My Golf Project

[L1J]

Can we get some details on the Mondeo?

There's enough fordage in the thread as it is, such as the colour of the golf, a mk4 escort battery tray and some recaro front seats from an RS turbo

I thought we had managed a thread without the mention of mondeos.......

That's it, how is it done again? Up the wrist or across the wrist?

Someone is sure to come along now and mention a Rover or BMW!

OLJ you are throwing WAY to much money at this Panzerwagen!

You should take a leaf out of my book, work slowly and spend as little as possible and never finish anything

No no no, you should take a leaf out of my book, work efficiently, spend as much as possible and actually enjoy driving the thing at the end. Having followed your project threads over the years I thought I'd better show them how it's done!

we should be hearing that engine turning over within a week i reckon!

Hopefully......... Once it's running it will have to come out though for *** gearbox to be overhauled.

Llyr - wicked progress, take my hat of to you, keep missing you on MSN though

Thanks, Iain. Most of the time I'm in the garage! Will give you a shout when I see you online next.

Update to follow..

 

[L1J]

Tonights update:

Wheels on, just about enough clearance for the brakes

Just to give you a better idea, light behind the wheel. It should get better as the pads wear down

It's now on the floor

Possibly a little too much camber on the front wheels?! Quite easily adjusted and nothing to worry about.

 

[L1J]

All the wiring now in the engine bay ready to be sorted and then taped up

Wheels will fill the front arches nicely

Needed to move a bracket on the passat pedal box as it wasnt fitting quite right. Old pedal box butchered to get this bracket out in one piece

This bracket needs to be moved from here

to here

It will be welded tomorrow

Will get the engine crane tomorrow morning so hopefully it will be in the engine bay by tomorrow night!

 

[L1J]

Looking good bud!

I am a bit surprised you have put those wheels on without giving them a good rub down / polish etc like everything else that has been allowed near the car?!

What are the plans for the loom? Will you be able to hide most of the wires? Perhaps get some braiding and a few tips from the Case Central guys on invisible cable management

Wheels will be refurbed in a few weeks, just checking everything goes together at the moment. No point getting the wheels done and finidng they don't fit over the brakes

Looms will be taped up using proper harness tape, dont worry it will be very neat and tidy by the time I'm finished!

 

[L1J]

As Leon mentioned the negative camber will increase when the engine is in place. It's nothing to worry about, it's easily adjusted by using the camber correction bolts I mentioned in a previous post.

The unsprung weight will not change when adding the engine, the sprung weight will though!

Homeslice, there should have been an extra smiley after that statement but I ran out due to the posting limit, so here it is

 

[L1J]

I don't like the idea of camber bolts.

I DO like the idea of those absolutely sexual adjustable topmounts you can get:

Yum yum.

Whats wrong with camber bolts? I spoke to a VW specialist about solid top mounts, he ran some on his own golf mk2 and crakced the windscreen after hitting a bump! That was a big NO from me for a road car!

Todays update:

Pedal box welded this morning (thanks Oly and Sam)

Passat rear engine bracket fitted to the block

Gearbox attached to engine and on the engine crane

Before

After!

 

[L1J]

Power steering pump touching the front cross member so will have to be grinded down when the engine comes out

Then the plumbing nightmare began, spent hours this afternoon trying different combinations of pipes, radiators and fan cowlings to gain enough clearance for everything. No joy, I have a page full of hoses here I need to order.

Second rad we tried toay, the cowling on this one wouldnt clear the coolant pipes

I was hoping for it to start tomorrow, this will probably put me back about 4 days. I can carry on with the interior for now. I was so frustrated today! Luckily I had some assistance, that gave me a kick up the backside when I needed it! Big thanks to Bob

Hoses for the bias valve arrived from Rally Design

As it is now

Planning a day off tomorrow, need a break from the garage!

 

[L1J]

Planning a day off tomorrow, need a break from the garage!

Was a little frustrated at the lack of progress yesterday, spent today out in the garden doing some wiring.

Loom before tidying and taping

Damaged connector wiring

Wiring split from connector

Heat shrink in place

 

[L1J]

Both original engine bay looms now taped up, going to do the modified one later on so it all matches!

 

[L1J]

do us a favour though and dont get a missus until you finish the job. hate to see another man lost in action with a half finished project.

^^ Quote of the thread Just made me LOL a lot!

Quick update:

Modified QP Eng engine wiring loom before tidying

and after!

Will try and put the looms in tonight. Back in work tomorrow so it's back to slow pace for the next 4 days!

 

[L1J]

Most of the wiring is now in the engine bay, needs securing and tidying. Reversing light switch needs lengthening. New headlamp connectors need to be wired up. Altenator and started need to be connected to positive battery terminal and earthing for the engine needs to be done.

Battery connections that need to be done

Drivers side

Passenger side

Cable ties only temporary to keep the looms together until they are secured

Will tidy it all up over the next few days, mount the ecu and connect all the pipework then I can try and start it!

 

[L1J]

I'll drive.

Laptop out > upload special "Leon" map (No boost, rev limit 4500rpm)

No probs mate

Can you take a video of this please??

If I have an extra pair of hands helping me, then yes!

 

[L1J]

Thanks everyone

Spent some time on the wiring after work

Reversing light switch wiring now extended and all sensor wiring etc protected with tubing

Bulkhead wiring secured

Various cables that need to be connected to the battery and headlamp connectors, the thick black and red ones going vertical are the new feeds for the starter and altenator.

Plans for tonight are to finish the wiring if possible!

 

[L1J]

Little update:

Managed to use the Leon battery connection slightly modified on the golf. The cover is missing though, could anyone with a Leon check what part number the cover is so I can get one ordered please?

Wiring WILL be finished tomorrow night!

 

[L1J]

Part Number on my cover = 1 JO 937 550

EDIT: Thickest cable should be furthest to the right

Thanks for that will get it ordered tomorrow, was hoping you'd reply

Cable on the right is the starter feed fused at 150 Amps! I had to measure the current pull when starting my daily driver to make sure it was under this. Max current was 140.2 Amps so it should be ok! If it isnt I'll connect it straight to the battery terminal.

Cable next to it is the alternator connection

Thanks again.

 

[L1J]

Looking at what you have there, it seems that there are bits missing that the cover clips onto? Behind the top most bolts for the fuses, there should be two rails for the cover to hinge on, but I can't see them?

Argh, they must have broken off before I got the loom. Time to go hunting for a new one in the scrap yard then.......

********!

 

[L1J]

Another little update:

Found a fuse box in a local scrapyard from a 2004 Ibiza, had to swap some bits over from the Leon one as the metal arm was longer. The lid on this one is broken so I've ordered a new one from VW (£4.93 bargain!)

Quite happy with how it's turned out, the vertical cable cover makes it look much tidier.

Headlamp wiring doen both sides. Silly design on the headlamp plugs I got from VWP. Would be much easier if the wire could run down from the terminal on the right hand side in the picture.

Battery negative cables done, only an earth strap to the chassis to be put in place now. Yellow cable ties are temp ones, they will be cut off when I get some clips!

Ordered some more bits from VWP today just to finish everything off. Hoses should arrive tomorrow so I can start plumbing again!

 

[L1J]

boo... needs more pictures and stuff !!!

Dont worry I'm off work after tomorrow

Everytime i log on to these forums i instantly check my subscribed threads waiting for an update on this project.

Incredible work here. great thread.

Thank you

Quick update

New headlamps, door membranes, starter motor bolts, track rod end lock nuts and blanking plugs for the brake master cylinder

Lots of nice silicone hoses!

Tried to make everythign fit over the past few hours, not much room here from the intercooler to the inlet manifold. It's catching on the circled areas! Lots of trimming and tweaking required with these hoses.......

 

[L1J]

Who are the hoses by/where you get em! Samcos are just too damn expensive and cant find what i want in their set!

Hoses were from siliconhoses.com, they werent cheap but they had the colour I wanted in stock!

I knew you'd go for black

They didn't have red in stock

didnt you only just go back to work!?

can i have your job please....

Went back to work Sunday, add 4 days then I'm off! I have two days left in work next week before my month off

Thanks for all the comments guys, it really does help to keep me motivated!

I made a to do list today of what I had left to do. Came out at 45 items, some big jobs and lots of fiddly ones, 24 days to go to the rolling road meet. I's just hit me how much I have left to do! Ah well who needs sleep...........

 

[L1J]

Good evening all!

Not much progress today, this silicone pipework plumbing is very time consuming to get right.

This alone took about an hour of messing around with different bends, trial fitting the rad, checking everything else had clearance etc etc. Will get some metal pipe tomorrow to finish it off.

My silicone hell at the moment!

Some hoses to convert the rear calipers to mk4 golf ones, the mk4 calipers have banjo fittings that are circled below.

Also fitted the MAP sensor to the inlet manifold

Days off start tomorrow so some better progress to report then hopefully.

A warning to all you thread dependants, I'm going away for a weekend on the 27th are you sure you're going to cope without an update for 3 days?!