Ashmond - 'mk4 1.4 bottom of range to 1.8t Dub'

[Ashmond]

Update! This weekend the engine got a bit of love! I polished the poop out of the bay and got some red piping. Stuck my two stickers from gti spring festival on too! 1) my dub sticker went on the slam panel and 2) my red wolfsburg sticker went on the top of my cold air feed pipe to bring a little bit more red in the bay!:

     

I cut a small air hole in the passangers side lower vent because the cold air feed is on now (encased in a water bottle so it doesnt get wrecked, with the pipe going straight to the pipe from the grill:

     

Calipers need to go back to red asap as the blue really isnt doing it for me now


another productive weekend for Ash!

[Ashmond]

video of wagon on way to gti spring festival

http://www.youtube.com/watch?v=zYeobfadJ1o

[Ashmond]

Update!

Saturday I went to pick up:

KO4 Turbo (from 225bhp S3) with wastegate
3" s3 maf sensor and housing
upgraded s3 injectors (bigger then standard s3)
3" red forge silicone turbo intake pipe
oil feeds
water lines
mainfold
twin cats and downpipe
brand new magnex decat pipe
all bolts, nuts, gaskets (brand new still in vag packets)

all for £450





Brought it all back then started on taking out the engine again, the front end off with the KO3s waiting to come off:



Did it all day saturday and replaced turbo and had it back in by saturday night. Did all the wiring exhaust/downpipe on sunday as the KO4 has a different downpipe and requires twin cats, so had to take off my standard single cat downpipe (which I only replaced the other week - for sale!) and replaced it with this bad boy:



Put the car back together and then started her up, started 1st time but have got 2 leaks; oil and water, had a look on ETKA and seen the parts we need to order in:

1) need a new gasket for the oil return pipe

2) need a new o-ring for the water feed as the one I had is slightly split.

About 3pm on sunday we stopped and the car had to be moved to my other mates for him to finish off after work as James had to put another car in his garage, here is a pic of me getting towed by Sammy on here to Bens



Could have driven it but didnt want to risk running out of oil whilst driving and doing damage!

Once we got to bens I took a few snaps, I also got some hitachi coilpacks as the standard aum bosch ones are weak and blew up with my ko3s so with a ko4 I think they would last about 2 minutes, new red forge intake pipe ties in well with the red hoses and main hose on throttle body. You can also no longer see the KO3s charge pipe but just the bigger manifold for the KO4  B)





My inlet manifold looked really dirty so I said whilst it was there we might as well take it out and i can sand and polish it for when it goes back in, so we did (look how dirty it is now and how mirrorred it came up in the newest post in this thread)





After I get these bits on then new boost pipes will need to be made up for my front mount, fit them and they get a remap and I should be looking at between 280 and 290 bhp.

pics to follow shortly, hopefully will be up and running by thursday, if not definatly this weekend!

I have a stage one remapped immobiliser defeated AUM ecu for sale now along with a standard downpipe, pm me if interested!

280bhp here I come, now even a bigger difference from the initial factory 75 brake it came out with

[Ashmond]

Right, with nothing to do apart from wait for a few parts to come in from vw (collected a few hours ago) I thought what better to do then reshine my inlet manifold and whilst its off do the tunnels that go into the engine as most peoples are shined up unless been done by a pro:

As it came off the engine, was shiny but where we had been touching it putting the lump out and back in it had collected dirt



Got a sander on it and sanded down the rough bits by hand:



Then went round Sammys and used his polishing wheel for a few hours - I like the outcome!





Also quick did the fuel rail and went over the rocker cover quickly to get the shine back up!

Putting them back on the car in a few hours, will get some snaps and hopefully some good news!

[Ashmond]

Right another update! Car has been off road for a week an a half now and I think the missus has got the hump a little bit. She said to me on friday, what do you need to get it running again and I aptley said "a HUGE front mount!" so right on queue she went and ordered me the biggest one she could find on ebay! (good girl!) Basically I need to get a front mount in for when the KO4 is up and running, didnt want to go the standard twin cat route and because I had a universal front mount piping kit I thought I would give it a go:

It turned up yesterday:





Some pics of the fitting! I picked up my gti twin fans and radiator the other week as the 1.4 ones I was running didnt even cool my KO3s let alone the KO4 but also the rad and slam panel wouldnt be big enough to have the front mount on top. After removing the air con rad (base model, no air con)


we noticed that this would need severe operating on if I did have the aircon rad just due to how thick the intercooler is (3"), we then test fitted the intercooler on it and saw that the crash bar needed to be modified slightly and cut back so it would fit over it:




problem solved!



Then we hung it temporarily with cable ties until we make up some metal plates to weld on to bolt into


Trial fitted the bumper, goes over just! May need slight cutting on the passangers side for when the boost pipes actually get fitted:

When we went to see how pipes out fit and how they would run we noticed that the fmic needs to be a bit higher up and that il need to make a choice:

choice 1:
Dont have any grills in and just have the hardpipes showing (I like this but think its a bit max powerish)

choice 2:
Raise the front mount up, carefully cut into my genuine ( ) r32 bumper so we can still fit the grills so the pipes are hidden


Then night caught up with us and we had to stop, so I just took a few snaps!





After everything we worked out that I need the following:

3 x 90 degree silicone elbow bends
3 x 90 degree aluminum elbow bends
1 x silicone reducer elbow (2" to 2 1/2")

Order these on friday and then hopefully be on the move again mid next week.

What do people think I should do with regards to the boost pipes, exposed or hidden?

[Ashmond]

Right, last night all my joins and piping turned up and we fitted it all and made sure it fit, unfortunatly they forgot one straight reducer for the intercooler (left side) so couldnt actually try it out. My battery died whilst we were doing it so only got one snap of when we fitted it all at first. Since then we cut the pipes shorter with a grinder so they are really compact and so they hardly take up any space. I am not going to have the pipes on show as we put the bumper on yesterday and I didnt really like the look as much as I thought I would. We had to cut my bumper so the intercooler fitted and then it got dark so couldnt do anymore. Need to put the jubilees on all the piping, do the electrics from where I replaced the fans, etc and then start her up and then see what problems I've got. I also put the magnex decat on yesterday and will get this taken into account when the map is done. With my cold air feed polished pipe and the rest of the bay polished I think its going to look really good!

Il get more snaps tonight when I go back to try and finish it or at least get closer to driving it again!

[dubsport]

any updates on this car mate? my favorite mk4 on the forum!

[Ashmond]

Right I need to bring this thread up to date! There's alot to do, going to copy from edition38

[Ashmond]

Posted 22 May 2008 - 05:44 PM

its been rolling roaded with the KO3s already so il have something to compare when it gets rollered with the KO4

*edit*

We did some more on the wagon this evening. Did all the boost pipes, fitted the decat and turned her over. She sounds the nuts, you can hear the turbo winding down from the back of the exhaust! But then we hit problems, we had an oil leak coming from the back of the turbo. We thought the lump would have to come back out to get access to it but we just dropped the turbo off the manifold and disconnected the downpipe. Turns out the oil and water feeds were not done up tight enough, when we had a closer look it showed the the helicoil threads were not flush and therefore I would have lost loads of power, sorted that. Now just need to pick up a reducer for downpipe to my milltek system and some gaskets from vw, hang the cooler, jubilee the pipes up and then turn her on and see what she runs like!

Should be done for Brands hatch meet! 
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Posted: 28 May 2008 - 01:03 PM'
I got the decat with the KO4 but they sell them on ebay for �100 delivered!

Was finishing this off last night so its ready for the Prept meet tonight. Hung the front mount properly and now just need to get some exhaust clamps and hang the exhaust. Had to cut away the bumper and if im honest the fit isnt perfect but it'l do for now until the weekend when im going to do all the few niggly bits (fit grill, empty car, etc) here are a few pics of how she looked and looks atm:









Hopefully see some of you guys tonight at brands, she wont be as shiny as the bay normal is due to not having time to give it a last once over

[jeynesey]

Holy thread resurrection!!