Golfyste - 1.8T

[jv]

[golfyste]

Cheers Jv 

[golfyste]

OK here we go 
i know i should have started this 10 months ago when i first got the car but just kept forgetting haha, so i have arranged all my receipts/paperwork and gone through all my photos and am going to try backtrack through everythin i have done so try to bare with me over the next week or so 

im going to start the same ways as a couple of other people have by listing all my current and planned mods and if it has a  next to it it means it has been installed and if it has a  next to it it means it has been bought and is probably waiting to be installed 

so he we go 

i bought the car in july 2011 with about 71000 miles, it wasnt perfect which i slightly regret as i was excited and probably bought to quick but its all a learning curve although i haven't let it put me off 

mods/plans......

Engine
R-tech stage 2 custom code remap 
K04-001 
Sachs G60 single mass flywheel 
sachs vr6 clutch 
Turbo back exhaust 
380cc injectors 
forge 007p recirc valve  with yellow spring   
Forge actuator with yellow spring 
4bar fuel pressure regulator  (not being used)
n75 J  (not being used)
creation motorsport silicone turbo inlet pipe 
creation motorsport 5 piece silicone boost hose kit 
blue silicone vacuum hosing 
THS front mounted intercooler with all boost pipes + pcr pipe 
powerflex dogbone mount 
THS tr3 engine mounts 
engine cover
paint manifolds
battery cover 
audi tt short shift kit 
saikou michi catch can 
walbro 255 Fuel pump 
ngk bkr7 plugs 
quantum platinum oil 
port exhaust manifold 
new bosch MAF before map 
water/meth injection

Suspension/brakes etc
HI-spec billet 4 340mm front discs with green stuff pads 
HI-spec 288mm rear discs with green stuff pads 
Weitec GT coilovers  
s3 subframe and bushes 
Front arb (s3)  
front arb polybush 
Polybush wishbones bushes
eibach rear ARB polybush 
s3 front lower brace  
rear ARB   
polybush rear beam bushes 
solid top mounts  

Exterior
R32 front
genuine r32 inserts
Anniversary rear valence
anniversary/r32 side skirts
rear spoiler 
de-lock kit 
bosch aerotwin wipers 
De-wiper on rear   
vw wheel centre stickers             
paint current front grill 
standard grill to modify for r32 front 
heko Wind deflectors   
hella celis projector lights 
6000k HID’s 
led side lights  (now have angel eyes)
Fix drivers side electric mirror     
refurb/paint wheels 
fill and paint chip next to boot handle 
Stubby Ariel 
Number plate LEDs 
Front 10mm Wheel spacers 
Rear 20mm  wheel spacer 
flared and rolled arches
Pressed plates 
new third rear brake light 
anniversary gti badge 
numberplate surrounds 
osram nightbreaker fullbeam 

Interior
Build sub box 
Subwoofer cover 
New steering wheel
paint centre console parts (around cd player, heater controls, ash tray) 
paint Door handles 
bora sport clock foils (with silver bit)
silver clock rings
pro sport boost gauge 
A pillar pod 
Bora air vents 
oem bora vent loom   
new gear knob 
new gaitor with white stitching 
tt pedals   
gti aluminium dead pedal   
new Rear ash tray 
Diagnostic Port cover 
Interior LEDs 
GTI on ashtray   
vw tax disc holder 

[golfyste]

So here we go, you will have to bear with the lack of pictures for the first 6 months of me owning the car as i didn't really think it was going to be a big project until i bought the ths front mounted intercooler and then it escalated from there 

So here is how i bought it in july 2011, the wheels were knackered and there was a small chip next to the boot handle but wasnt to bad apart from that, already had the k&n typhoon induction kit, custom turbo back exhaust, forge actuator, 312 discs on the front, component spekers in the front and sub in the back.
a few pics next to my old black mk2 gti 8v and my dads mk2 gti 8v ...





and after its first wash....





August 2011
Mods were slow to start with as i was still learning about the 1.8t but i started by buying a forge 007p with yellow spring 
i then did some more simple modding including using blue silicone vacuum hosing to do the n249 and n112 bypass.
 

September/October
I decided to do something about my wheels as  they were a disgrace and i had budget tyres on the back which were dangerous! (nexan  )
This i what they looked like to start with 




And what they looked like after with goodyear eagle f1 tyres 





A comparison photo 


 

After a wash 



I got pulled over by the police for have a sidelight out  they said i have to have it fixed and proof of this by having a MOT station stamp the paperwork and then return this paper work to the police station withing two weeks.....so i though ok no worries not a problem.....i couldn't have been more wrong.....my sub box was in the way so i thought "ok lets pull it out" but no, some plonker had screwed it in place before they put the wooden front on and then usebody filler to attach it, long story cut short i had to smash a hole in the box to get to the light 

This then started a little project of rebuilding the box using fibreglass which was quite interesting as it was my first time doing anything like that but i was determined to do better than the last guy so I took my time and took a sample of the boot carpet to get a close a match as possible rather then using lack like it was before 
Sadly i didn't get any pictures of the process but this was the final product 



I had huge boosting issues for a while and found a boost leak coming from the charge pipe to pancake pipe, so i tried a new o-ring and sealant but it didn't work so thought i would buy a piece of silicone hose and hose connector to try and fix it, I also bought a prosport boost gauge and the centre vw wheel stickers to replace the scratched and worn bbs ones.....

first small delivery (with many more to come  )

[golfyste]

November/December

I started doing a few more things towards the end of the year including the boost gauge with a temporary plastic pod.

I originally t'd the boost gauge into the line between the fuel pressure reg and 007p which has since been swapped so that the fpr has its own.



I then ran the hose around the back of the engine bay to the drivers side and went through the firewall through two rubber grommets using a welding rod which took the hose into the drivers footwell. I then ran it up the side of the dashboard to where the boost gauge was going to be placed.
I ran the wires for the boost gauge down the side of the dashboard and to where the fuse board is, I then fed the wires from the appropriate places that it said in the instructions (sidelight switch etc)

[golfyste]

I had quite a busy weekend which consisted bits of painting and fixing a boost leak ...

i decided it was time to get rid of the horrid wood look interior 
someone had already changed the door handles for matt black one but i wanted to make it all personal so decided to paint it all 

To start with...


all rubbed down ....


And primed...


And painted along with the backing plates for the vw stickers going on the wheels...


And fitted  ...


(i also did the ash tray but havent got a photo...will try remember to take one  )

Door handles and ashtray before...



being cleaned


And after painting 


another painting job i did was a large chip next to the boot handle and then handle itself was all corroded etc,

After disassembly and filling etc...
#

during painting ...


and afterwards 



the next job was to fix the dreaded boost leak on the charge pipe - pancake pipe c clip connection 
I decided to go about it by eliminating the c-clip and using a piece of silicone hose and a coupler 

I started by jacking the car up onto the axle stands and then locating the charge pipe at the back of the engine bay


i then removed both the upper and lower clamps...(you can see where i had previously tried using a gasket sealer to stop the leak)



i then removed both the jubilee on the pancake pipe and the small nut mounting it about the arb ...




and removed the pipe



i then removed both the recirc hose and n75 hose on the top of the charge pipe and also loosed the jubilee on the turbo outlet and pulled out the charge pipe



and then with a lot of wiggling and turning i managed to pull the charge pipe out from above, you sort of need to twist it and pull it up a little and then twist it the opposite and pull it some more  its awkward but not impossible 



i then removed the rubber hose...


and clamped the charge pipe in the vice


i then proceeded to cut off the end and cut a load of slits into it ...



i then folded them over and flattened them to create a lip ... (i actually shorted them abit afterwards which would have been easier to do before hand)


i then removed the metal end of the rubber hose using a dremil and being careful not to catch the rubber underneath ...



i then warmed all the hose in a bucket of hot water to make it all more flexible ...


i then assembled it all together


i then reversed the removal process and put everything back together 
this mod worked fine but i have since bought i standard change pipe which i checked for leaks and then polished up but have kept this one incase it leaks 

[markallen]

This needs updating Ste!

[golfyste]

True story hAha
I'm tempered to just start one in the dub rides section when I strt the new project 

[markallen]

Big turbo, big power! Like it. How much are you thinking of for all your fmic setup and all the pipe work you won't need? 

[golfyste]

Be about £320
Gotta sort myself out first you don't need it yet anyway....your turbo needs sorting before anything else