Frankensteins monster: Golf turbo 1.9t build

[QazGolf]

Insane build! Keep it coming.

[iain cooper]

brilliant work and progress pictures.

very well done sir !!

Iain

[LJB]

Evening all,
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Apologies for the terrible photos again, Unfortunately i lost all my data from my phone so lost all build pics, so I have had to pluck the pics from instagram..
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Making a start on finishing the cage off.
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Front end pretty much there, bases formed and welded to main cage & dimpled A pillars
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Getting the job done sometimes means being a contortionist.
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Flattened off shifter gap ready to accept the new shifter
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Time to tackle the FMIC, typical assache but nothing is impossible.
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Time to tackle the biggest turd on the mk4 platform AKA front sponge mounts. Turning some 6082 T6 billet down...














Also made a brace for the rear end.

















..... Guess whats going on here?.......
















Cleaned up (mild):













On to the stainless:
















Profiling the wastegate take off (Will take pics soon)





Added some Aerocatches on the rear - again, no pics as I didnt back up my phone... Sigh..........





Okay so, I got lazy and purchased some weld in seat rails from *inserts company name here* so as usual, was not happy with the quality so ended up fabricating our own:



Also, have half of this fabbed up now:





Also made some purchases too:





Im over at the unit next weekend, and plan to have most of the manifold (If not the lot) fabricated. So will do an update next weekend. Its growing increasingly closer to the end of the fabrication stage, so should start to assemble bits and pieces soon!

Until next time.. !

[LJB]

So managed to get to the unit this weekend, had some wheels made up to a specific spec (3 month wait for manufacturing.....) Unfortunately they are a little off but offer a fantastic neigh on perfect scrub radius. Before people start to think these are not wide enough, the whole purpose of this vehicle is maximum grip while keeping the handling as precise as possible. Wider wheels / crazy offsets will just ruin the characteristics of the vehicle, so no show wheels but fit well..







Sitting pretty tight up front, needs a 5mm spacer to clear the strut (Could have gone with ET30 here) but allows me to run 8j with full width tyres.







Please ignore the messy under car, have not had time to tackle this and re Schutz the under carriage..




VS Incorrect wheels - 9j ET18 (Looks great, super wide but scrub radius is well off, arches needed also)











Okay so, Have been working on a new type of manifold, a solid solution for those whom wish to run a sidewinder with 1.8t:



Sitting about right, out the way of everything.



Jig fabrication:



Oh my spare head I had lying about, made a start on the primary runners.
































& finally the money shot:



So unfortunately thats it for now folks, but these manifolds are going into production with immediate effect. Will be posting up many results & have a few designs to cater for every build.

Thanks again all

Liam

[LJB]

Firstly, thank you all for the kind words and positivity, its nice to see and hear you guys like it. @ Newguy; the sole reason of going FWD was to not only try something not many want to try, but because everyone is so against it, I wanted to prove a point that it CAN be done. With careful chassis mods and a reliable and well set up geometry should yield some interesting results, I have high hopes and hopefully with shed more light that FWD can be fun. Anyways, 4MO sucks ass, haldex is pure fail. I have a genuine quattro running gear from an S2 already lined up if the FWD goes completely tits up...

Anyways, got the manifold finished this weekend with a good friend of mine:








Which now leads me onto... HELL ON EARTH. Cleaning the inside of this was hell, And when I say hell I mean a full day of cleaning, prep, degreasing, sanding, scotching, cleaning, cleaning, degreasing, cleaning... And mainly breaking my back...









Left to dry off & baked

On to top coat and final interior colour:














I should be able to get to the unit this weekend for a few hours - But birthday has been and its time to socialise over food, drinks, and more drinks, followed by a cold drink to wash down.

Also, Ill try to remember to take out the spare DSLR!

Talley ho!

[lemski]

Top work. I agree halxex does such ass...
I just got offered a 4mo with a blown engine that i was temptex on to put my spare 20vt in but id have to swap out the haldex... Anyway keep up the good work. Always an excellent read

[LJB]

Seasons approaching so fast now and I get the feeling im not going to make it due to being a perfectionist and wanting everything just so, but the more im on forums & instagram checking out other builds, I get more ideas of what I can change for the better. Its a constant cycle that seems like its never going to end.. Haha.

Anyways, I managed to get the downpipe on, amongst some other interior bits and pieces. Unfortunately hit a massive barrier, where we welded in the custom seat rails we used one seat with a single mount (Purchased a couple of seats some years back and always had one of the seat mounts in the box, so simply purchased another - Seems that some have a 45mm width base and others 55mm giving me a total of 20mm difference between mounting points (Due to difference in offset) which has basically meant that both seats are welded the same, but one mount is totally different to the other. Now I have the pressing issue of trying to contact manufacturers to see who has a batch of these 45mm wide mounts. Ball ACHE !

Oh well, on with the potato quality res pics:





Downpipe on and clearance can now be seen:





Got some time on the lathe again, ***** the standard gear shifter knob, so turned up a rather, phallic looking gear knob. It feels great though (Mind the pun!)














Id like to say id be off next weekend again to rest up, but ill be back at the workshop again .... Updates at the weekend!

Thanks all

Liam

[xtetx]

holy hell! This is one awesome build

[LJB]

I managed to get to the workshop this weekend, nothing drastic was done as I thought it would be fun to chop the tip of my thumb off with a chefs knife last week when cooking up a storm rendering my back F**d and now unable to work with my thumb.. Onwards and upwards! :mad:

Had an awesome Bday gift from a good friend of mine:



I have a thing for ordering loads of nuts and bolts.. Love keepimg a good stock.



Made a start on the brake lines using some Copper Ni brake lines, decided to run them inside just because racecar. Actually, so I don't stuff it and rip them off.. More of a safety thing really.









Lets get some lines flared:









ET VOILA:



Skinned over:









My OCD kicked in full force, sometimes it works in my favour..







The ends are still unfinished as the protection is not the same length, so will be sliding an additional layer over post brake testing, again, just being OCD about things..

As you may be able to tell, I also set out and installed all of the 7/16 harness eyes and spreader plates using m5x10mm & nylocs to keep in place. Again, overkill but better do it once and do it right than do it twice and have a cry.






Having a full weekend on the car this coming weekend, so some more updates for you all!

Cheers everyone.

All the best

Liam

[QazGolf]

Wow! Actually speechless at how epic this build is.
Teach me please!!!