My Golf Project

  • Thread starter Thread starter L1J
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Lopéz said:
Remember the window I had in my Lian-Li? I used rubber blowhole moulding for that, from the usual electrical factor IIRC.

Thank you both :)

Will it fit over 2mm thick sheet?
 
Look what I found on my old PC case! Fits nicely on the alloy sheet :)

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begbo - Read the first post ;)

Jonnycoupe - Have you tried that method?
 
benneh said:
Bit late in the day but a Rover Ti airbox looks about right.

Here's my old one off the car




I've seen them in >250 BHP cars with various panel filters inside (seem to do a fine job). Not too big either, but plenty of flow.

That looks ideal, what model rover and years is that fitted to? Might try and source one to see how it fits to try and keep an OEM look under the bonnet.
 
-Mike- said:
The Ti is a Rover 620. I'd imagine they were fitted to the life run of the car.

Thanks, will have a look around.

Mini update for today

Some of the bits I removed from the Leon engine so far, in no order knock sensors, brackets, secondary air pump, purge control system etc

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I needed to block off this hole after removing all of the above

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Made a plate out of alloy using the gasket as a template

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Fitted in place

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Back of the engine now

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Busy night, got loads done thanks to two friends that came over to give me a hand

Rocker cover on leon engine removed for cleaning

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Was cleaned and preped by a friend, gave it a coat of primer. Top coat tomorrow.

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Managed to remove all of the dash with some assistance

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A big thanks to both for the help :)

Just waiting for the welder now, once thats done we can paint the engine bay and put everything back in!
 
Tonights update!

My Konis arrived finally after parcel2go messing about, stripped them down and going to get them shot blasted tomorrow

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Started to work on the old engine loom, the wrap was falling apart and I'll need to re route some of the cables to the new battery and windscreen wash location

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Some of the wiring I need to repair after removing the alarm

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Started painting the rocker cover but ran out of paint! Will get some more tomorrow and finish it off.

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hominid said:
Progressing nicely :)

Now you are getting on to my nightmare - the wiring..

One thing that did cross my mind was traction, do think you might need a LSD for helping getting the power down? I only say that because with my Golf GTI(MK5) it's a pig for traction in anything but bone dry weather and it could really use a LSD to reduce wheelspin.

Keep us posted!

Trying to get the wiring tidy is proving difficult!

LSD wise I've had a quote for a Peloquin ATB diff from the states. Will get it ordered soon.

On todays to do list:
Get various suspension parts and cambelt/tensioners from VW
Take bits to shot blasters
Get some high temp paint

Will update later
 
L1J said:
On todays to do list:
Get various suspension parts and cambelt/tensioners from VW
Take bits to shot blasters
Get some high temp paint

All done but not going to plan!

Stripped the leon engine down to fit cambelt etc that should arrive tomorrow

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Started to paint the rocker cover but it reacted really badly with the existing paint, rubbed it down and tried again. Finish still wasnt right.

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So it's going to be powder coated with all these bits

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Managed to confuse staff at GSF, I ordered a VR6 clutch and 1.8 20V water pump last night online. They phoned me this morning to check that I ordered the correct parts as they dont fit the same car! :D
 
:D at airbox

Mini update

Took some other parts to the powder coaters and they had already finished shot blasting the Konis down to bare metal

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Decided to put some primer on them ASAP to protect them

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Primer needs about 3 hours to dry so top coat tonight

Not sure what colour to paint the shocks red, yellow or black?!
 
MrSix said:
Black for stealth.

I know what you mean, the guy at the powder coaters looked at me funny when I asked for the rocker cover to be done in black. He said he's never done one in black before, people usually go for silver, red, blue etc.

tbz_ck said:
Red deffo

A little contrast would be good under the arches as the hubs are being powder coated black so red is winning at the mo!
 
Yellow I had wasnt as 'Koni Yellow' as the cap indicated so I went for the.....

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Few more coats to go on and some more wiring to sort out tonight
 
I HATE WIRING :D

Before

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After

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Spot any differences? Tip: They are blue and should have been on before taking the loom out, but some muppet forgot.....

All of this to run these 3 wires to the other side of the car

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Need to run a positive feed to the starter from the new battery side then I can tape all the loom up

On a plus note the Konis look good!

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Not much done today as the daily driver was given a once over and a few bits replaced on it.

Picked up some bits from VW

Cambelt, water pump seal, idler roller, Heavy duty front suspension top mounts, various spring cups, washers, bushes and flywheel bolts. With all these I should be able to finish off the suspension struts.

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This is going to be my High/Low boost switch :D

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Picture of the finished Konis in daylight

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dsb said:
looking good mate, how much do u think the whole poject will cost?

About 4k in the end I think including buying the car

wonder_lander said:
Keep the updates coming, like the patio chair installation in the engine bay

Spent hours on that chair, very comfy ;)

Next update will be Tuesday night as I'm away at the moment. Welder should be coming over on Wednesday hopefully.
 
Conanius said:
you going to be coming to the OCUK motors meet (Rolling Road day 6) to see what it puts out?

If it's finished and I have time available I will be there.

EDIT

I've added myself to the list on your thread.
 
Last edited:
Another update

Collected some more bits from Celtic Coatings

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Close up of the rocker cover, it looks much better in the flesh and exactly the finish I was after

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Welder should be coming around tomorrow so I did some prep work

Rust cut out from where original battery bracket was

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New battery tray in position, had to put a little bit of steel under it to get it to sit right

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Engine bay emptied ready for welding

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A good update tomorrow hopefully!
 
MrSix said:
Loving that powdercoating.

How much do you pay for that, if you don't mind me asking. I need to get my wheels and lower fork legs done on my bike soon and want to know how much I'm looking at.

The last lot of 12 items cost me £95 including shot blasting the Konis. That's for a coat of primer and top coat.
 
Lopéz said:
You'll need 500bhp just to get off the line what with all that powdercoating on it.

I reckon 600bhp just to be safe ;) Room for another 20V in the boot?


Lopéz said:
Oh, Gordon has swapped his Escort Cossie for a Bugeye, have to have a race ;)

Scary thought, considering the distance I'll be from him if all goes well next week!
 
Will look into the fiat airbox, thanks :)

Right, things didnt exactly go to plan with the welding today

I cut a plate out for the area that needed reapair

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Marked all the areas that needed to be welded

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We thought we'd try TIG welding it to try and minimise any sparks etc that would fly about and land on the bodywork and it looks tidier. It didnt work, lots of seam sealer still in the seams that cant be removed but caused havoc with the welding arc. Welder is going to come back on the weekend and blast it with a MIG.

Managed to secure the battery tray and weld some clean seams, but then we ran out of gas!

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Nothing seems to be going to plan at the moment, I even managed to bang my head on one of the Konis that was hanging up in the garge!

Can't refit anything until it's painted!
Can't paint it until it's welded!

Can't do anything to the engine until a cambelt tensioner thats on back order arrives in 7-10 days from Germany....

Plus the deadline for finishing might be 6 weeks from now dependant on how something goes next Monday which I cant mention at the moment.

Argh!

Going to create a to do list and take it from there I think!
 
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