My Golf Project

[L1J]

Ok, how much do we all need to chip in for you not to go away that weekend?

Messing with the Golf vs catch up with a load of uni mates....... No chance

Spent most of this morning sourcing the following parts:
Radiator, slimline fan, heatwrap, heater matrix and brake hose fittings ordered. They should arrive tomorrow.

Finished the bay wiring loom today:

Battery earth feeds done

Alternator done

Starter done

All the above will be clipped in place when the engine comes out, as I need to drill holes for the clips.

Engine block earthing done

Spent a frustrating 2 hours trying to get the pedal box to line up properly so it pushes the clutch master cylinder in a straight line. The bracket I had welded on needs to be moved slightly (again!!!!). Will get it done tomorrow.

 

[L1J]

My way of thinking!! Why do today what you can put off 'til tomorrow??

You about over the weekend? I'll try to pop up for a nose about if you are.

Kev

More a case of I'll get someone to do it tomorrow

Will be in the garage all weekend, give me a call first to make sure I havent gone on a parts run!

Will hopefully be trying to start it Sunday....

22 days to get it finished....

 

[L1J]

Lunchtime update:

Some bits arrived this morning

Exhaust wrap for the downpipe

Slimline fan

Fan vs old cowling, the old fan sticks out of the cowling an extra 70mm ish so lots of room gained.

ECU secured to mounting bracket

Bracket on pedal box cut out and ready to be welded

 

[L1J]

Did some plumbing today

The leon has a coolant header tank where my washer bottle is now situated. I removed the connection arrowed and connected the pipes that were left over with a straight joint.

This meant I had to connect my header tank into the cooling system. Pipe cut and a T piece used.

Brake lines now connected to bias valve

Going to pick up a radiator and some pipework this afternoon and get the bracket welded.

 

[L1J]

Cracking progress mate. How much more work is there to do now?

Far too much!!

Went to pick up the radiator this afternoon, the listings they had were incorrect. I wanted a Corrado G60 radiator and they had the normal 1.8 16V one listed against the model. Corrado VR6 radiator now on order and should arrive Monday.

Picked up a new heater matrix (common fault on Mk2 Golfs) and some hose clips

Pedal bracket welded again (thanks to Mark)

The fuse box is situated by the pedal box and the bracket wouldnt fit with the new pedal box in place. I had to cut a section out.

Pedal box and fuse box bracket in place

Wiring started to be reconnected

Interior back in tonight if all goes well!

 

[L1J]

na..... get metal ones

No chance! As everyone has said previously far too slippy!

As to a total spend, I've stopped counting!!

Little update for a lot of work!

Started to reassemble the dash, headlight loom mounted passenger side.

Brake and clutch master cylinders in place

Not a lot of room between brake master cylinder and cambelt cover, I had to take a few mm off with a grinder!

 

[L1J]

christ L1J, thats a fair bit of work there, do you not rest?

Not at the moment no!

Dash back in this morning

Flexi lines from bias valve mounted to the bulkhead

Starter mounted after testing it turns on the key

The wiring is a nightmare at the moment, it's a good job I have the black one about to compare.

Plans for this afternoon is to get the dash finished and everything electrical working...

My Uncle has turned up and is fitting a new engine in his Landrover so I'll probably be helping him aswell!

 

[L1J]

Found one source of wiring problems

Will replace the complete loom with one from the black one once the Mondeo is back (Wednesday hopefully)

Handbarke light wasn't coming on, switch removed, cleaned and refitted

Everything on the dash now works as it should

I need to get an adaptor made up for the oil pressure switches. The Leon engine only has one port available and I'm going to need 3 as the GTi loom has 2 oil pressure sensors and an oil temp sensor.

 

[L1J]

Mate, give that interior a hoover - it doesn't do the exterior (or what's under the hood) any justice!



P.S. I know that hoovering comes last.

Carpet is going to be coming out for a jetwash soon

Interior does look a mess at the moment

 

[L1J]

Common problem on VW's at that age it seems

Agreed!

Last update for today

Downpipe wrapped, will get a jubilee clip for the other end Monday.

Found a place for the oil temp sensor, now only need a T piece for both pressure sensors (arrowed)

Dash half in place, cant attach everything until a speedo cable that's on backorder arrives. High low boost switch in place (circled), I've also used the light within the switch as a shift light that will only come on when high boost is selected

 

[L1J]

Will you be resetting the mileage or is that not wise?

Don't see the need to really, I'm looking forward to seeing it turn to 200k

 

[L1J]

dumb quetion, whats witht the heat wrap, why is it needed?

It basically keeps the heat under the bonnet down. As the air filter is situated under the bonnet I'm trying to keep the air intake temps as cool as possible. The heat shield around the filter should help a lot, but no harm in making it's job easier! That reminds me I need to route a cold air feed to the filter somehow!

EDIT helpimcrap got there first!

 

[L1J]

as ever you were more detailed.

No I wasnt I forgot what andi said!

Yes hotter exhaust gasses have more energy and should flow faster!

 

[L1J]

save up and take it to MJ's for a retrim all inside

p.s. the hazard switch will light up when full boost is on? sounds great.
maybe a custom switch though? just plain red would be nice.

not my car though...and my golf days are long over

tidy wrap job there mate!

The light inside the switch will come on when it's time to change gear when high boost is selected. I'm looking into removing the triangle on the switch, will get a spare and experiment!

Wrap is going to be painted with high temp paint tomorrow to try and seal it so it doesnt absorb as much water when it's wet! I'm not keen on it looking like a steam train!

 

[L1J]

never thought of that. only ever seen manifolds wrapped not the downpipe.

will the paint take to it?

Will post some pics of it painted later, the paint seems to be absorbed quite well.

Quick update

After checking the fuel pump primes, starter turns over etc I installed some security devices this morning. This pic is all you're getting (black wires are part of the system). I'll feel really sorry for anyone that has to fault find the system if it goes wrong. They are going to spend hours trying to find the units and trace the wiring. I've also installed a few extra measures.

Carried on with some under bonnet plumbing this afternoon. Slimline fan gives much more room for all the pipes. Everything looks so messy at the moment, it will be cleaned before it's finished! I have a new rad on order and the intercooler needs painting.

Tonight I'm going to try and fabricate some pipework for the air filter to the turbo and the turbo to intercooler.

Slight problem with trying to start it, I didnt put the clutch or flywheel in as they need to be lightened and balanced. Firing up date will be May the 8th after the gearbox has been overhauled!

(I really cant believe I expected it to start without a flywheel, MUPPET! )

 

[L1J]

wow its really coming on now... can you see the end yet?

Lots of fiddly time consuming jobs left. I dont think it's goign to be 100% finished by the RR meet, but it will get there and run! I'm going to be booking the MOT for the 10th of May....

Pic of the exhaust wrap painted, looks like it's sealed it quite well

Needed to make some pipework up from the turbo outlet to the intercooler. Made a template out of some old pipes and hose I had around.

Popped into work (better workshop!) armed with some pipework, everything joined using tape for now to make sure it all fits before it's welded.

Test in place, all ok and fitted first time. It'll be welded up tomorrow. Thanks to Paul for the help

 

[L1J]

obviously this is just in case it fails the MOT spectacularly, but do you want me to find you some local garages to powerstation that do MOT's? Just if its looking a bit last minute tis all....




.......or if you just want it booked in there if you were to be asked.......ahem......

I like your way of thinking

MOT should be fine, I have a very understanding tester! If it's looking bad I'll let you know

The sooner I get an MOT the better as I need to take it to get a custom exhaust made! If I source another gearbox the timing wont be as tight!

 

[L1J]

Tonights update and a sigh of relief!

I've managed to find a second spare gearbox to get it running for now to get it MOT'd and the exhaust done! Picking it up tomorrow with a flywheel and clutch. So if the diff doesnt arrive from the USA I can still use the car. Phew....

Took a drawing of the adpater for the oil pressure switches to the machine shop this morning. Picked it up this afternoon.

Adapter fitted after work

Picked up a new radiator and mounted the slimline fan using the "quick mounts" supplied. Basically they work as a cable tie. They pass through the rad and some rubber washers each side, there's a "nut" at the other end that tightens the tie.

Pipework that was measured up yesterday welded up and in place. Feed for air filter also in place with a hole drilled through the heat shield. All plumbing done now apart from intercooler outlet to inlet manifold. Some pipework should arrive tomorrow for me to do this.

Last day in work tomorrow for a month so expect some proper progress from now on!!

 

[L1J]

Tonights update:

Last inlet pipe done

Not much room at all here, I'm thinking about taking a bit off the alternator case to gain some space. I'll see how much the engine moves and take it from there.

Throttle cable bracket mounted

Dump valve and boost solenoid take offs welded to the pipe we fabricated and everything connected (thanks Oly).

Picked up the second gearbox today. Also booked it into the custom exhaust place for May the 4th

 

[L1J]

Whats the plan with the custom exhaust? Do you need one as your using the 1.8 20vt in the Mk2 and the Leon one doesn't fit?

Correct!!

Downpipe is 2.5" o.d. and I don't want to reduce this down if possible, I can't find anything off the shelf that's going to be quiet enough for me!