boost monkey

We've moved out of Oxford now into Brackley in the south of Northamptonshire about 1.5 miles from my work. Jo is using the golf as a daily now, and it seems to be holding up well. I'm planning to do an oil and coolant swap this summer which gives me the perfect opportunity to change the oil-water exchanger too. The 2 hose connections on it are all gunked up with what looks like varnish or something similar(?) so I'm going to swap it out as the engine will be fully dry. Anyone in the brackley/northants area feel free to say hi!

Check the part numbers to avoid disappointment! :salute:

I'll probably start selling these kits with an endorsement for only £50 :norty:

A wise decision. We're moving house in a week, and so my wife will be commuting - I don't feel happy having her drive a 23 year old car as a daily, and so I'm thinking of getting a mk5 tdi for her too. 80 miles one way is a killer commute. My 50 miles return is just about enough in the mk2 before I start needing a break! What's the DPF like on yours? I hear stories but have no experience myself. Also I hear the direct injection petrol engine heads coke up faster than Kate Moss - no petrol washing the back of the intake valves means they crust up pretty quickly I guess. On another note, the car flew through its MOT yesterday! I am very pleased as it is on about 185,000 miles now and has sketchy history at best. There was an advisory for rear wheel bearings, but they're silent so i'll pop the wheels off and hand tighten them up :salute: Still after a Corrado at some point. I think i will have to have a VR base this time, perhaps one with a dead engine.

Sam, it's a shell but I have data for locations of hard points on the chassis (suspension turrets, wing locations, slam panel, subframe mountings, rear axle mountings etc)so I'm hoping to build it up into a more usable model. Badger I'm not sure, I'll try to find out.

I'll try to clarify with the machinists this week, just got back from holiday.

Couple more with wheels, included in main assembly (brakes too!)

Welcome buddy! Yeah it does need wheels on for sure! ha ha! :D Good to see you have joined the site. @swift, you can download it from GrabCAD.com if you register - file is about 150mb iirc. there's SW2012 and also step up there now.

And so, the plum lives on.... Angel Eyes and other bits need some work, but it's an incredible model - best i've ever found by far. All credit goes to Alex Worsfold on GrabCAD - i just changed colours etc, but it's his model. jon :salute:

Pricing for 6 series Ally is coming in at around £200 a side, so a saving of £100 there. Bear in mind this is a material only cost to give a ballpark figure for those of you wanting to know how much they will cost. With the 10+ hours machining per side, it will probably be nearer £1000 a pair but I will check on that.

I love how you do your own work on the car buddy! :D

Fair enough buddy. I do 60 miles a day at the mo, and see low to mid 30s in the golf. It is just too much fun to drive slowly! I was all for getting something like a mk5 golf, but I've heard that these direct injection engines mean the heads coke up within 20k miles and need to be taken off to clean. I guess having the fuel wash the back of the intake valves isn't such a bad idea after all! :D

Yeah, the company like to do things the best they can and I think 7075 machines really nicely! With regards 6 series Alu, my boss seems to think that we might need to change the machining slightly as 7 series was specced initially. Unfortunately, I was too busy to check 6 series prices today.

Hey buddy, yeah the mk2 is still going ok. I now have a slight exhaust leak, but I did a run from Ox to B'mouth last weekend and it averaged 37mpg over 200 miles so I was quite happy with that. LBJ extender is still being worked on. I've kinda of left that in Jay's court for now. I've turned my attention to the custom machined hubs from Ally project! Found a treasure trove of design models for racing Corrado (Ken Lark's) and also a mk4 1.8t owned by Frazero Racing! So I'm a happy bunny for sure. How come you sold your mk2?

Ah ok. Well if your car is standard I don't really see how it will improve the suspension or handling apart from reducing the unsprung mass as it will be lighter than the original one I should think. I have to do a bit more processing on the current model before I can get the mass properties out of it. ---------- Post added at 12:47 PM ---------- Previous post was at 12:35 PM ---------- Just heard from Ken Lark (just happened to be in the office...) that these uprights run RS6 bearings in, so that's going to put the price up some more..! He's given me a heads up on when the best parts were made so I'll have a hunt on the server and backup drives to see what I can find. Exciting!

It's an answer to some of the CF members wanting to redesign the original hubs to allow for easy fitment of big aftermarket brake kits for example. Also allows LBJ height adjustment for lowered cars to correct suspension geometry. What do you mean by derivation?

Completely custom mark. That's what the recesses are for on the left and right of the hubs. It is to mount 4/6 pot calipers and such like (opposite side obviously for steering rod pickup) PCD from the model is 5x100. Is that same as Corrado? It's a very easy thing to change if not! I'll try to find the 3 custom brackets that attach to left, right and bottom sections of the upright so you can see the complete item. EDIT: with the brackets it wouldn't be too hard to make some different sizes (especially for LBJ pickup) then you could have a standard length one which would work for those of you just wanting the simplicity of having a hub that can take bolt-on big brakes, and for those of you running extra low you culd space the LBJ pickup downwards to correct the geometry further. I like it :D

Cheers buddy! I'l get some prices on this stuff in the morning. Materials aren't my forte! ---------- Post added at 10:20 PM ---------- Previous post was at 10:18 PM ---------- Well, the cad/development work is already done - the only costs should be the material cost and then the machinist's time on the 3 or 5-axis machines we have at work. I have no idea how long these would need to run, I'm guessing a number of hours so perhaps could leave them running overnight. SO the good news is there is no tooling costs etc which need to be covered by a min GB - I'll have to check with my boss to see whether he'd be happy to just run off 5 pairs or something. I'll check tomorrow and let you know by lunchtime all being well. ---------- Post added at 10:21 PM ---------- Previous post was at 10:20 PM ---------- Yeah that's right. Frazero turned into Luzzo Bespoke 2 years ago and they're still in 1 of their old 2 buildings in Brackley. I'm the new cadmonkey there :D

I'll see what i can do. Steel would be pointless due to weight.

Well, it looks like the material alone will be ~£300 PER SIDE, so we're looking at upwards of £600 a pair and that is just for the main bearing housing /body, and the centre spindle that the disc attaches to. Other brackets for LBJ, Steering and Caliper shouldn't add to the cost massively. But yeah.... glad I put it in the title!

No buddy, remaking the parts from the CAD - car is still going AFAIK! ---------- Post added at 9:22 AM ---------- Previous post was at 9:20 AM ---------- Well the CAD is done, so it would be machining cost plus cost of material. The originals were made from 7075-T6 which is aircraft grade ally and it'll be a solid block. I'm hoping to get material prices today, and then will update you all. Cheers for the interest! :salute:

So it seems like I have come into some lovely CAD data for the above! Here are the details. For those of you who follow VW Racing / VW Cup, there used to be a company called Frazero which used to run a number of VWs (Golf 2/3/4, Vento etc) and in specific the Mk4 Golf shown below: As you can see it has some pretty trick hubbery going on - different bracket attachments on the side for caliper swapping and also below for a kind of LBJ extension replacement. Here's the CAD: We are looking into putting feelers out for a lot of the Frazero parts both here and on ClubGTi primarily as the cars are well known over there. If anyone wants to let me know what they are looking for, I will do my best to help. This is also a great turn up for the books for those of you like KevFishWire who were thinking about getting the VR hubs remade - they're already here! :salute: Any thoughts more than welcome, Jon.

CazzaVR deffo has some.

Are you sure you're fitting it right, and replacing the thrust washers?

Not sure if anyone saw it, but thought I'd point it out as I had a hand in it! Bentley EXP 9 F SUV Concept Our company (independent design house) did the work on steering wheel, gearstick and also little sunglasses case (walnut topped box by gearstick). I worked on the CAD for all 3 parts, but the original concept design was done by someone else. It was my very first project in my first real graduate job, so quite chuffed how it turned out! :D Jon (really does like CAD) :salute: