g60karmann's g60 - The Latest

[g60karmann 0]

Here is the current spec : -

 

Exterior : -

92 Aqua Blue K plate

painted rear lights red

clear side repeaters

in-pro front fogs / indicators

Dutch pressed plates (stupid police and their fines!!!)

passat keyless door handles

black VW / G60 badge grill badges

Aqua Blue VW badge rear

shark fin aerial (don't bother with one of these the reception is really bad, but lets face it the radio stations are generally pants)

Currently undergoing some home repairs on the rear near side arch and lower boot panel, learning is fun :)

 

Interior : -

black leather interior

Momo steering wheel / gear knob / pedals

Auto Meter vac / boost gauge

Auto Meter air / fuel gauge

Auto Meter oil pressure gauge

home made stealth shelf

 

Chassis : -

KW varient 1 coilovers

VR top mounts

PowerFlex mounts all round

Original G60 15" / 6.5" BBS wheels

Perreli p6000's

Zimmerman drilled disc (replacing for brembo solid as these squeak a lot) Brembo standard non-drilled / non-grooved discs

 

Engine : -

BBM solid front engine mount (may replace as this snapped the mounting point... see images on later post)

BBM RSR charger outlet

BBM / Samco / home made stainless steel boost pipes

Jabba Sport charge cooler (1.6 MK2 Golf water radiator, R32 electric water pump and alloy secondary expansion tank)

Jabba Sport uprated belt tensioner

G-Werks 68mm charger pulley

G-Werks 2.5" SS 2 box exhaust with original ported manifold

380cc fuel injectors ? (grey Cossy injectors)

SNS stage 5 chip

K&N panel filter and modded original induction box

VR clutch

VR 1st / 2nd / 5th gears and re-built box by Silverstone Racing Specialists

referbed gear linkage with poly cable mounts (need new gearbox tower - got just need to fit it hopefully this weekend!)

Mocal oil cooler kit

G-Werks boost return delete kit

Alloy oil catch tank

Slimline water radiator fan

Battery relocated to the boot with 300amp fuses front and back

lots of life saving, but not pretty industrial Macarno

 

ICE : -

G60 note :D

Edited July 6, 2012 by g60karmann

[Slimg60 0]

Impressive list of goodies!!

Sweet colour too.

[g60karmann 0]

you gotta love the Aqua Blue Slimg60 ;)

 

how are those custom made boost pipes doing for you?

[Slimg60 0]

Still waiting for him to finish them, problem is finding the time when I can spare my car to leave it with him.

Thinking of possibly changing the routing of the pipes as they're behind the fan so get a nice hot breeze when the fan kicks in!

[g60karmann 0]

got round to fitting the poly rear beem bushes last week was easier than I thought it would be but did take a while longer than I thought it would due to hangover :? freed up the brake bias valve as well so no mad snaking under heavy braking :clap:

 

I know people argue about poly or not to poly the rear beem bushes but after fitting these the rear end is working so much better than before. It's more comfortable and all wheels stay on the ground for longer, roundabouts are fun again :D I would thoroughly recommend that anyone who hasn't replaced there rear beem bushes already to try it out.

[g60karmann 0]

oh yeah fitted the boost return mod

 

nice whoosh but now my engine bay is covered in K&N filter oil :bad-words:

[Philuk 0]

soudns good mate, get some pics up so we can all see :D i completely understand what you mean about not been arsed to go on a pc after working on them all day, i used to do it! :D

[JMC 0]

Nice looking car mate, and a good list of mods :thumbleft: . Did I read that right, that you bought this in Staines? As in Ali G Staines. Just up the road from me, but I've never seen that one around before.

[g60karmann 0]

yeah that's the Staines :) was owned by a crazy old lady, Darren at G-Werks knows her as she used to take the car there as well :grin: has been a well looked after car although the bodywork could do with a re-fresh. I will get some pictures up tonight :lol: honest

[g60karmann 0]

ha ha I'm at home and on the computer!!!

 

here we go some pic's :

 

(even though the images are only 800 wide they seem to be getting cropped so I have left a link as well)

 

http://i266.photobucket.com/albums/ii274/hawky84/rado3.jpg?t=1221077887

only thing that has changed since this pic is the G60 badge is now black

 

http://i266.photobucket.com/albums/ii274/hawky84/rado6.jpg?t=1221077886

 

http://i266.photobucket.com/albums/ii274/hawky84/rado9.jpg?t=1221077885

 

http://i266.photobucket.com/albums/ii274/hawky84/web.jpg?t=1221077884

rado at stoner park sunk in the parking lot

 

http://i266.photobucket.com/albums/ii274/hawky84/rado2.jpg?t=1221077887

me in the hat with dirty wet car and Rev.Steve

 

http://i266.photobucket.com/albums/ii274/hawky84/16032008109.jpg?t=1221077892

new shiny club sticker

 

http://i266.photobucket.com/albums/ii274/hawky84/23062008388.jpg?t=1221077887

fitted new gauges and relocated stereo (thanks dad for sending these from the states)

 

http://i266.photobucket.com/albums/ii274/hawky84/06072008432.jpg?t=1221077892

mmm shiny toys :)

 

http://i266.photobucket.com/albums/ii274/hawky84/18062008372.jpg?t=1221077892

fairly dented but working and massive second rad

 

http://i266.photobucket.com/albums/ii274/hawky84/18062008373.jpg?t=1221077891

sweet fitting of second rad leaves inlet and outlets with plenty of room

 

http://i266.photobucket.com/albums/ii274/hawky84/18062008375.jpg?t=1221077890

first use of awesome thread rivet tool, also used to put a thread on the gear box mount to fit the charge cooler mount

 

http://i266.photobucket.com/albums/ii274/hawky84/18062008376.jpg?t=1221077890

results of awesome thread rivet tool

 

http://i266.photobucket.com/albums/ii274/hawky84/18062008377.jpg?t=1221077890

first fit of charge cooler pipe work

 

http://i266.photobucket.com/albums/ii274/hawky84/18062008378.jpg?t=1221077888

charge cooler set up for now still with cr@ppy pump and no header tank

[g60karmann 0]

need some advise from any one with a charge cooler set up as to what pump to go for?

 

I have seen a nice meziere 30GPM 12v pump but that is $500 which is a little too much for my pockets

 

I have also found a place selling the R32 Aux pumps for $100 so with postage customs n all that it seems like the best option, does anyone know how much and where to get them from here in the UK?

 

Also does anyone know a good rad company? I'm looking for the same size as the 1.6 golf one I'm using at the moment but want to use larger core with bigger gaps between for better air flow to the main rad, just like a intercooler design.

 

last but not least, anywhere that is any good at alloy fab to make a custom header tank to go in the scuttle?

[JMC 0]

Great build thread mate (always good to see pics) - but sorry can't help with your questions... Interested to hear how you get on with the charge cooler.

[g60karmann 0]

Cheers JMC I'll try and dig out a couple more shots of the rest of the work at some point, yeah I really want to get the charge cooler set up properly, the pump is the main issue as the current one just doesn't flow enough water, header tank is just a nice to have really.

[Super-G 0]

There's a company near Glos called Allisport. They do alloy fabrication.

I'm really interested why you have chosen to go for a charge cooler instead of an intercooler. Surely your setup will weigh a hell of a lot more than just a front mount intercooler, due to the extra parts and the water? Whats the benefits of it? :scratch:

[g60karmann 0]

throttle response is very good and to be different :D plus it wont weigh as much as a VR engine :) I'll take it all off and weigh it (including liquid) and I think you will be supprised that it isn't an extreme amount of weight. Plus there are no sharp bends in the flow from the charger to the thorttle body. The main reason though was because I got it dirt cheap and it is far better than the original intercooler, it doesn't feel slow I can asure you of that.

[Super-G 0]

Mate, don't take it off to weigh it. I believe you. Honest. and i know what you mean about the throttle response. Bet it's loads better without an sharp bends and being shorter. Do you go to any meets?

 

Here's Allisport website:

 

http://www.allisport.com/

[g60karmann 0]

LOL I have to take it out for other reasons :D a decent mount for the charge cooler and replacing a water pipe below it :(

 

yeah there is the dublands meets run at the rat trap in stratton next one is on the 20th Sep would be good to see you there and I am starting to go to the hungerford meets but missed this months which is the second tuesday of the month at the rail way crossing pub.

 

Any good meets up your way?

 

Cheers for the alloy fab link will get a proper look tonight.

[g60karmann 0]

right I just got a slim line fan for a bargain on ebay and I am looking to put a lower temp thermostat in at the same time, where can I get hold of one, do VW do one for a different model car that will go on my g60?

[g60karmann 0]

Am i also right in thinking I need a 2 pole fan switch not a 3 pole switch :scratch: 100c and 105c is standard isn't it?

[JT 0]

i know in the past i got mine from GSF.. if i remember correctly the part no. 93478 .. think i may well put one in mine too thinking about it :) what make is you slim line fan and who did you get it from? if you dont mind me asking.

[g60karmann 0]

I'll find out who the seller is when I get home tonight, but was £40 (well £35 as I got another voucher sent to me from ebay :shrug:) brand new delivered and I think it is a Davis Craig fan. I'll post some pics up of fitting it as I hope my new charge cooler water pump will arrive before the weekend as well :D another bargain at £15 :D

[JT 0]

was it these guys?

http://cgi.ebay.co.uk/SLIM-LINE-RADIATO ... 286.c0.m14

 

if it was what size did you go for?

[g60karmann 0]

yeah thats the guy, 12" although I forgot to add that to the payment details so will drop him an email in a sec :shock: thanks for reminding me :notworthy:

[KipVR 1]

Hey buddy I just used a VR aux pump for mine, it worked a treat and you should be able to find one on here easily.

[g60karmann 0]

Hey buddy I just used a VR aux pump for mine, it worked a treat and you should be able to find one on here easily.

 

LOL i had no idea VRs had an electric aux water pump, I had been looking at getting an R32 one :) cheers for the info

 

well if this pump of ebay is no good I'll give a wanted post up ;)