...joe - black mk2

[...joe]

well i've mentioned it a few times so thought i'd better make a start with the engine build. so far i've done sweet fanny adams other than take these photo's and stock pile parts! i always planned on starting the re-build after e38, so i realy should get my arse in gear but i've been busy with leather stuff. so anyway i almost have all the parts i need and i'm planning on getting the head re-built in the next week or so. then i'll get the bottom end re-honed and re-built, after getting the pistons skimmed to lower the compression.
this engine won't be chromed like the last one as up-keep was too much effort....well it wont be chromed as much any way! anyway photos of stuff:


audi s2 inlet manifold with the 5th leg chopped off and a flange for the throttle body welded on.


ported/polished g60 throtle body


the two bolted up and offered up to the head.


and a shot of the head, inlet and throttle body. the rocker cover and linlet will be the only bits to be polished and chromed.




head...nothing special here!


9a cams and KR cams. the KR ones will be used not sure what to do with the 9a ones.


new 2ltr crank, tempted to get this lightened.


brand new vw alloy sump!!!


g60 green injectors on 20vt fuel rail. injectors will be re-furbed.


minging 9a bottom end, shouldn't be looking like this for long!


i've got two totes full of extra stuff like gaskets, hoses etc. i got most of this off one guy who had an unfinished project.

i have a turbo on order that i need to chase up and a turbonetics exhaust manifold. also i have a g60 02a gear box and cable shifter i just need a corrado pedal box to complete the shifting elements. all in all most of the parts are her, like i said i need to just get off my ass and start spanner weilding!

[...joe]

well today i thought i'd make a bit of headway with the engine. started to polish the inlet manifold... what a tedious task that is! coming along nicely though...
i also went through the two totes and made a list of everything i currently have, quite a nice little amount of parts but i'm missing a distributer which is obviously a must! next step is to get the injectors re-furbed and the head reconditioned. i might try to get the majority of that done this week just so i feel like i'm actually doing something productive! i'm not sure who i'll get to do the pistons yet but the guy who did my re-bore last time will do the honing of the bores. great update eh?!

[...joe]

tonight i went over to JMR's place to pick up my turbonetics exhaust manifold. its a nice bit of kit which is very compact which suits me fine, also with the turbo flange being on the right hand side of the engine (as you look from the front) it means there shouldn't be any clearance issues with the brake servo etc.



i then cleaned up my head in his cleaning bath, came up nicely and considering the amount of crap that was on it. i'm not sure if i'll paint the head yet and i didn't bother cleaning out the ports too much as its going to be ported anyway. john said he'll teach me how to do that and cut the valve seats so when we've both got the time i'll get that done and thats the head sorted.





little pic of the manifold in place, you can see how compact it is. the turbo got held up but i've been told it'll be here in the next week, so i can then do a mock up to see how it'll all look.

[...joe]

turbo is paid for and should be with me next week! boring update! sorry

[...joe]

turbo arrived a few weeks back and is huuuuge!





i've dropped the block off to get honed, but its at the guy who did my last re-bore and he kinda works at his own pace, so i'm not expecting it back anytime soon but i'm in no rush for it. been doing lots of thinking about what to do with the engine bay. i reeeealy need to pull my finger out thoughas time is going to fly by and i want it done so i have a sorted car for next show season!

[...joe]

well as i said, time is flying by! done very little to the new engine other than organise myself and do alot of thinking! i'm helping a mate out to do a overhaul on a g60 corrado this week and as soon as its finished we'll do my head so that'll be one job down.
a little while ago i bought some eibach anti roll bars and poly-bushed wishbones. i also bought new bolts and clamps from vw because i knew i'd have one or two glitches! so anyway, they went on with alot of swearing! while i was at it i did an oil change, renewed the brake fluid and did a few other little jobs that i'd been putting off. they work reeeealy well in the dry but are a bit scary in the wet as they are so stiff. good stuff though!

one rubbish photo of them:



i also uploaded some pics from the no-rice show that i got third in so here they are:









and i know i've posted this before but for the sake of the project heres a scan of me in fast car, from the edition 38 show:



and lastly some pics adam_c took of his, mine and our mate tom's cars:







thats it for now, more when the head is done!

[...joe]

well the head is now at my mates waiting to be stripped and then ported etc. its my own fault its not done already... felt rough over the last few days so i haven't been back to do it. but the new valve guides and cam chains are on order so once i start it should be pretty straight forward. we have 3 heads to do, mine, his (which is going in his westfield!!) and a 3rd which will probably be sold on to raise some dollars! i'll be doing the stripping and re-building but he'll be doing the porting as he's done plenty in his time so knows what he's doing and how much needs working. but it'll be a good learning experience for me to see what he does.
i also got a call from vw to tell me the rear headrest kit i had ordered had arrived from germany, so i picked that up and went home to re-trim some spare headrests i had laying around. a few hours later and they wer all fitted and back in the car. for something so minor as fitting a few rear headrests it makes a big difference i think, however i keep forgetting to take some pics in the light so you'll have to make do with these ones off my phone (taking pics with the flash makes them look sh!te!)





mind you the seats look a bit pale in these pics anyway?!

and lastly i bought a set of winter wheels i'm happy with off ebay last night and went to pick them up this morning. they're ok for now and i believe they are a pretty old school wheel. tsw omegas i think? but they have quite a nice dish to them which is cool. i'll give them a quick re-furb and spray before they go on but at least it will save my BBS from the ravages of winter! they are also the 6th set of wheels i've bought this year, not including my bbs! pics to follow when they are cleaned up...

* oh also forgot, don't buy any "chrome" door catch pins off ebay or anywhere else that have a dull orange plastic striker. i bought a set and they're f**king rusty already and i only put them on after the respray a few months back! so i bought a set from LMR but when they turned up they just look like stainless ones and not highly polished chrome so i'll collar him at no-rice and have a word..... not impressed though. and to be honest i feel a rant coming on!

[...joe]

well rant resolved, turns out i got sent the wrong door pins and he did send stainless ones. he was very helpfull so i guess i'lkl see what the 'chrome' one come back like before i pass further judgement!!
i've started spraying the winter wheels and so far i'm really chuffed. i bought new centre cap badges for them and they look cool! they are starting to grow on me now. i'll get pics once they're on the car... i need some tyres fitting to them so will get that sorted soon.

finally i made some good progress on the head! got it all stripped out so its bare, its now getting checked for cracks etc before the porting starts. good news is it looks in bloody good shape! i don't know the history of the engine but so far it look sall good! the valves are still nice and shiney on the seats so it shouldn't take much grinding on the re-build. i neeeeeed to get cracking on this though, i had hoped to have got further than this by now but time just seems to fly away at the moment!

head before stripping:


stripped of valves, springs, etc:






^^^actually in these pics the studs and valve guides are still in place so i'm talking crap! the fully stripped pics came out all blurred so these will have to do......

[...joe]

mmmmm shiney pistons!



they are bahn brenner low compression ones specifically for forced induction. just got off the phone to G-werkes and ordered them and they are hoping to get them in before christmas! now i just need those con rods to arrive.....

also took some pics of one of my winter wheels:





not bad for some rattle cans and a badge! the trye on this one has had it but i've got two toyo's and two firestones to go on them.

[...joe]

well not alot has happened on the engine build. still waiting for the block to come back, which should be monday or tuesday. head is still stripped, no polishing or porting yet. pistons still aren't here...annoying.s o thats all kinda been put on the back burner.
other than that, i noticed a puddle in my golf from the classic lack of door skin seals! so i dried it out, then thought i might as well do it properly! i stripped the whole interior out, pulled up all the carpets, pulled out all the old crappy felt underneath them and gave it all a good clean.
while everything was out i had a look at my alarm as it had been doing a few annoying things recently, like the indicators weren't flashing when you arm/disarm and the intellistart hadn't worked for a while, not sure how long as i rarely use the thing! after pulling the fuse box out and tracing wires i found there were two wires which should have been on the fuse box which had obviously come loose, plug them in and ta da everything works!
right back to the floor, i covered it with a few layers of sound deadening. i was going to do the exhaust tunnel as well but most of it is double skinned anyway so only did small amounts of it:







then i used the old felt (which was flat as holland) as a template to cut some new felt out of some real nice dense stuff which is normally used to soundproof planes! (cheers lewy) then layed it in place, while making up some extra pieces to replace some knackered sections on the bulkhead.



then i put the rear carpets back in, rear door cards on and then it got too dark!

will finish it next weekend i guess as its normally dark by the time i get home from work. i started my car up and you can tell its quieter already, should be good once the setas and door cards are back on. oh yeah i've also made some door seals and this will also be a good opportunity to re-do the front door cards, whcih i've never been happy with) and fit my audiobahn components in place of the JBL ones i currently have.