My Golf Project

  • Thread starter Thread starter L1J
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Conanius said:
indeed... I was listening really carefully to see if I could hear anything, then heard an almighty crack ! :eek:

absolutely stunning car mate, workmanship is totally first class

Thanks :) It was good to get positive comments from everyone that saw it, even in its unfinished state.

Best one for me today was when I told Fox at the pub it made 257BHP, the look on his face was brilliant!
 
Conanius said:
257 bhp, with det, and with 1000rpm to go :p

I loved our convo before you went in there

<me> so does the power switch make some difference?
<you>yeah I think so *presses high boost switch* I definately think its a bit quicker

*5 minutes later*

yep... its nearly 100 bhp different ;) :p

Been driving diesels for far too long, low boost feels fast at the moment! :D

commited said:
Top work man.

When you going to get it mapped?

I will order the interface, some stuff for det cans and an AFR meter Monday, I will map it after I come back from the 'ring (low boost only trip!).

wonder_lander said:
Anything from the seller of the original engine yet?

Nothing yet, will also deal with it after the 'ring trip!
 
saitrix said:
I have been following the thread all the way through. Really good project. :D

Now I don't normally like Golfs, but wow, I love sleepers. Want to sell me it for £20? ;)

Have any idea how much more power you will get when you stop getting det?

Original power target was 210bhp :D I'll be very happy with a safe 250bhp.

No chance, say £25 ;)

Randell Floyd said:
Are you based anywhere near North Wales mate?

Yes, near Caernarfon.
 
Not bored at all then everyone?

On the way to the 'ring in the golf. The exhaust is doing our headsin at 70mph! seriously boomy and annoying!

I'm sure someone has a vid of the RR run, I remember a camera pointing at me at one point.

Had a small breakage last night whilst out testing. An exhaust bush snapped in half, I think I need stronger engine mounts!

The suspension geometry got done this morning, feels a lot better at high speed now, looks at speedo :D

It should be a lot of fun round the 'ring.

As for my next project, I need to finish this one first. It really needs a diff!

I do have a "spare" 20V turbo engine now and I'm seriously impressed with the power delivery of the one in this. It would be awesome in something like an Elise ;)
 
Adz said:
Earplugs are clearly the solution here. Either that or drive faster and try to drown out the exhaust with road + induction noise :D.

Faster seems to be the preferred method by the driver at the moment!

I also have a stereo now :p

Leon,

I'm sure you weakened it first!

To do list for when I'm back:

Fix wipers
More sound proofing!
Wind noise from door seals
 
Well I'm back from the Ring.

Started down to Monday tea time and stayed overnight at Ashton. Golf warming up at 6am before we head off for our 8am crossing. The "support" vehicle in the background for all you Mondeo lovers!

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We arrived at Nurburg Tuesday afternoon, booked into the hotel and went down to the Ring for a quick look. The original intention was to take the Mondeo round for a few recce laps before the Golf. As soon as I saw a few cars go flying past I decided to take the Golf instead.

First lap in the Golf was terrifying, the speed that other cars catch up with you is unbelievable, spent more time checking my mirrors for traffic than I did on the track itself. Not knowing where the track went didn’t help either.

Went to Pistenklause for food that night, highly recommended. The food was really good. After a few beers it was time for bed.

Woke up the next morning and someone opens the curtains and says what we all didn’t want to hear “Oh ****, it’s raining!”. It was soaking wet outside, the hotel owner was recommending to all the bikers staying there no to go out on the ring as it was far too treacherous. I think at this point we were all nervous….

Down to the ticket office we go and purchase a 4 lap ticket. Seeing an Intergra Type R with a smashed front end reminded us all of what could happen if we got it wrong. First lap off the day was much better than the one the day before. As it was soaking there was a LOT less traffic and the closing speeds were much lower. About half way round I was starting to enjoy myself. The Golf was brilliant, turn in is superb on it and it inspires so much confidence as it feels so planted at speed.

Everyone had a lap each in the Golf and Mondeo in the morning. By the third lap I was remembering the danger areas which helps, a dry line had formed on some parts of the track which helped to show where the track was going and what lines the quick cars were taking.

We had some lunch and went karting which was great fun. In the afternoon we purchased another 4 lap ticket. It was ******* it down with rain. After a couple of laps we got chatting to a M3 owner in the car park that was complaining his traction control and ABS light were coming on, I mentioned that the Golf had no such luxuries :D

Saw a few accidents on the above laps, a Z4 had ploughed into some Armco on one of the fast corners, a GT2 was wedged into bank and a Morgan and 911 had a coming together at the start of the main straight. Very scary seeing all this bent metal.

With two laps left on the ticket and the time running out we decided to pick up the pace. I really enjoyed my last lap in the golf, I caught up with a few cars and it felt fast and smooth. More accidents on this lap and lots of mud on the track from where people had offs. Gareth did the last lap of the day in the Golf which he also enjoyed!

So in total the Golf did the round trip to the ring and 9 laps without any problems!

A few pics:

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It survived!

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A little mobile phone vid

Vid

Big thanks to Gareth, Elfyn and my Dad for such a good trip.

EDIT

Just checked the uploaded vid, quality is awful!
 
iPWN said:
lovely job, glad you got back in one piece, hope the wpiers weren't too much trouble :)

Wipers were fun, only worked on full speed and had a "skill stop" feature as WillGill called them :D

tbz_ck said:
Did you try it on high boost or was it a "low boost" only trip

Low boost only, high would probably blow the engine!

Few bits to sort now:

The exhaust is really boomy and noisy at speed and makes it unbearable. I purchased some earplugs at the first services on the way!

Door seals need adjusting or replacing to seal correctly

Heat shield at the rear is rattling on the exhaust

Map it for high boost

Finish off the interior

Lower the front seats

Will be done next week sometime, I have a few months worth of college work to finish before Monday....
 
tbz_ck said:
Its all gone quiet, and we know you haven't properly finished it off yet, so whats the latest?

Working Monday to Friday at the moment :( Which means not a lot of time for the golf.

Done about 2500 miles in it now, so much fun to drive. :D

Few little jobs to do, but working on it compared to driving it is so boring!

I need to:

Modify the front arches, tyres catch when landing hard on some bits of road we have here.

Change the brake fluid and get some better pads, they heat up a bit too soon.

Take the exhaust back, as its far too loud, to get another box fitted to the system.

Spoke to the company that supplied the ECU, they are going to remap it for free as it should "be right out of the box". So a trip to them at the end of the month hopefully.

Change the oil

Fit a 16V fuel pump

Finish off the interior

Once thats all done, I think I'm goign to sell it and buy something else!
 
Stolly said:
You want to sell it after putting all that work into it ?

Yes, I'm bored!

I fancy another Scooby I think, not sure yet though. It will take me a few months to finish the Golf so plenty of time to decide! We have another ring trip in September so I will be keeping it until then at least.
 
vwtechie said:
My Golf at the Ring ;)

Nice car, nice pics :)

Hydraulic clutch works well in mine and no problems with it so far.

It's a pain having to remove the engine to batter the bulkhead flat isnt it?

Quick update on mine while im here!

Car is going in next monday to get an extra silencer added to the exhaust, should be a lot better then.

I've "modified" the front wheel arches and now it doesnt scrape when landing!
 
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wonder_lander said:
Sorry if I missed it but what was the outcome with the seller of the borked engine??

Tried to contact him a few times but no luck :(

Put it down to experience I suppose.

Golf was taken back to the exhaust place today to fit an extra silencer, so maybe an update with pics on Monday!
 
Weather has been awful here today so no pics. Extra silencer has been fitted to the system and it's a lot better. I'm going to add some sound proofing to the doors and rear panels and it should be spot on.

vwtechie, start a thread with loads of pics it would be good to see how someone else has done it :)
 
Little update:

The diff I ordered months ago finally turned up yesterday with a lovely £97 bill for import tax... :rolleyes:

Diff with fitting kit

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Close up of diff

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Will be taking it along with the gearbox down to Cardiff to be rebuilt in 2 weeks time, so it will hopefully be fitted for the next ring trip in September!

Can't wait to get the power down :D
 
Nice diff, how much did it set you back?

Are you running the 02A gearbox?

Yes I'm running an 02A box, ratios are a little short but the acceleration makes up for it! Diff was about £540 including import tax.

Any Updates

Rebuilt gearbox with the diff fitted is being picked up on Saturday. It will be fitted next week as I'm going to the Ring again on September the 7th.

Car will be given a thorough spanner check next week to ensure everything is ok befiore leaving!
 
A post with some work done!

As I'm going to the 'ring again a week Friday, it's time for the last minute prep work to start!

The to do list:

Fit new ATB diff equiped gear box
Fit lightened flywheel
Change oil and spark plugs
Fit new air filter
Lower front seats
Spanner check
Fit sexy new KW Variant 3 coilovers if they arrive in time :D (ordered today)

Car was weighed today to ensure the correct spring rates were selected for the coilovers .

Total weight with a full tank of petrol was 1060Kg with a front rear weight distribution of 62/38%.

Reasonably happy with that figure. The back seat, spare wheel and some tools were in at the time.

The Golf has now got a new home for the next week as my garage has a mk3 Golf waiting for a 20V turbo engine in it. A friend has let me use his super shed to do the work.

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Look at all that room! :D

Car up in the air, front end removed

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This is what 3000 miles of abuse does to lovely clean components!

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Another update tomorrow night!
 
I am in awe. Particularily of the wiring looms What are you using to tape those up? I've always used self amalgamating tape myself, it;s very effective but bulky and it looks like ****, so blatantly DIYd.

http://www.vehicle-wiring-products.eu/VWP-onlinestore/sleeving/tape.php

I used the cloth tape

Lopéz said:
I would kill for a "shed" that size mate

So would I! A big thank you to Bob for the aircraft hanger and help last night and tonight!

Engine is now out

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Gearbox is split from engine and shift tower removed:

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Flywheel before it was removed as it's being replaced by a lightened and balanced unit:

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Front arches need soem more cut back as the tyres are still catching when landing hard:

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Picture of the extra box added to the exhaust system to quitten it down a bit:

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Going down to Cardiff on Saturday to get the gearbox.
 
Last edited:
Small update:

Picked up the gearbox yesterday:

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Plan is to get the engine back in by Tuesday and fit the new suspension Wednesday (if it arrives).
 
Just read the entire thread. What an achievement.

What is DET and did you cure this problem/high boost problem?

It's basically the air/fuel mixture in the cylinder igniting itself, due to pressure and temperature in the cylinder, before the flame created by spark plug reaches it. This creates large pressure spikes within the cylinder and can damage the engine internals.

The ECU hasn’t been remapped yet to sort the problem out. Work has been stupidly busy since May. I need to take it down to the ECU supplier to get done for free one weekend.

It's running fine in low boost and I don’t really want high boost until the diff is installed!
 
You still going to the ring on friday?
I take it you will be going round the sunday, if so email me your mobile number so i can call you when I get there ill try get your car going round.

Sent a mail to your trust address.

Another small update:

Engine and box put back together

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Oil pressure sensors replaced as one was leaking slightly

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Engine and box back in the bay

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Wiring and plumbing will be connected up tomorrow afternoon.
 
Everything is now back in

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New air filter fitted

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New seats didnt turn up today :mad: Will chase them up in the morning.

Oil change and some coolant tomorrow and all that will be left to do is the suspension and seats when they arrive.

It's a really weird feeling having some time spare and not being in a mad panic :D
 
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