My Golf Project

[L1J]

Have you looked at the Ibiza Cupra one?

No I haven't, a custom made one is going to be much easier for me and be a perfect fit! There's not that much in it price wise either.

That oil pressure adaptor looks a big bulky and heavy to be fitted to an ally part? Maybe route that on a short bit of hose so the engine vibration doesnt make it crack off.

It has to be that size to clear the turbo oil feed pipe. I don't see it being a problem as it's securely attached and going to moving with the engine anyway? There's about 12mm of thread going into the alloy part so any load (if any) is going to be well distributed.

 

[L1J]

Todays update:

As I now have a spare gearbox it was time to fit the flywheel and clutch....

How it looked before I started at about 4pm

Engine and box removed, clutch and flywheel installed D) and put back together.

Engine bay now empty so finished off what needed to be done before the engine goes back in.

Cross member and towing eye bracket ground down to clear the intercooler and power steering pump

Engine bay as it is now, one brake pipe line to the rear from the bias valve to be done. Steering connected, downpipe in place, fuel lines ready to be connected.

A really BIG thanks to Elfyn for coming over to help, it's so much easier with two!

Hopefully engine to go back in tomorrow

 

[L1J]

Looking good L1J. Once the engine is back in will it be ready to fire up?

Ta, everything is here now for it to be started, it's just a matter of putting it all together.

Managed to get the engine in earlier

"uprated" this engine mount last night!

Bigger turbo inlet pipe compared to the standard VW one

Much more clearance for the power steering pump now

Gear selection cable now in place and seem to be working

Need to connect up the fuel lines, vac lines, rad, intercooler and all the ECU wiring before I can attempt to start it.

Need to order a clutch hydraulic line as the one I've got here isn't long enough.

PS I'm not taking any reponsibility for any F5 buttons today!!

 

[L1J]

Can't get the staff these days, would have had that finished and running within a week + complementary hovis shots

Get your arse over here then and help Bring some bread with you

Run into some problems, the VR6 radiator thats fits "No problems, like a glove" behind the rallye intercooler according to ClubGTi doesnt! It's 50mm too long! Should have checked it before I installed the slimline fan. On the hunt now for the correct radiator...... ARGH!

Pics to follow later.

 

[L1J]

who needs coolant?

Can we say that about oil? Big leak coming from the back of the engine when I turn it over on the starter.

Won't start either, I have a spark but it doesnt fire. Before I can investigate the wont start problem I need to sort this oil leak out. I hope it's not an engine out job! Trying to think what I've missed.....

Someone remind me why I started this project?!

 

[L1J]

He needs to setup a webcam

You'd need subtitles

IT JUST STARTED

Filled the garage with smoke as the exhuast isnt in place, looks like the turbo oil feed is leaking slightly. Yes it's an engine out job!

Pictures to follow in the next post as I've used the smiley limit!

 

[L1J]

Todays pics

Both radiators and the rallye intercooler. Need to source a 630mm rad instead of the 675mm that was supplied to me. I dont think they will take that one back after I've fitted the fan!

Everything in place ready for starting, wiring loom was just connected up just in case I ran into problems!

The ****** oil leak, looks like its coming from the area circled

I'm going to try and tighten it in place, I dont *really* want to take the engine out again!

 

[L1J]

ahh, a 14 hour day is rewarded with a few quality updates. nice one

Same here

Had to take the engine out to find the leak, found a really loose banjo on the turbo oil feed. Hands up my fault!

Put the engine back in and it starts first time, idles and no worrying noises or leaks (apart from the unfinished exhaust).

I have an MP4 video on my phone of it starting and running, nothing I have on the PC will play it though. Any programs out there to convert it to something playable?

Permission to have the weekend off please?!

 

[L1J]

That Rallye intercooler looks a good size. How much did it cost and are they freely available?

Very rare! Paid £300 for it with the rad, was very lucky to find one!

Congratulations mate, must be very satisfying when it finally fires for the first time

Shame about the oil leak, hopefully you won't come across too many 'little problems', always a pain but fault finding is going to be the name of the game for a while till you nail it 100%

Thanks, its so good to see it starting. All the little problems have been my fault, it's what you get when rushing I suppose!

Will download quicktime now!

 

[L1J]

Weekend off! Steady on m8!

You can have the sabbath but I'm guessing you won't be able to help yourself since you've got a tight deadline!

I'm going away for the weekend of beer and catch up with all my uni mates, next update will be Monday!!

How much would you charge to drop a 1.8t in our lupo??

I'm not doing one of these again!

 

[L1J]

What a weekend

Lots done today.....

Mondeo is back and running, which means the daily driver can be stripped of parts to finish the project. A friend came over and swapped lots of trim, rubber seals, locks etc etc for me. The boot area is now finished apart from the carpet and side covers which need to be jetwashed.

I picked up the correct radiator from VW this morning. After fitting everything and starting, I had a slight problem with overheating. A radiator hose join popped under pressure and covered me in boiling coolant! Managed to get out the way quite quickly so just a red hand the damage.

There was a big air lock in the system, only half the rad was warming up and no heat inside the car. This was causing massive pressure build up. Managed to get rid of it by filling the system under pressure from a hose through the heater matrix and then draining to get a normal level.

Pic post "burst" needs a proper clean now!

It's been idling for the past 3 hours, water temp showing half on the gauge with the fan kicking in and out now and again. Oil temps settled at around 100 degrees C.

Plans for tomorrow are:

Fit the driveshafts
Fit new track rod ends
Adjust the camber
Finish brake and clutch lines
Refit front end
Start on the rear axle and suspension

 

[L1J]

That Rad looks like its meant to have two of those fans side by side. Why the little fan?

It's the biggest diameter slimline fan that will fit the rad. The Corrado VR6 that the radiator is usually fitted to has a twin fan setup. After yesterdays test I think temps are going to be fine with one, if not it's quite easy to add another.

 

[L1J]

If its meant to have two then stick two on it !

Last thing you want is overheating when you finally get around to ragging it

There's going to be plenty of airflow when I rag it

Brake fittings didn't arrive today and motivation went AWOL for some reason! Had a relaxing afternoon doing nothing

Did some little bits and bobs this morning, driveshafts and new CVs are fitted, front brake lines are done, camber is adjusted and track rod ends replaced.

Lots of helping hands coming over tomorrow night to finish the interior etc.

 

[L1J]

c'mon, ive got out of my deathbed to check this!

Not worth you getting up tonight

Major milestone tonight, it moved under its own power!

Not many pics as there's nothing new really!

Swapped the steering column and igniton wiring over from the black one, sorted the clutch hydraulic line and bled the system. Goes into gear fine and clutch works as it should.

New brake fluid res in place and clutch line fitted

It's new home until tomorrow morning!

Better update tomorrow I hope as it's being picked up tomorrow night to go to the custom exhaust place!

I will take a decent video of it starting and moving tomorrow!

 

[L1J]

Busy day today!

Finally outside in the sun!

Rear view, that awful tailpipe is being replaced tomorrow! Car has just been dropped of at the custom exhaust place. I should get it back tomorrow night.

New sunroof seal fitted, what a job, had to remove the runroof and strip it all down.

Some badly swirled paint, dont know if I'll have time to sort this out before the RR meet.

Dash finished and wiring done inside

Big thanks to Bob for his help again.

 

[L1J]

Some vids, first is the engine starting up, ignore the smoke at the end it's what happens when you dont have an exhaust and the wind is blowing towards you! Looks really bad though! Second is the car moving, brakes have no servo assistance at the moment so I got out of the way quick at the end!

Golf Starting

Golf Moving!

Cant do much tomorrow as the car wont be here, going to assemble everything I can tomorrow and pick up some new rear calipers.

 

[L1J]

I clicked before I read about the smoke and panicked on your behalf!

Nice Job

Good to see some video!

Are you going to consider getting it properly detailed at some stage? If it were me I'd get someone in to do a proper job of it first time, and then take care of it myself afterwards.

I have a PC and plenty of polishes, I intend to do it all before fitting the body kit but time is going to be very tight!

 

[L1J]

good stuff.

bet it all made it seem that extra bit worthwhile when you seen it move!

I can actually see the end now, good job actually as I only have 7 days left!

As the car is in the exhaust place I decided to try and remove some of the swirls from the doors and bonnet.

Before

Few passes with a PC, a coat of polish then wax

It's goign to take too much time to do all the car before the RR meet, so the bonnet and other door were just polished and waxed.

Not a bad result, car will look OK ish by the RR

 

[L1J]

Tonights update...

Picked up some Golf Mk4 rear calipers, they looked at me funny when I didnt have a reg number and said they were going on a Mk2!!

Car is back from the exhaust place, tailpipe pic. Its exactly how I wanted it, nice and quiet and 2.5" from downpipe to back box.

View underneath (I know the back axle needs doing, it's on the list for tomorrow!)

One problem found tonight, the gear selection cable clip popped out, leaving the car stuck in reverse. Will get a new clip tomorrow hopefully.

 

[L1J]

Surely they must recognise you by now as the strange guy building a VW hybrid entirely from parts?

I dont usually use the one I did today, they were the cheapest for calipers!

It's quite scary actually, I phone the VW parts department and they answer the phone with "Hello Llyr, you got more part numbers for me?" I even have a box with my name on it on the shelf in their stores!