My Golf Project

[L1J]

Don't lose heart in it There are plenty of us on here very keen to see the finished project

Havent quite got to that stage yet Thanks for the reply, Im quite keen to see it finished also

The to do list:

Get engine bay welded
Get engine bay painted
Trial fit engine
Measure up all pipework required for engine
Rebuild front and rear suspension
Fit new wheel bearings to front hubs
Swap over passat steering arms to golf steering rack
Finish off engine bay wiring loom
Refit dash
Refit interior trim
Refit exterior trim
Build up doors (they are bare at the moment)
Fit new cambelt and water pump

Stuff to source/buy

4x Road tyres
ECU and engine wiring loom
Silicone hoses for air intake/intercooler
280mm brake disks, pads and carriers
Front cross memeber bushes
Rocker cover gasket
Peloquin diff
KO3S Turbo
Fuel pump
Drive belt from a non AC golf/leon

Should be able to do quite a bit of that list in the next week.

 

[L1J]

Would it have not been easier to have just rented a welder? Or is it something you aren't comfortable taking on yourself?

Amazing progress non-the-less though

It will look a lot better if I get someone to do the welding, mine is more function over form

He has about an hour of welding work to do then the wet and dry comes out to prep for paint.

 

[L1J]

Llyr welds like me. Messy and over-engineered

My stainless steel TIG skills are fine thank you

The rest is exactly as described

 

[L1J]

Slacking here, no update for two days....

Did a few bits tonight after work:

As mentioned somewhere in the thread I needed to make a 'tab' for the throttle cable to attach to the inlet manifold. Marked on an offcut of alloy

Cut out and ready to be welded

Started to clean the engine block so I can paint it in the next few days

Old front suspension removed, the top nuts were FT, lots of heat and leverage required!

Plans for tomorrow:

Take springs to be powder coated
Get tensioner and rocker cover gasket from VW
Fit bearings into passat hubs
Start painting block

 

[L1J]

Plans for tomorrow:

Take springs to be powder coated
Get tensioner and rocker cover gasket from VW
Fit bearings into passat hubs
Start painting block

Springs done and bits here from VW

Fitting the bearings was a pain as the press didnt work some reason, we had to use a vice and be very careful as we didnt want to damage the powder coating!

Got there in the end

Going to start painting the block and wheel hubs later on

 

[L1J]

Tonights update

Managed to give the block 2 coats of paint

Hopefully it will be welded sometime soon so I can carry on with it!

Away for another 2 days tomorrow so next update will be Tuesday night.

Just realised I've missed a bit by looking at the pic, back to the garage I go!

 

[L1J]

Quick update on the parts to source list!

Stuff to source/buy

4x Road tyres - Ordered F1s from mytyres
ECU and engine wiring loom - Loom being sent away today
Silicone hoses for air intake/intercooler - Need to wait until engine is in place
280mm brake disks, pads and carriers - Disks and pads ordered, still looking for carriers
Front cross memeber bushes - Ordered from VW
Rocker cover gasket - Picking up from VW tomorrow
Peloquin diff - Emailed, awating reply
KO3S Turbo - Ordered a new one today, should be here tomorrow!
Fuel pump - Sourced one from ClubGTi, should arrive next week
Drive belt from a non AC golf/leon - Ordered

Welder should be here tomorrow to carry on with the welding

I've also ordered the following:

Parts washer, lots of bits that need to be cleaned before reassembly
Some deox-c and dynax s50 from bilt hamber

Update to follow tonight on actual car progress.

 

[L1J]

It was.......

£440 for a brand new unit, I thought that was quite reasonable, closest quote to that was £480 for a recon unit, but I didnt have an exchange unit so a surcharge of £150 would apply!

 

[L1J]

Thats better than I would have predicted. I've heard four figure sums for some replacement turbos !

I did price one up from VW, £1032 for an outright purchase

Once it arrives and I know it's the right one I'll post some details of the company!

 

[L1J]

I thought you said you were skint

I am now

Scary amount of cash spent today, budget has just gone up slightly. If I do everything to it now, I wont have to touch it for years hopefully!

 

[L1J]

if you don't mind me asking (and i totally understand if you don't fancy answering) what sort of area is your budget for the project?

Looks amazing btw - big props for doing it i'm sure the end result will totally rock

Costs so far:

I'm sure I've left some things out, will update as they come back to me!

 

[L1J]

lol ~@ ECU. Explain?

See

http://www.qpeng.com/products/vag_p...nagement_kits/18t_20v_plug_and_play_kits.html

The easiest way to do it I think, price includes 2 stage boost control and a new throttle body.

Few more bits have arrived

VR6 Clutch

New water pump, note the metal impeller, the standard pump has a pastic one that's a common failure point

 

[L1J]

Look what arrived this morning about 8:30am

Awesome service form www.turbosonline.co.uk

 

[L1J]

Parcels just keep arriving this morning!

Golf G60 brake disks (280mm), Fast road pads and a non AC drive belt

 

[L1J]

looking forward to seeing more updates on this

very interesting reading so far

i'd be useless at time management for this. First thing i'd have done would have been spending ages making the Cupra Turbo engine nice n shiny lol

You're welcome to come over and clean it

Welder is coming on Friday now, not much I can to until then.

Peloquin diff is on back order until the end of the month so will get that ordered soon.

Will pick some oil, filter and other bits from VW tomorrow, so tomorrow night the engine will be ready for fitting, shame the car isnt ready for it!

I should get the springs back tomorrow, so I can rebuild the suspension.

 

[L1J]

Another avid subscriber here and really enjoying reading your updates! Keep up the great work!

What are you planning for the body kit? Is it an original big bumper model? I see from your first pics that the front end is missing a bumper all together and I don't think the back is a big one?

My last two cars were a Mk2 8v big bumper Gti and a Seat Ibiza Cupra with the 1.8 20V Turbo, to have mixed them up like you are doing would have given me the best of both worlds!

I Just wish I knew someone who could do something like this, I would love to sit in on it all and just learn!!

Anyway, awesome stuff, can't wait to see it finished

The golf has big bumpers, it will look totally standard outside!

How did you find the Ibiza handled the power?

Hopefully this thread will give you some idea, any questions just ask

 

[L1J]

The Ibiza's stock suspension was what really let it down. I believe the Cupra R had a better setup, but the standard one was a bit pants. Show the car a series of bumps or undulations in the road and the balance was all over the place

Another thing I did do was to get the rear wheel spacers fitted. These were hub-centric ones (?) or something and were meant to be quite a safe upgrade compared to other offerings on the market. This really did help the handling as it increased the rear track to be at least the same width as the front. I believe as standard the rear wheels were closer together than the fronts!!

That's what I don't want the golf to be like, hopefully the diff will help with the traction and the softer springs with better shocks will cope with the bumps. If that doesn't work its going to get a set of coilovers.

I 'm having some spacers made to fit the rear to widen the track about 10mm each side. Front will be about 18mm wider each side. Should help a lot with stability. Going to order some uprated anti roll bars also.

Thanks for all the comments guys it really does help with the motivation.

Going to get some parts from VW on the way home from work so I should be able to service the engine tonight.

Hopefully taking a half day tomorrow to help with the welding.

Coming along nicely at the moment

 

[L1J]

Aye, I used to go to uni with the Gog git

He introduced me to OcUK!

Better a gog than a confused englishman

Dont tell everyone, they'll blame me

Actually I think you/Kate need to thank me

Picked up some bits from VW, Inlet manifold gasket, bushes, bolts, cambelt tensionner, injector inserts, brackets etc. Im now on first name terms with all three parts guys at the dealership!

They didnt have an oil filter or sump plug for a 1.8 20V turbo engine, most of the stock they keep is now for diesel engines!

 

[L1J]

At last a proper update that actually involves work done on the car!

F1s arrived today

So did this

Will pick up some degreaser for it tomorrow

Paintwork protected prior to welding

Before shots of both inner wings

 

[L1J]

After shots

Close up of some of the welds

Will get them cleaned up and primed tonight