go four miles..............
(http://i130.photobucket.com/albums/p271/20vt_project/0509071.jpg)
and so began the next engine rebuild.
Pity me yet?
-
Gareth was on hoilday, so it all happened on my driveway. Which was nice.
It all fitted so nicely under there:
(http://i130.photobucket.com/albums/p271/20vt_project/050907.jpg)
But sadly it had to be stripped down. First thing was to remove the Mercedes Sprinter intercooler- marvel at the way Gareth and I had spent ages building brackets so it all fitted really neatly under the grill.
(http://i130.photobucket.com/albums/p271/20vt_project/0509072.jpg)
With that gone next came the Golf3 TDi radiator. Brand new :cry:
(http://i130.photobucket.com/albums/p271/20vt_project/0509073.jpg)
Unfortunately on removing the rad, I found the exploding bottom end had punctured it :( so new one needed:
(http://i130.photobucket.com/albums/p271/20vt_project/0509075.jpg)
Luckily the fans were undamaged :)
(http://i130.photobucket.com/albums/p271/20vt_project/0509076.jpg)
Next job was to remove the oil cooler, disconnect the loom, the gearbox cables, various plugs and connectors, the fuel lines and the vacuum pipe. All done and it all looks a huge mess again
(http://i130.photobucket.com/albums/p271/20vt_project/0509077.jpg)
Ran out of time after that and had to head off to work, so the old girl was tidied up. Clearly it felt very embarrassed and tried to hide under a bush
(http://i130.photobucket.com/albums/p271/20vt_project/05090710.jpg)
Next job- pick up the new BAM engine from somewhere oooop north!
-
So, a stooooopidly early start and 215 miles ugh!
(http://i130.photobucket.com/albums/p271/20vt_project/IMG_0027.jpg)
Just why are all these people on the motorway at this time? Turned out it was because somebody in a yellow NSX had some how spun their car and was facing the oncoming traffic.
(http://i130.photobucket.com/albums/p271/20vt_project/IMG_0028.jpg)
The north and south border was unmanned but I still knew when I had arrived.
(http://i130.photobucket.com/albums/p271/20vt_project/IMG_0029.jpg)
The engine was checked and loaded into my car by quite the most cheerful breakers I have ever met.
(http://i130.photobucket.com/albums/p271/20vt_project/IMG_0031.jpg)
Mission today was to get the engine out and that means disconnecting the drive shafts again. Oh joy!!
So after two nurishing bowls of coco pops I hit the ground running, spanners in hands and attacked the dreaded driveshafts.
I dont like doing the driveshafts as it makes my arms ache undoing all those bolts, and lying on your back with the car two inches from your nose really doesnt help.
Lying on your back with the car two inches from your nose in the 25 degree mid day sun with your three year old sun saying "whats that?" every twenty seconds helps even less.
(http://i130.photobucket.com/albums/p271/20vt_project/0609074.jpg)
However after about fifteen minutes the engine was lifted out. Its been in and out about thirty times this year already.
This is the last time!
(http://i130.photobucket.com/albums/p271/20vt_project/0609075.jpg)
Sam immediately dived straight in the bay and had a bloody good look around (mainly enjoying picking up the 50p sized chunks of engine block that were liberally scatterted aroud)
(http://i130.photobucket.com/albums/p271/20vt_project/0609076.jpg)
Lifting the engine allowed me to look in the hole- this is my finger (entering from the rear :o ) and pushing the conrod forward. That knarled bit is the end, but not the small end, its actually snapped about one third of the way down!
(http://i130.photobucket.com/albums/p271/20vt_project/0609078.jpg)
Next job was to try and get the new engine out of the Volvo. Tempting as it was to just bolt it in and make the Swedish wardrobe mover a 400bhp racer, it would leave no room for the dog.
(http://i130.photobucket.com/albums/p271/20vt_project/06090711.jpg)
Unfortunately whilst I was having a throughly lovely time enjoying myself with my oily tools, number one son, Oliver, decided to go head over heels on his scooter. Ouch!!
(http://i130.photobucket.com/albums/p271/20vt_project/06090713.jpg)
The next three hours were spent fixing the pipework on the engine where it had been removed in a rather non caring manner from the donor car and fitting the parts I need for the conversion. I started at the back of the engine and sadly it looks like not much has happened- so I'll tell you:
(http://i130.photobucket.com/albums/p271/20vt_project/06090715.jpg)
On there you can see a K04 turbo with new gasket, the water rail fitted with new washers, the exhaust primary fitted with new gasket, the rear engine mount from a Corrado fitted after re routing the oil return line. Also done was the re-circ valve, and throttle body (changed from fly-by wire to cable operation) and a few other hoses.
So that just left me time to close the garage on it all at 6.30pm
(http://i130.photobucket.com/albums/p271/20vt_project/06090716.jpg)
-
First problem of the day is that the AGU and BAM engines use different coil packs. I thought I could have my loom altered to reflect this but unfortunately its not that simple:
(http://i130.photobucket.com/albums/p271/20vt_project/070907.jpg)
Fortunately Ben at QPEng came up with an obvious solution- use the rocker cover from the AGU on the BAM engine. The AGU coil packs are more reliable anyways.
So with that in mind I set about stripping the old block. Trouble is removing the flywheel is always bloody impossible without a windy gun as the engine turns over everytime you apply pressure to the bolts.
(http://i130.photobucket.com/albums/p271/20vt_project/0709073.jpg)
Unless somebody has made a convenient hole in the block to jam up the crankshaft!!
(http://i130.photobucket.com/albums/p271/20vt_project/0709074.jpg)
After removing the sump, the oil pump fell out- dont think I will be using it again!!
(http://i130.photobucket.com/albums/p271/20vt_project/0709077.jpg)
Conrod didnt look much better.
(http://i130.photobucket.com/albums/p271/20vt_project/0709079.jpg)
Or the piston
(http://i130.photobucket.com/albums/p271/20vt_project/07090715.jpg)
Will be adding them to my trophy cabinet!!
Finally the block was stripped
(http://i130.photobucket.com/albums/p271/20vt_project/07090713.jpg)
Which allowed me to see the amazing damage I managed to do- I record even by my standards I think!!
(http://i130.photobucket.com/albums/p271/20vt_project/07090714.jpg)
Finished the day by fitting new water pump and cambelt, as well as alternator and various pipes.
(http://i130.photobucket.com/albums/p271/20vt_project/07090716.jpg)
In the meantime I am worried I might have become addicted to working on this. I decided I would take a day off and spend time with my kids. Which I did. :)
(http://i130.photobucket.com/albums/p271/20vt_project/IMG_0072.jpg)
Then as soon as they went to bed I went into the garage. The BAM 225 engine uses different (and less reliable) coils to the AGU 150 engine. Unfortunately my engine loom wouldnt accomodate the BAM ones and so rather than buy a new loom, it was decided to replace the rocker cover from the AGU and keep the better compatible coils.
This is the BAM rocker
(http://i130.photobucket.com/albums/p271/20vt_project/0709072.jpg)
When I removed the rocker cover I was horrified. Seems something has gotten inside (I imagine whilst its been in storage) and so I had to clean out all the journals and cams, which was a horrid job.
(http://i130.photobucket.com/albums/p271/20vt_project/0809071.jpg)
However once finished it was just a quick swap aound of these two
(http://i130.photobucket.com/albums/p271/20vt_project/0809072.jpg)
Put the AGU coils in.
(http://i130.photobucket.com/albums/p271/20vt_project/0809074.jpg)
Et voila, job jobbed.
(http://i130.photobucket.com/albums/p271/20vt_project/0809073.jpg)
My trophy cabinet is growing....... :(
(http://i20.photobucket.com/albums/b207/wh00sher/0af85d0f.jpg)
Will my hands ever be clean again?
I took ten mins just to paint the bulk head in order to stop reflections. This is not the finished product, lots of wiring to do and having a dash pod made hopefully. The interior is a nightmare, I had no idea what to do!!
(http://i130.photobucket.com/albums/p271/20vt_project/0909071.jpg)
-
Today I thought I'd take the engine out for a little drive, after all it had been sat in the garage all weekend and I thought it might like to see the countryside.
(http://i130.photobucket.com/albums/p271/20vt_project/IMG_0112.jpg)
I drove down to my mate Jason's Triumph dealership, which also has a handy Renualt dealership alongside, and asked the guys nicely if they would mind removing the dual mass flywheel (horrid heavy lump of iron) and replacing it with my sexy skimmed outrageously light one. Then fit the clutch as I didnt have an alignment tool.
(http://i130.photobucket.com/albums/p271/20vt_project/15.jpg)
30 mins later job was done. Sorted, thanks fellas!
(http://i130.photobucket.com/albums/p271/20vt_project/IMG_0113.jpg)
That left me just enough time for a coffee and a natter with Mel at Triumph before fitting the gearbox and getting ready for work.
(http://i130.photobucket.com/albums/p271/20vt_project/IMG_0114.jpg)
Following Saturday Jason popped around to help with something and pinched the Golf's key. His cunning plan was to watch me suffer, having finished the car I would run around frustrated not being able to find the key.
What actually happened was my poor three year old son got shouted at- alot! Poor little fella, he has a habit of pinching my keys, but he was innocent all the time, and to think I'd sent him to the naughty step too!
(http://i130.photobucket.com/albums/p271/20vt_project/CIMG5108.jpg)
Still revenge was mine when I popped around to his place the following day and nicked the keys back. Oh didnt I mention I had them Jas? Was fun watching him run around trying to find them!!
Anyway so back to progress:
popped the engine back in and started connecting those bloody driveshafts. God I hate that job! Once in I needed to reattach the electrics and hydraulic clutch. This is a picture of a hydraulic gearbox for all those who dont have one!
(http://i130.photobucket.com/albums/p271/20vt_project/1709071.jpg)
Having finished that a few problems raised their head- the cam cover was far too close to the brake m/c. Grrrrr turns out I had fitted the engine slightly twisted (god knows hows how) so I had to undo everything and fit it all again!! :angry:
(http://i130.photobucket.com/albums/p271/20vt_project/1709072.jpg)
So once it was all in I had the pleasure of priming the engine. This is a truly horrible, hateful, hideous task, which I think Gareth makes me do for his own sadistic pleasure.
Basically you remove the spark plugs and insert a long socket on the crankbolt, then turn the engine over by hand.
(http://i130.photobucket.com/albums/p271/20vt_project/1709073.jpg)
Keep turning until oil comes out here, or you bleed, or you get bored, which ever occurs first.
(http://i130.photobucket.com/albums/p271/20vt_project/1709074.jpg)
That took twenty minutes- why couldnt i just let the starter crank it over, surely its the same thing??
Gareth?
Next task was to fit the AGU loom to the coils
(http://i130.photobucket.com/albums/p271/20vt_project/1709076.jpg)
And then fit the fans to the nice shiny new radiator
(http://i130.photobucket.com/albums/p271/20vt_project/1709078.jpg)
reassemble
(http://i130.photobucket.com/albums/p271/20vt_project/1709079.jpg)
add oil, water, cable ties and bolt the front back on
(http://i130.photobucket.com/albums/p271/20vt_project/17090711.jpg)
so did it start??
did it hell.......
(http://i130.photobucket.com/albums/p271/20vt_project/17090712.jpg)
-
I primed the fuel pump three times to pressurise the lines et voila
(http://i130.photobucket.com/albums/p271/20vt_project/th_17090713.jpg) (http://s130.photobucket.com/albums/p271/20vt_project/?action=view¤t=17090713.flv)
Yes I know it sounds like a sewing machine- that's the injectors. Its not the sexiest sounding engine in the world!!
Rather foolishly decided to add up how much this small episode has cost me:
Engine £1200
engine collection £40 diesel
broken hose £14
radiator £55
fan fixing kit £10
oil, filter, coolant and ancillaries £65
total £1384
and the to do list is still endless:
Fit hi-pressure fuel pump
Bleed clutch
Fit seats and harnesses
Fit bumpers
Fit wing mouldings
Fabricate and fit dash
Clean contaminated brake discs (after oil exploded over them)
Fit indicators
Bolt in quick release bumper irons
WIRING
Fabricate an airbox
Fit AFR meter
MOT
But things were looking up
The first drive (no seat!!)
(http://i130.photobucket.com/albums/p271/20vt_project/n272701053_613367_2326.jpg)
Beaten into submission
(http://i130.photobucket.com/albums/p271/20vt_project/n272701053_613376_5406.jpg)
Hooking up with Jason
(http://i130.photobucket.com/albums/p271/20vt_project/2909071.jpg)
Thought seats might be a good idea- binned the Monacos and fitted these
(http://i130.photobucket.com/albums/p271/20vt_project/29090710.jpg)
-
I KNEW IT WAS GOING TO BLOODY WELL :embarassed: :angry:
I am now reaching for matches and petrol. I HATE THIS CAR :angry:
Seems when the engine was being manhandled by the breakers they cracked the sump. I never thought to look (school boy error) I will in future.
(http://i130.photobucket.com/albums/p271/20vt_project/IMG_0233.jpg)
That little seep is a crack that merrily drips all my cars life blood all over the floor.
Luckily I had to go to work now- it was my birthday trip and I was going to St Lucia, it was sunny, silly and boozy. Perfect restbite!
Gareth shouted at me. This is by now normal.
Whilst I crawled around in the pouring rain on my back I noticed it might be possible to remove the sump with the engine in situ. Gareth agreed to give it a go.
10 mins later and voila:
(http://i130.photobucket.com/albums/p271/20vt_project/IMG_0014.jpg)
sump removed!
(http://i130.photobucket.com/albums/p271/20vt_project/IMG_0015.jpg)
a closer inspection revealed the sump had got gravel in it, so if I had done a tempo patch I would have actually fooked up my engine when the oil pick up got blocked eventually.
(http://i130.photobucket.com/albums/p271/20vt_project/IMG_0016.jpg)
Grrrr! As usual Gareth was right!!
Interestingly the colour of the conrods was the normal silver- unlike the other engine where they were baked golden. I have high hopes for this motor!! Crosses fingers, legs, eyes etc!
So the final scores on the doors now:
1988 Mk2 Golf, stripped of everything I could sell, c 950kgs
SPAX RST coilovers lowered 40mm (30 at the rear)
28mm rear ARB
G60 280mm brakes with DS2500s, braided hoses and all that jazz
15" wheels with either 888's or T1Rs
Audi TT BAM engine with 1bar boost- c.250bhp
Golf3 TDi radiator with twin 10" fans
Mercedes Sprinter Intercooler
13 row 235mm Oil cooler with 82 degree thermostat
Corrado VR6 gearbox with hydraulic clutch conversion
Helix paddle clutch and lightened flywheel
Custom made 2.5" exhaust downpipe, connected to Magnex s.s system
Perspex rear three windows
Big bumper conversion
Lots of stickers
A blind hope that this one holds together.
-
Managed to work on a few things that had been driving me mad but i just couldnt be arsed to do.
First was the fitting of the cold air duct for the air filter. Eventually the plan is to build a cold air box where the battery used to be, but for the time being this option should do the trick.
I was going to put the duct in the bumper, but frankly it looked sh!te, so Jason suggested mounting it behind the grill in front of the intercooler. This meant removing the slam plate and the radiator, but the end result is quite neat.
(http://i130.photobucket.com/albums/p271/20vt_project/2910074.jpg)
it did mean taking a hacksaw to the grill to remove some blocks
(http://i130.photobucket.com/albums/p271/20vt_project/2910075.jpg)
But the end result is quite pleasing and not in your face
(http://i130.photobucket.com/albums/p271/20vt_project/2910078.jpg)
Next was fitting some evil grippy stuff to the floor. It is like sand paper and it really would take an idiot to try and rub it down with their fingers, after all it would obviously just take your skin off.
Ouch. :rolleyes:
So this is how it was before:
(http://i130.photobucket.com/albums/p271/20vt_project/2909078.jpg)
And this is now:
(http://i130.photobucket.com/albums/p271/20vt_project/29100719.jpg)
(http://i130.photobucket.com/albums/p271/20vt_project/29100720.jpg)
Next job was fit the crutch strap- not a tricky job when the seat was on a nice high frame, but finger-nipping tastic when its bolted to the floor. Even worse if you finger is sore cos you might have rubbed some sandpaper type matting for some reason.
(http://i130.photobucket.com/albums/p271/20vt_project/29100718.jpg)
Next it was time to try and sort out the wiring- it is quite frankly a bloody mess, but most of this is the way it is in the car itself, its just hidden by the the dashboard.
(http://i130.photobucket.com/albums/p271/20vt_project/29100711.jpg)
I started with my hand crafted and loving cut out centre dash. I'd wired the boost gauge into the wrong light feed so everytime I used main beam it switched off. Also needed to change the feed to the AFR meter and get the switches earthed properly.
(http://i130.photobucket.com/albums/p271/20vt_project/29100713.jpg)
That done I needed to create some kind of feed for my V-box and GPS. The answer was a multi plug from eBay for a fiver, wired via a switch and fuse from the battery.
(http://i130.photobucket.com/albums/p271/20vt_project/29100714.jpg)
I love these LED tipped switches- this one glows a lovely red when its switched on!
(http://i130.photobucket.com/albums/p271/20vt_project/29100716.jpg)
Finally I spent an age tidying the fuse box wiring. When I'd finished it looked exactly the same!!
(http://i130.photobucket.com/albums/p271/20vt_project/29100721.jpg)
I finished the day by going down the barn where the Caterham is kept- seems it is in good company:
2x DB9's
(http://i130.photobucket.com/albums/p271/20vt_project/29100724.jpg)
My cousins very spoiled 964RS rep
(http://i130.photobucket.com/albums/p271/20vt_project/29100726.jpg)
The old girl enjoying an easy life!
(http://i130.photobucket.com/albums/p271/20vt_project/29100727.jpg)
-
By now it was Novemeber 2007 and the car was to be used at Cadwell in a few days. Yet again it was at Gareths workshop to be checked over- particularly as there was a dreadful clunking when going on and off the power.
(http://i130.photobucket.com/albums/p271/20vt_project/IMG_0135.jpg)
Embarassingly the clunking turned out to be loose gearbox bell housing bolts- oops :huh:
An oil leak was also fixed and a few days later I headed north again to Cadwell
So after a very suceesful few sessions in the Golf all apeared to be working very well- it's quick, it handles and whilst the gearbox was very noisy, it didnt fall aprt either:
(http://i130.photobucket.com/albums/p271/20vt_project/DSC_5356-mod.jpg)
Brakes got HOT!
(http://photography.5h4k.co.uk/cadwell/images/DSC_5701.jpg)
however whilst the car proved to be brilliant, the driver had a few issues:
(http://i130.photobucket.com/albums/p271/20vt_project/DSC_4535.jpg)
Using armco to stop seemed to be having an effect on the quality of my front wing, it also bent my bumper and oil cooler mount :blink:
(http://i130.photobucket.com/albums/p271/20vt_project/IMG_0178.jpg)
Luckily my mate Jimmy had a useful panel beating kit and I took the bent bits with gay abandon (calm down Weemna- this just means I attacked it with no idea what the hell I was doing)
(http://i130.photobucket.com/albums/p271/20vt_project/IMG_0190.jpg)
Bit of hammering and soon the brackets were straight and the cooler refitted
(http://i130.photobucket.com/albums/p271/20vt_project/IMG_0191.jpg)
My Gucci bumper pins had gotten bent too, so more hammer work soon fixed them- just got to add a splash of black to protect the uncovered metal
(http://i130.photobucket.com/albums/p271/20vt_project/IMG_0193.jpg)
Damage post Cadwell:
1. Both drive shaft gaiters have split
2. Slight water weep from fan sensor on rad
3. bent wing
4. split bumper
5. knackered indicator
Pleasingly everything else seemed to be ok so I gave it a wash.
Then set about fixing the bumper. I should really just buy a new wing and bumper but it seems more "race" to try and repair, so I made up a small metal bracket and rivetted it in place.
A quick splash of Gareth's gothic nail varnish and you would never know. Ok well you would, but if you close your eyes a lot, you would never know.
(http://i130.photobucket.com/albums/p271/20vt_project/IMG_0223.jpg)
(http://i130.photobucket.com/albums/p271/20vt_project/IMG_0225.jpg)
A quick trip to the local scrap metal dealers to use their weighbridge (was worried they would junk it) saw it weigh in at 920kgs
then it was loaded up and sent to Surrey Rolling Road
(http://i130.photobucket.com/albums/p271/20vt_project/IMG_0222.jpg)
the rolling road vid is here (tried to make it interesting but quite frankly its not!!)
(http://i130.photobucket.com/albums/p271/20vt_project/th_SRRNov07.jpg) (http://s130.photobucket.com/albums/p271/20vt_project/?action=view¤t=SRRNov07.flv)
So now it is double the bhp/tonne it was when it was first built. Doesnt go twice as fast though!!
-
New to do list
FIT BIGGER BRAKES
1. Make a dash
2. Fit plastic front windows
3. Fit new door cards
4. Fit some kind of passenger foot rest
5. Flooring
6. Tidying
7. I would like an electric heated windscreen
8. Re-do the wiring again!
I built a bracket to mount the digidash on
(http://i130.photobucket.com/albums/p271/20vt_project/IMG_0525.jpg)
Gareth was clearly impressed by my metal working skills!! we both went to the same school and I think its fair to say our metal work teacher would not have been using my work as an example of perfection!
However after a splash of paint it looked ok- then it was just a case of undoing the steering column mount
(http://i130.photobucket.com/albums/p271/20vt_project/IMG_0527.jpg)
Dash fitted and I'm really pleased- it appears to float above the centre of the wheel
(http://i130.photobucket.com/albums/p271/20vt_project/IMG_0530.jpg)
And actually looks pretty tidy
(http://i130.photobucket.com/albums/p271/20vt_project/IMG_0533.jpg)
Then fitted some Hi-Spec 285mm 4pots
(http://i130.photobucket.com/albums/p271/20vt_project/IMG_0630.jpg)
(http://i130.photobucket.com/albums/p271/20vt_project/IMG_0526.jpg)
Next stage is interior sorting and lilly guilding.....
Needed somekind of flooring as the quality blagged grippy wore straight through at Cadwell.
Liked thes checker plate solution but I'm far too lazy to go cutting up bits of metal so I bought some from DT.
Really need to clean the floor:
(http://i130.photobucket.com/albums/p271/20vt_project/IMG_0544.jpg)
Also bought a passenger foot support
(http://i130.photobucket.com/albums/p271/20vt_project/IMG_0545.jpg)
(http://i130.photobucket.com/albums/p271/20vt_project/IMG_0546.jpg)
Next job is to bond/glue some suitable rubber matting I think on the heel part of the pax side to stop it wearing through.
So this is my finished interior!! Hmmm comfy!
(http://i130.photobucket.com/albums/p271/20vt_project/IMG_0547.jpg)
Then I fitted my helmet hammock and put my helmets to bed!
(http://i130.photobucket.com/albums/p271/20vt_project/IMG_0549.jpg)
-
Decided to clean the cars:
(http://i130.photobucket.com/albums/p271/20vt_project/IMG_0556.jpg)
The 911 has a new fab speed exhaust and its very LOUD!
(http://i15.photobucket.com/albums/a397/leavingeasy/th_Fabspeedexhaust.jpg) (http://s15.photobucket.com/albums/a397/leavingeasy/?action=view¤t=Fabspeedexhaust.flv)
Fitted new rear discs and bearings
(http://i130.photobucket.com/albums/p271/20vt_project/IMG_0625.jpg)
Couple of hours fiddling about and some guidance from Gareth saw the job done
(http://i130.photobucket.com/albums/p271/20vt_project/IMG_0626.jpg)
Fitted my boost pipe after the last one burst (still waiting for the silicone hoses to arrive :angry:)
(http://i130.photobucket.com/albums/p271/20vt_project/IMG_0632.jpg)
(http://i130.photobucket.com/albums/p271/20vt_project/IMG_0633.jpg)
Finally fitted the short shift
(http://i130.photobucket.com/albums/p271/20vt_project/IMG_0635.jpg)
The at last my christmas present from the wife arrived - only took eight weeks!!!
(http://i130.photobucket.com/albums/p271/20vt_project/IMG_0646.jpg)
Didnt have a heap of time today but the plan was to remove the glass windows and fit plastic sliders, then replace my home bodged ali door cards with these new ones.
So it started like this
(http://i130.photobucket.com/albums/p271/20vt_project/IMG_0647.jpg)
And ended up like this
(http://i130.photobucket.com/albums/p271/20vt_project/IMG_0650.jpg)
fitted the pax side - very bling bling!
(http://i130.photobucket.com/albums/p271/20vt_project/IMG_0673.jpg)
Also decided to remove the locking pins as anybody could reach through the window sliders and unlock the door otherwise :o
(http://i130.photobucket.com/albums/p271/20vt_project/IMG_0668.jpg)
That brings us up to date :grin:
Next things to do:
Sort other intercooler pipe
Fit camera mount
Fit silicone hoses when they eventually arrive
Fit rear turret brace and harness mount.
Oh and Bedford on 23rd if anybody is coming :grin: :grin: :grin:
-
Oh just realised I missed some stuff I didnt photograph!
The car was taken to track'n'road after Surrey Rolling Road to sort out the fuelling. Basically at 4000rpm it was hugely overfuelling and washing the power away, literally.
Steve Greenald is recognised as one of the top mappers in the industry, but he struggled with the MBE set up Ben Leach had provided for me. Whilst it was safe, there were some strange anomolies he couldnt work out.
It took him a week to sort out but had transformed the way the car drives.
As I've had a bit of history with engines and this BAM is totally stock, we decided to run it at 1bar only. However, with his expertise it produces the same bhp as Ben's map with 1.5bar. :smug: That said torque is now down to 230lbft, which sounds a shame, but actually it makes it much much easier to drive and has more of a n/a feel to it now.
I also bought a G60 gearbox with rebuilt internals and ATB Quaiffe diff. Fitted that (but forgot my camera). The gearing is shorter than my previous 02A which suits the track but not the road.
Guess the next test will be on 23rd Feb at Bedford :lipsrsealed:
-
Bedford this weekend so it was a desperate panic to get everything ready in time.
First thing to do was get rid of the old intercooler pipes and knock up something more permanent.
Still not happy with the end result, but they are way better than the half Mercedes half Audi hoses I had bodged together before. They can stay like for this til after the weekend and then I'll try and improve them further
(http://i130.photobucket.com/albums/p271/20vt_project/IMG_0058.jpg)
(http://i130.photobucket.com/albums/p271/20vt_project/IMG_0810.jpg)
Next stage was to put together a decent camera mount- this was done using an old exhaust clamp, a camera tripod mount and POV.1 bullet cam
(http://i130.photobucket.com/albums/p271/20vt_project/IMG_0817.jpg)
One of the rules of Bedford is that each car must have their towing eye attached. Errrrr- problem there, I cut mine off to fit the intercooler. Bugger! This schroth belt was the answer- £10, problem solved!!
(http://i130.photobucket.com/albums/p271/20vt_project/IMG_0813.jpg)
of course the car now looks like its sticking its tongue out
(http://i130.photobucket.com/albums/p271/20vt_project/IMG_0814.jpg)
I've always been unhappy about attaching my harness to the seatbelt mount in the fllor under the rear seats, so I bought a bar of CDS, a mate rolled some endplates for me, I profiled it using a die grinder and my mate Gareth welded it in between the rear struts.
(http://i130.photobucket.com/albums/p271/20vt_project/IMG_0053.jpg)
The end result looked like this
(http://i130.photobucket.com/albums/p271/20vt_project/IMG_0820.jpg)
Also had a problem with a knocking under load and turning. I feared it was a drive shaft UJ, but it was lot simpler to fix than that- the driveshaft bolts had worked loose- I guess doubling the torque will have that effect :drool:
Couple of other bits of tidying, including re-earthing the water temp sender and generally checking it was all in one piece and now its ready.
Tomorrow a wash, then back to the barn, put on its trailer, ready for taking to Bedford Friday night.
-
Feb 23rd saw the first track day of 2008 at Bedford GT Circuit.
It seems I am quite probably the unluckiest bloke in the world, or probably more likely, the clumsiest.
Suffice to say the car didn't make it unscathed!
I pitched up early, the day was cold and clear, I was over excited.
Noise testing was an embarrassment- it was a 98dB day. I did 79dB @ 4500 rpm. The marshalls checked twice, they thought I was lying about the revs I was doing!
On track the car was definitely quick, handled well and, as is often the case with mk2s, it continued to upset a few expensive bits of kit.
(http://i130.photobucket.com/albums/p271/20vt_project/DSC_7190.jpg)
(http://i130.photobucket.com/albums/p271/20vt_project/DSC_7670.jpg)
During the briefing the instructor had made a big song and dance about how tough Bedford is on brakes, and how car's with standard brakes would suffer fade. I chose to stick my fingers in my ears, sing la la la and stare vacantly out the window, why should I worry, after all I have brand new freshly fitted Hi-Spec four pots with highly recommended new compound EBC red stuff pads.
(http://i130.photobucket.com/albums/p271/20vt_project/IMG_0630.jpg)
I dont like EBC pads but the guy in Rimspeed really rated them and suggested I try them.
About 11am after maybe 90 mins of track use (not continously) they started to fade. Fair enough I thought, after all the VBOx data showed me hauling the car from 130mph to 90mph, back to 120 and then down to 45mph in quick succession lap after lap.
I let them cool over lunch, but in the afternoon they were no better.
There is a clue here- but I stuck my fingers in my ears, sang La La La and kept lapping.
Earlier in the morning I had suffered an almighty clunk going round one of the many fast left handers. Popping the bonnet up over luch revealed the first problem- the intercooler hot pipe (upwind of the intercooler) had thrown the bracket. God knows where- probably into somebody elses path!
I tried a temp fix with wire before giving in and hoping if I used lots and lots of cable ties it wouldn't melt through.
Can you see the fix?
before:
(http://i130.photobucket.com/albums/p271/20vt_project/IMG_0632.jpg)
after:
(http://i130.photobucket.com/albums/p271/20vt_project/IMG_0068.jpg)
see also how the rubber hose I used (silicon one was sat in the back of my Volvo still) melted and deformed.
Turns out that wouldn't be the only thing getting hot.
As the day went on the brakes got worse and worse. Following Tallchap in his mk2 saw me pushing hard on the pedal when he braked rather earlier than I had anticipated (not due to lack of skill incidentally but courtesy to other slower traffic) and the harder I pushed the less effective the brakes were.
Decided to call it a day as I was nearly out of fuel anyway, just doing the cooling down lap, gentle braking into the chicane and the brake pedal hit the floor!!!
Jesus! A few pumps felt it come back up but I slowed to 40mph, kept off line and plodded back to the pits. I decided a few experimental left foot pumps might be required, see if the pedal would come back.
Suddenly there was a huge cloud of smoke and fearing I had blown the car up I dived off the road and yanked on the handbrake to stop me.
The smoke was coming from the front wheel and the disc was covered in fluid. The calipers had burst a seal. I was fuming, so angry that faulty goods had nearly killed me.
Or so I thought..........
-
What causes DOT 5.1 to boil?
Ask a mate of mine who accidentally fitted a pad back to front in his AP 6 pots when he was in a hurry to get out on the Ring! Piston pushed through the pad material, pushed the metal backing plate onto the disc, heat was conducted from disc, to pad plate to piston and boiled the fluid. Pedal hit the floor, he hit Adenau bridge!
Well I didn't put the pad in back to front.
However, it seems Bedford GT circuit is hard on brakes!
This is the best pad I had left:
(http://i130.photobucket.com/albums/p271/20vt_project/IMG_0861.jpg)
This is the worst:
(http://i130.photobucket.com/albums/p271/20vt_project/IMG_0859.jpg)
it got so hot it warped
(http://i130.photobucket.com/albums/p271/20vt_project/IMG_0860.jpg)
did this to the disc
(http://i130.photobucket.com/albums/p271/20vt_project/IMG_0862.jpg)
and this to the caliper pistons
(http://i130.photobucket.com/albums/p271/20vt_project/IMG_0856.jpg)
here's what the other side looks like, note the non burnt dust seals as well as the normal shaped pistons
(http://i130.photobucket.com/albums/p271/20vt_project/IMG_0858.jpg)
A long chat with Hi_
-
A long chat with Hi-Spec suggests the Red Stuff pads were a very VERY bad recommendation.
They recommend carbone-lorraine D6's for my type of (ab)use.
However they have been incredibly helpful and have offered to rebuild the calipers on Monday whilst I wait, they will also skim the discs to get them back in shape. Guess we'll see what happens then.
So I put the car on the ramp today at my friend Gareth's workshop. His other track day creations were also there:
(http://i130.photobucket.com/albums/p271/20vt_project/DSC_7401.jpg)
A post track day analysis shows:
Centre exhaust hanger melted through (luckily we fitted two just in case)
(http://i130.photobucket.com/albums/p271/20vt_project/IMG_0854.jpg)
Fitted another intercooler hose bracket, with nyloc nuts this time
(http://i130.photobucket.com/albums/p271/20vt_project/IMG_0069.jpg)
Also the damn drive shaft bolts were loose AGAIN!
A slight weep from the radiator temp switch
Dodgy earth on the water temp sensor (explains the sudden 148 deg temp spikes being displayed!!)
Going to address some of these issues tomorrow and Monday, more pics to follow.
Also need to sort out the damping, it looks a bit too soft at the front which would explain the loose back-end despite slacking of the rear ARB. Will play with them a littel on my next outing in March!
(http://i130.photobucket.com/albums/p271/20vt_project/DSC_7607.jpg)
-
OMG I got up horribly early this morning, in order to get my buggered calipers up to Hi-Spec in Dartford.
Spoke to Jeff there (looks like he spends a lot of time indoors!) he was full of top advice "when it starts making a grumbling noise they are buggered"
Actually, he was really helpful and 90 mins later my calipers were refurbished with all new seals, two new pistons and the discs freshly skimmed. He also recommended the carbone -loraine 5 pads.
So lunchtime today the rebuilt brakes were refitted and bled.
(http://i130.photobucket.com/albums/p271/20vt_project/IMG_0865.jpg)
the new skimmed discs from this
(http://i130.photobucket.com/albums/p271/20vt_project/IMG_0862.jpg)
to this
(http://i130.photobucket.com/albums/p271/20vt_project/IMG_0866.jpg)
Fitted the silicon hoses
(http://i130.photobucket.com/albums/p271/20vt_project/IMG_0871.jpg)
and finished the afternoon by getting rid of the recirc valve electrical gubbins as it turns out the way I had the recirc set up, it wasnt doing anything and potentially stalling the turbo. Arse.
(http://i130.photobucket.com/albums/p271/20vt_project/IMG_0870.jpg)
Finally I refitted the number plates and gave it a road test
(http://i130.photobucket.com/albums/p271/20vt_project/IMG_0868.jpg)
The brakes are fooking amazing:
From cold they are ok, they work which I wasn't expecting, but when they are hot, well OMG, the biggest problem was moderating them sufficiently to stop my eyes popping out and white van man from marking his sun covered dashboard in my boot.
Next test is North Weald on 13th March. Will keep you all posted.
-
I did a car limits driver training day today at North Weald airfield.
Car was awesome.
Driver remains rubbish.
But what it did show is how much the body flexes when you are really pushing hard!
(http://i130.photobucket.com/albums/p271/20vt_project/3wheel1.jpg)
next lap I picked up my grille!
(http://i130.photobucket.com/albums/p271/20vt_project/IMG_0038.jpg)
-
Friend of mine just sent a few pics from the car limits day. This is what they make you do. Sometimes you recover it, sometimes you dont!!
This time I did!
(http://i20.photobucket.com/albums/b207/wh00sher/carlimits/Stanningley_0030-1.jpg)
(http://i20.photobucket.com/albums/b207/wh00sher/carlimits/Stanningley_0061-1.jpg)
then it fell apart like a clown car!!
(http://i20.photobucket.com/albums/b207/wh00sher/carlimits/IMG_0046.jpg)
(http://i20.photobucket.com/albums/b207/wh00sher/carlimits/Stanningley_0226.jpg)
here's my mate Floyd rescuing the grille of the test circuit!!!
(http://i20.photobucket.com/albums/b207/wh00sher/carlimits/Stanningley_0436.jpg)
I'm fitting a new wing next week, making an airbox with a sexy cf NACA duct and the its off for paint.
Next month it's being abused for a magazine article. Can't wait!!
-
Time to get a bit of work done on the old girl.
My patented cold air ducting to the air filter sucked quite frankly. It was always supposed to be a temp affair but I always seemed to find something else to do instead.
Today we bit the bullet and decided to fit a NACA duct.
Stage one was to make a pretty pattern and then cut it out
(http://i130.photobucket.com/albums/p271/20vt_project/IMG_0132.jpg)
(http://i130.photobucket.com/albums/p271/20vt_project/IMG_0135-1.jpg)
The result was a hole in my bonnet
(http://i130.photobucket.com/albums/p271/20vt_project/IMG_0136.jpg)
Which was promptly filled
(http://i130.photobucket.com/albums/p271/20vt_project/IMG_0138.jpg)
bonded in place
(http://i130.photobucket.com/albums/p271/20vt_project/IMG_0139.jpg)
next was time to remove the knackered front wing
(http://i130.photobucket.com/albums/p271/20vt_project/IMG_0134.jpg)
before loading it up and sending it off to the painters
(http://i130.photobucket.com/albums/p271/20vt_project/IMG_0142.jpg)
Now do I need new tyres??
(http://i130.photobucket.com/albums/p271/20vt_project/IMG_0140.jpg)
Should be finished by the end of the week- then I can fit my GolfGTI.co.uk stickers :laugh:
-
Picked up my car from the painters today.
From this:
(http://i130.photobucket.com/albums/p271/20vt_project/IMG_0142.jpg)
to this (in £240!)
(http://i130.photobucket.com/albums/p271/20vt_project/IMG_0145.jpg)
(http://i130.photobucket.com/albums/p271/20vt_project/IMG_0146.jpg)
Next step was to fit the trim, indicators, newly painted bumper and new grille (no red stripe on this one)
From this
(http://i130.photobucket.com/albums/p271/20vt_project/IMG_0147.jpg)
to this (in three hours)
(http://i130.photobucket.com/albums/p271/20vt_project/IMG_0148.jpg)
(http://i130.photobucket.com/albums/p271/20vt_project/IMG_0151.jpg)
Problem is the bloody thing REFUSES to start. Seems the crankshaft position sensor has finally quit :angry:
-
Also fitted my stickers ready for the magazine article!!
Thanks JV
(http://i130.photobucket.com/albums/p271/20vt_project/IMG_0948.jpg)
I'm preferring the non striped grille
(http://i130.photobucket.com/albums/p271/20vt_project/IMG_0952.jpg)
but I need to make up some brake ducts rather than leaving these holes where the foggies used to be- I have some spare carbon fibre that should be a useful start
(http://i130.photobucket.com/albums/p271/20vt_project/IMG_0954-1.jpg)
Here is the car with the old striped bumper and brake ducts
(http://i130.photobucket.com/albums/p271/20vt_project/IMG_0868.jpg)
I also need to find another big bumper wheel arch trim- this one got broken when I span at Cadwell in the rain :laugh:
(http://i130.photobucket.com/albums/p271/20vt_project/IMG_0955.jpg)
-
NOW FOR SALE!!!! :sick:
http://pistonheads.com/sales/444145.htm