Dan_GTi8v, 20vt project

[F17BAD]

im after non Res matey for deffo


and yea see what you mean about that cat, i notice Jetex do sports cats so iv mailled them about the bore size on that, 23O notes tho

[Dan_GTi8v]

I'm thinking I may get the 2.5" and weld a sleeve to either end. when its all butted up nice and tight there shouldnt be too much strain on it to pull it down, just need to make sure I get all my lengths just right

Picking up a mk4 bora alternator today from a local breakers, so I wont need to keep bring my battery in with me and charging it up every day  If all goes well I may get a new battery as well, all the manual charing cant of been good for it

[Dan_GTi8v]

cat has been on hold since posting this, been having charging issues and also my fmic has been annoying me the way it fouls the bumper so much

fitted a new alt and that didnt solve the problem, so had a chat with rubjonny and after trying a few things found out that I'm an idiot and had it connected up wrong. I had the chunky positive wire connected to the negative terminal on the battery rofl  anyway after feeling like a tit connected it up right and all is good

Job for the weekend now is taking the slam panel off and cutting the fan mounts off the drivers side, then moving the rad back 10mm or so and making up a new mount for the rad and fan so the rad sits straight in the slam panel, that way I should be able to have the FMIC sit high enough to not foul the bumper. If this works I'm gonna be a very happy dubber

other bits and pieces need doing as well, VW finally called me about that pipe that was a 2 day order 2 weeks ago  So I'll be fitting that as well. May even get my intercooler pipework done!

Looking forward for going to a drive though without the worry its gonna run out of juice 

[Dan_GTi8v]

Moving the rad was a bigger job than I thought, ended up taking all day so I didnt manage to get any piping done, but did move the rad back and mount the intercooler properly

This is how it looked before I started work, not much room as you can see



So started by taking it all apart again!







I tried just cutting the top and side so the fans pulled forwards kinda like a door, and fitting the rad on the passenger side using the original mounts but mounting it behind them instead of infront, but this moved the rad too far forward so I couldnt get the bottom hose connected as the crossmember was in the way

So I ended up cutting all the way down again cutting the original mounts off so there was around an inch gap so I could make up some new mounts. Pics are a bit hard to see whats going on, I was kinda rushing towards then end and also nearly knocked myself out standing up and cracking my head on an open cupboard door! Dad came home and thought someone had been murdered in the garage 




and here it is fitted




And heres how the cooler sits now, a bit higher and much better clearnce on the bumper. Unfortunatly on the previous attempt at making it fit before I learned about moving the rad I cut all the fins out, regret it now and have put some black mesh there for the time being




Now I'm off to lay down and recover from my concussion

[tshirt2k]

It worked then? 

[Dan_GTi8v]

Yeah it worked great, cheers for the tips I'd probably have ordered a new cooler without your advice 

Still havn't made up mounts for the passenger side yet but its pretty secure pushed up against the cooler. probably wont be until Monday now that I get another chance to work on it. Everything seems to be going well atm though 

[tshirt2k]

I had the same thoughts at the time. But considering i had AC and didn't want to lose it. Although i still haven't had it charged up yet. Looks loike you could do with a new bumber now though.

[Dan_GTi8v]

Yeah bumper has been added to my long list of things that need doing  which rad did you end up using? Mines in pretty bad shape after all the moving around and being pushed up against things etc, and it wasn't too great to start with. I may also get some new fans eventually as well and tidy the whole thing up a bit, but I deffinatly have more pressing issues to deal with first!

[tshirt2k]

Yeah bumper has been added to my long list of things that need doing  which rad did you end up using? Mines in pretty bad shape after all the moving around and being pushed up against things etc, and it wasn't too great to start with. I may also get some new fans eventually as well and tidy the whole thing up a bit, but I deffinatly have more pressing issues to deal with first!

I ended up getting a new rad same as the original. You would be best to keep the fans in it as the slimlines are not supposed to ba as good. Not that i've had any probs with mine so far, but i have to run them both as i originally only had one at a time running.

Try and get some flat ali sheet (Easy to bend) from B&Q for the brackets. I put one in front and behind the rad on the loose side.

[tshirt2k]

Seeing threads like this has really got me contemplating having one of these engines in my valver at some point.

If you have a valver already. You can add a turbo to that.