Wazzzer - 1.8T

[Wazzzer]

Bit of repair work carried out over Xmas, I've been putting off fitting the new seat base for ages now so thought I'd better do it before the material wears away and ends up costing a lot more

no pics of during as it was a complete arse of a job but this is the state of the base I pulled out





Totally knackered

new one feels lovely now but it's not a job I want to do again lol

[Wazzzer]

Managed to find myself a genuine Miltek downpipe/sports cat for £150 so bought that, fed up trying to get a bent MOT.





All did not go well though, had it fitted and it was blowing from the flexi join

Got in contact with the bloke who sold it to me asking for half the cost to repair it and he gave it to me which I was very surprised about.

So it was off to Advanced Automotive to have a new flexi welded in and it runs like a dream now.

While I had the decat off I had a good look over it and I was shocked at the condition of the inside of it





The flexi on the inside has come apart...

Should see if this has restricted the flow when I pop over to JKM for a rolling road day on Saturday, it will be the first time it's been tested since the FMIC and sports cat have been fitted

Speaking of the FMIC, I found a massive boost leak on the MAP sensor boss on one of the pipes. The blank that was fitted (as the early Golfs don't have a MAP sensor) wasn't sealing 100% so I made a decision to have a plate welded over the top so there was no doubt it would be sealed. I found lots of other small boost leaks on various vacuum pipes so these have all been sorted as well

Fingers crossed for a good result on Saturday

[Wazzzer]

Here are my RR results from JKM at the weekend 

Took it over hoping for a similar result to what I had last time it was mapped and came away very happy

222.2bhp with 243lb/ft so close enough. I was expecting to be slightly down on power due to fitting the sports cat and it hasn't felt as torquey since fitting the FMIC so I'm guessing that's down to the longer pipework run.

lovely smooth power and torque curve



It's a little lean at the top end but I knew that already, gives me an excuse to fit the VR6 MAF and Calibra injectors next time I visit R-Tech

and a few pics my mate took





On another note it flew through the MOT which was another bonus

Charcoal cannister delete is also done but I need to upload the photos so I can write a little how to as well

Next job is to modify the grilles to fit over the intercooler, then finally get my 256mm rear discs on

[Wazzzer]

Grilles are trimmed up and fitted back in, along with the wrapped intercooler pipe to make it a bit more subtle













and a pic of the MAF sensor boss that has been plated over

[Hurdy]

Saw this at JKM and it is a lovely motor and makes good power. Keep up the good work Wes

[Wazzzer]

thanks mate, yours wasn't too bad either 

[Wazzzer]

time for an update....

I covered the pillar pod with the same material I used for the headlining and pillars to make it blend in a bit more







and fitted the oil temp gauge





and a night shot



I've also got my hands on some TT arms with threads for the standard droplinks



and a subframe from the same car with TT bushes fitted to it



some new bolts with the larger washer (needed for the TT subframe bushes apparently) these were nearly £5 each!



The wishbone/subframe setup is being fitted tomorrow 

stuck some later spec boot and bonnet struts in as I like the aluminium bling lol





DIY'd my door triggers to make them look like the R32 versions



oh and thinking of a private plate too, very cheap at £36. I might have also put a deposit down on a Devils Own water/methanol injection kit   

[Wazzzer]

Not updated this in a while so here goes...

All TT bits are on and it threw the tracking out a country mile... but once that was sorted it was like driving a different car (maybe a TT lol)

Ordered my number plate which was a bargain at £36



Found a cheap little mod from China, not bad for under £17



Had a full service done which meant I could fit my sump plug adapter for the oil temp gauge which works perfectly, a steady 85deg most of the time only rising to just over 90deg when I get snarled up in slow moving traffic 

The controller for the WMI kit has a new home



just need to work out where the pump and tank will be living in the boot and also paint the inlet manifold black and I can get cracking with fitting it

Audi TT light has been modified and fitted

LEDs fitted





loom soldered



and fitted, it was a bit of a squeeze but a bit of the old brute force and it's in, not sure if it will ever come out though 



and button backlights and LED mood lighting all operational



Bought myself a set of immo3 clocks for the grand total of £19 so they will be my modified set along with MTE and illuminated needles, and a colour change from blue to....? 

Also won some Passat clocks so I can rob the needles and trim rings from them

Ordered some new TT ball joints to cure a nasty grinding/rattling that has appeared and felt like it was coming from that area when the steering was turned...



now all done but the rattling is still there 

so a bit of head scratching and poking for a hour about while it was on the ramps and the problem was found. The ball joint bolts are fouling on the brake disc splash guard. My fault for not fitting the 312mm guards when I fitted the discs a while back. This wasn't a problem until I fitted the TT arms which makes sense now. Not a huge fail though as the old ball joints were a bit loose 

Here is the evidence of the ball joint studs touching on the 288mm guards





you can see the witness marks either side of the cut outs, not massive but I can't tell you how annoying it was

and the 312mm guards fitted



Took it out for a quick blast giving it full lock in both directions with no noise or rattling so a complete success 

Plates arrived and the last few bits of admin have been done so they can now live on the car

[Wazzzer]

The meth injection is in!

Not had a chance to test it yet but I'm sure I can do that on the way to Inters tomorrow

Some pics of the fitting

Decided to spray the inlet manifold and throttle housing matt black as opposed to satin this time





Pump and level sensor wires routed under the carpet from the controller



The feed pipe from the tank routed with the fuel pipes





The pump living in its new home



Tank mounted on the back of the rear seats



I've rigged up a rocker switch so the pump can be isolated if needs be. All feeds are also fused with a 20amp blade fuse



The controller is alive...



Inlet manifold fitted



And the nozzle installed





Just got to fill the tank up this evening and prime the pipes. I'll also be getting a level sensor to install in the tank at some point. Another little thing I've been working on is fitting a boost gaue to my Bora vent and this is the result



Not too bad if I do say so myself

I've also bought these PSI Tuning poly top mounts which will be fitted soon



I'll report back with how the meth injection performs after Inters

[Wazzzer]

Not sure that the WMI nozzle was in the best place so got cracking with moving it today

my hose take off from Devilsown...





Silicone hose marked out ready for the hole (eek)



and fitted (phew)



nozzle installed



plug fitted to original hole on the inlet manifold and paint touched up



pipe re-installed showing nozzle location



re-routed the pipe to make it a bit more subtle



and engine bay shot, WMI hidden away nicely 



Will take it out over the next few days and do some charge air temp logs and see what I get

I've also been modifying my VR6 MAF housing and spare airbox lid to mate to each other

VR6 MAF with a piece trimmed off so not to foul part of the lid



then to the airbox, small lugs to be trimmed/ground away





I then tried the MAF in the TIP, no chance it would fit without some finger file treatment, so I sanded it down and even added my own lip to aid the jubilee clip



The result is a perfect fit but I will be sealing them together as there is no rubber O ring to seal them together as there would be with the standard MAF. The TIP will need about 2" cutting off where it joins to the MAF once it's fitted as the VR6 MAF is longer but that will have to wait till I shoot up to R-Tech. I also bought myself a spare MAF to use on the car now so my newer one can be fitted to the VR6 housing

I'lll report back with some logs at some point this week