Wazzzer - 1.8T

[Wazzzer]

Silicone sealed the VR6 into the airbox lid

 

 

took the sensor out of the standard MAF to swap with mine, it's a bit greasy so I'll give it a very careful clean before it goes on mine, then the newer sensor can go in the VR6 housing

As promised here are some pics of the clocks I've been working on

These are the SMDs Ray (aRd) replaced for me, he also changed the blue backlights for the LED displays to red



My Creation Motorsport Bora Sport foils turned up



Now these aren't as straightforward to fit as they look as they don't have tinted parts for the indicator arrows or an icon on the full beam light. This is because the genuine Bora Sport foils have these built into the dash fronts. So a little bodging is needed 

What I did was to cut the bits I needed from the old foils and overlay them onto the new foils with a bit of sellotape 





Then assemble them together with the needles, doesn't look pretty yet...



but with the face on you'd never know 





Very happy with the outcome and they'll be fitted soon along with MTE and lit needles enabled 

The wires I need to make the MFD work have been ordered and I thought while I was there I would fit comfort indicators too so they are on their way as well

A bit of tinkering was needed as I heard a big pop while putting my foot down...

Turns out I hadn't pushed the pipe I took off to fit the WMI jet on enough and it had popped off. Not enough to affect it too badly though, it still pulled 182g/s @15psi, which using the very rough MAF/0.8 calculation comes to 230bhp 

I've also sorted the throttle angle out, I remember Nick grinding the stop away slightly last time I went up to R-Tech HQ and since then I've swapped inlets with Dave...

VAG COM reading as standard



and a screwdriver to open it a bit more...



Then the reading fully open



so I've now ground a bit of the stop away on the throttle housing to get it to open up fully



I decided to sort my pipe route at the back end for the WMI as I wasn't 100% happy with it

Result is I managed to lose about a foot of pipe and it's a bit more direct now

Underneath



Inside the boot



I also added my tap in case I ever need to shut off the system and remove the tank (like when I fit my float switch)



The stop ground back, not pretty but you can't see it unless you look for it



and the result..





The comfort indicator parts arrived



and the wires ready for the clocks changeover, nicely numbered both ends with some labels from work 

[Wazzzer]

Here's a few pics of the float switch fitted. It was leaking a tiny bit since I fitted it but I checked today and it's stopped







This switch works in the reverse of the devils own version; once the float falls level it will create a connection giving me a warning light on the controller. The devils own version needs to fall to a 45 degree angle to create the connection. This means I can fit the version I have lower in the tank wall. Also it looks like it's fitted on an angle as my tank is fitted on the back seats 

Clocks are now in!!!

Had to fit a different wiper stalk as my original had no controls for the MFD and also add the wires needed to control it. This was the worst bit as the airbag, steering wheel, ring gear, stalk retainer and finally stalks had to come off 



After this was all back in I started on the green mutiplug. I had to run four new wires to this to add the controls and the outside temp sensor



Very fiddly job as VW fit blanks to the spare slots meaning you have to pick them out first

Put the new clocks in and coded them to my keys, then added miles to empty and illuminated needles

This is the result





I absolutely love them

[Wazzzer]

fitted my boost gauge back on the steering column with an offset pod, looks loads better



The view of the clocks isn't as restricted as it looks as the camera was closer than my head ever is lol

Also changed the illuminated needles so the faces also light up with them. I still know my lights aren't on as the clock/mileage displays don't light up until they're on

My oil gauge is being sent back for a replacement as I've noticed the gauge face shows light through it when it's dark

[Wazzzer]

Just had the bright idea of replacing the front hubs with TT items to give it the proper front setup as I've found out the differences

This is the difference in the hubs, golf on the left, TT on the right



It should lower the arms level and help with the handling even more than just the arms. I'm hoping to get the TT quickrack too

A 3" exhaust system is also on the cards, I want the 42 draft design copy...

[Wazzzer]

My US spec centre console has arrived, brand new from Mexico



Will get it fitted over the weekend

Also had my replacement oil temp gauge arrive so that's been fitted back in, just waiting for it to get dark to make sure it's ok lol

[Wazzzer]

US centre console is in, then taken back out again as I need to adjust the handbrake mount holes to be able to move it over. I've got myself another handbrake mechanism to play with though.

Hubs and rack are all paid for so they should be here soon. I've also bought myself the 3" exhaust system from the US which I had a bit of a nightmare with; box was damaged and I lost all the nuts/bolts and gaskets. Can't fault the seller though as I got a partial refund which was enough to buy a genuine turbo to downpipe gasket and some copper silicone sealant for the other join. I found some spring washers, bolts and lock nuts at work so that's all sorted. Just waiting on the tailpipe as I wanted a 90 degree downturn due to my Anni diesel valance rather than the one they provide with the exhaust.

One thing I've noticed over the last few weeks is a dip in power so I managed to get some logs last night to see what's occurring.

First thing I noticed was the boost gauge only reading 15psi so something was amiss. After looking over the logs I found the problem, throttle position was only 70degrees on full throttle. Manually I can get it to 89.7 degrees so the cable was at fault. Unfortunately I'm on the last adjustment so I'm ordering a new cable today

[Wazzzer]

Finally got my backside in gear and sorted a tailpipe for the exhaust

From this



To this



Then finally



Should have it fitted next week

[xtetx]

Go on wazzzer!!!

[Wazzzer]

Well here we go, had a few niggly problems which I will elaborate on...

Stripped the Blueflame off with my mate today to put the 3" system on. First problem we encountered was the lack of room next to the pipe at the turbo flange end meaning you couldn't get much purchase on the nuts to do them up. Got over this with a spanner, just took a long time.

Next up was the downpipe join. Easier to join this together off the car as there isn't much room under there to get to the nuts/bolts.

All in all it fits well and I haven't had any banging off the rear beam or on any heatshields. The only problem I am getting is the joins are far too slack. I swamped them with high temp silicone but this acted as a sort of lube meaning the downpipe to mid section kept twisting. I'll be doing this again soon with a nice big U clamp.

Oh and it's quite noisy. Only around 77db on tickover but it does shout a bit at 2-3k. I'm hoping it will calm down, if not I'll have to get an extra box added in as the missus and kids will go nuts lol

Pics of the finished article





My 45deg tailpipe straight onto the backbox and way too close to the valance



Cut the tailpipe right back to give it a bit more clearance

[Wazzzer]

Right I've finally sorted out some strut top caps for my poly bushes as the Polo caps were falling through the strut top



(borrowed this pic from Robin over on R32OC, hope he doesn't mind)

So I came up with this idea, Robin beat me to it though lol

Standard Golf cap with the cup part cut off leaving a big washer



Then the remaining lip ground flat and centre hole enlarged slightly



Polo and modified Golf cap mated together



Comparison of difference in diameter between the two caps



Rubber buffer added to both caps





Fitted on now and they work perfectly

I'll be fitting the engine bits over the new year; VR6 MAF, ECU, injectors, WMI nozzle so I'll report back with some pics once that's all done