jezzaG60

Bottom end is an ABF, head was actually a kr one that i started porting about 2 years ago. I think the ABF was the 3rd or 4th bottom end that i've been basing the engine on... just kept changing my mind! I'm running the equivalent of a 69mm pulley, the belt is a 1440x20mm from http://www.rswww.com

Well, it runs!.... but it didnt make it down to the cornwall jamboree. Its not looking like it will go to E38 either. I could possibly get the few little bits on the engine sorted by friday but there are many other bits that need looking at. I don't think i want to drive it out the workshop and straight into a 700 mile round trip to E38!! Should have pulled my finger out a week earlier and then it may have been done! On the up side i'm pretty pleased with how it all looks in there, will be even better once the 'bay has been re-painted and all the other little niggles sorted! Pics to follow.

looking good Tim.... I think you'll be putting mine to shame this weekend. If i can even get it to move that is!!

The intercooler is a cheapy ebay jobbie that i've cut the end tanks off and fabricated new ones. Couldn't have got a much bigger one in there tbh! I'm hoping it will be up and running this weekend..... but there is a lot to do. All those little jobs that you don't really think about are slowing me down a bit! You will have to excuse the mess its in as well, the engine bay wont be very tidy as i'm leaving the old loom in there and running the other one in as well. I just want to see it driving now! I will reply to your P.M's later...... like i say work has gone very busy and i'm working all hours!

LOL, i wouldnt say mine is going to be finished.... i've just got to the point where i'm fed up with thinking about how i'm gonna make this work or make that work so i thought i'd get it all together and running. Then i can take it back out again and sort out the engine bay and get a few more bits powder coated. Power wise i really don't know what to expect. Anything under 250 and i'll be a bit gutted. That said a guy on Vortex has built a similar spec to mine and made 244 at the wheels..... which would be getting close to the magic 300 :-D Gonna have a dam good go at raggin 300 out of it when i'm happy with everything on it!

OK, sorry for the lack of updates.... but as you can imagine i've got my work cut out to get this finished..... or at least as close to finished as its going to be for the moment! Thats the engine pretty much together and ready to go in. Engine hung in the car for the first time. Happpy to see the alternator clears the front cross member ok. Quick pick of the fabrication for the intercooler. Had to make it twin pass really to be able to have a sensible pipe routing.

Right, time for a quick update.... been pretty busy on the car this week. Finally think i've got the belt routing and alternator mounting sorted. Engine is pretty much together and ready to go in. I've pulled the old engine out now. Today i fitted a different front subframe which has all been powder coated along with new powder coated wishbones, R32 rear wishbone bushes and Powerflex front bushes. Dug out the big H&R box that i've had hiding for the last year and fitted the new front ARB as well... Pics to follow!! Hopefully the engine will be chucked in this week and i may even manage to fire it up...... Cornwall jamboree is less than 2 weeks away and i'm determined to drive it there!

Looking good mate! Are you going to make an appearance and the Jamboree and E38?

Hmmm, not sure if that sounds a bit sarcastic or not! The borbets serve a purpose. Just waiting for a different set of alloys to come back from being polished and then they will be on there for the rest of the "summer".

Yeah, thats right, it is a 1.8t fuel rail...... This engine is starting to feel a bit like scrap heap challenge. I think there are bits on it from about 8 different engines from the VAG stable!

Well, quick update for the few who may be interested. Engine is coming together quite well, got the rods and pistons in, got the head built back up and bolted on. Pretty much finished the S2 manifold and had a quick trial fit of most of the parts to see how things will look! Nice shiney scat steel rods Engine with a few bits trial fitted. Don't worry, most of it will get some paint before it goes together. WIll probably have it all apart again after E38 but i just want to get the thing running and get some kind of map sorted for the emerald Got a G60 auto throttle body from the states which gives me a throttle pot for the standalone management. It also has a pair of throttle switches which may come in handy for some added NOS at some point! :-D Only got 3 weeks to get it in and running...... soooooo much to do!

Well.... its 1 month till E38 and i've realised my engine is no closer to being built than it was 2 years ago! So, last week i finally finished porting my head and sent it back to the machine shop for the finishing touches. A few other bits are starting to come together now so i'm finally making progress! The engine as it stands..... one month to go, well actually less as i'd like it up and running before a local show over the bank holiday! For those who haven't guessed it yet i'm builiding a 16vG60 2l 16v G60, Scat H beam Rods, Fully ported head, Cut down S2 manifold, Emerald stand alone management, Custom front mount I/C, Standalone charger oil system, ...... and a few other bits n bobs!

Any chance of some pics of his work??? I know there is a lot of variation in peoples idea of a good mirror polishing. I'm very interested in having a set of porsche rims fully polished. Cheers

I've got a set of leon calipers and carriers if you fancy a straight swap...... i just can't get the 323's inside my wheels so i'm looking to get 305's instead.

Just back from the paint shop..... looking pretty 8)

Leon discs are 5 stud mate.... you need the ibiza discs for 4 stud.... and you will need the ibiza caliper carrier to position the caliper correctly

Flywheel can't go on in any orientation..... and if your using a mk2 gearbox.... then things are completely different because you have a rod change 'box. Its still very difficult to get it wrong though unless you remove the dowels that line everything up. If it were mine i would set my cam timing from the flywheel and the cam pulley. If it means moving your cam timing 1 tooth then you shouldn't have any problems giving it a go. I'm not that keen on the bit of pressed steel with some nick cut in it.

Agreed, i'd go for the flywheel mark every time.

You don't remove the flywheel on a G60 when doing the clutch... it is unlikely to have ever been removed unless for major engine work or a crank shaft oil seal. Its not like a rod change box flywheel where it comes off everytime and people get them back on wrong. One thing you may be able to do.... take out number 1 spark plug and poke a screw driver or similar slim object down there. As you turn the crank the screw driver will come up with the piston. It won't tell you exactly where TDC is as the piston has a certain amount of dwell where it doesn't move at the top of its travel. It is howver possible to rock the crank back and forth and make a good guess as to where the middle of the dwell period is. Hopefully this will give you an idea on which mark is correct.

LOL..... I wondered how long it would be until you posted a constructive comment! The car is still in having a bit of paint done at the mo...... and i have done my back in a bit hence why i have time to sit in front of the computer for a change! Anyways.... while i'm writing a message i'd best add another pic or two. I had a spare rear beam shot blasted and painted, new backing plates, bushes discs, bearings handbrake cables, all new bolts and some fabia vrs rear calipers. Mmmmmmmmm new!!! And at the front, some wilwoods came up at a price i couldn't refuse. Car is running in winter spec here with the satin black borbet c's

Ok..... well i've had my lovely G60 for nearly 3 years. I thought it was about time that i posted up a few pics of whats been done so far. I've got a huge pile of other parts which hopefully i'll get round to fitting soon including new wheels, suspension, arbs, poly bushes, engine, gearbox (wow.... looks like i've been spending loads of money when i've actually been stock piling these bits over the last 3 years as and when they have come up!!) This one is the car a few weeks after I got it. I had swapped the wheels and lights on to it from my old corrado. Other mods at this stage were the rubbing stips removed and a change to a late spec grill. I think i had installed a load of sound deadening and made a custom boot build which i'll have to take a pic of at some point. One out in the snow we had in Feb last year Few other bits done in the pic below, mud flaps are on..... contraversial i know but i kinda like them and i think they make the back of the car look lower. Removed the rear towing eye and smoothed the bumper, painted number plate surround and de-locked and painted door handles. One below is a pretty rubbish shot of my engine bay.... i'm not much of a picture whore really and i don't have many good ones! I think some other people have better pictures of my car. The car is now wearing the very first of the full length scuttle covers. Its also got some aero wipers (ones from a passat that i got from the scrapper for £5 and modded to fit the 'rado) One more pic in the snow as it make the paint and the wheels look good!!! Right... thats enough for one post. I'll see if i can find some pics of the other mods!! :clap:

Cheeky git ! :) I'm their favourite Welsh customer i'll have you know! And yeah RKE = RK Engineering in St Agnes, they charge less than any of the other prices mentioned and do a fecking good job while they're at it! Technically speaking Walesy... your our only welsh customer. That means that you are both our favourite and least favourite customer all in one! Just for you mate we will make a special forum hourly rate of £35.... a bargain don't you think!!! (wow being in cornwall really sucks) Maybe i should start sorting out some sort of holiday/servicing combo cos i think at £28/hr most of you peeps could drive down here, have a stay and repairs and still pay less than your local places!!!!

Get a new crank pulley, drill it to accecpt a couple of hardend roll pins. Fit the pulley up to the crank and drill through to pin it in position. Use some thread lock and a dx crank bolt done up nice and tight and you shouldnt have any problems. I have done a couple like that and they are still going ok.

As i've said before Tim.... the 'rado is crying out for a big front mount i/c. The golf G60's always make a lot more on the rolling road and i think its mostly down to the front mount

Gaz have had my order for a little while now so i'm expecting them to turn up any day... i'll let you know how i find them