GrahamU's 2.0 TFSI with DSG

[carrots 1]

i sprayed my gear box it looked great buts its started to corrode so i will have to do it again,i am going to brush paint it next time with smoothrite

[GrahamU 5]

Sprayed the gearbox and rack with hammerite smooth in a rattle can

[sexybourbon 0]

Cheers mate ill do simar i think it looks very neat

[GrahamU 5]

Picked up the subframe etc from being stripped and dropped them of tp be zinc plated and chemically blacked

 

 

Then had a play with the front struts:

 

I have a pair of Koni height and ride adjustable coilover bodies without springs that have been rebuilt by Koni's for the front and a pair of koni height and ride adjustable standard spring bodies for the rear.

 

I bought some AVO no progressive springs to go on them so I have a matched set of springs front and rear so have taken the cups from a set of shocks I got given to put on the front coilovers.

 

They seem to sit ok, I just need to get the correct top plates (the shocks I was given were from a caddy van so different top plates) then form a way to lock the cups to the adjusters.

 

 

old caddy shocks for cups

 

 

cups and springs on the coilovers

 

 

New springs :)

 

 

 

P.S. if anyone has a good reason as to why this spring / coilover combo wont work, please tell.

Edited July 11, 2014 by rado20vT

[GrahamU 5]

Picked these up today

 

 

all zinc plated and blacked.

[mic_VR 3]

What's the deal with the zinc plating and blackening over powder coating?

[DriverVR6 11]

I like the way you've done the front struts and using non progressive springs is imho a very good idea. I'll be interested to hear how it rides and handles. When I ditched the progressive springs on mine it was much better.

 

 

 

Then had a play with the front struts:

 

I have a pair of Koni height and ride adjustable coilover bodies without springs that have been rebuilt by Koni's for the front and a pair of koni height and ride adjustable standard spring bodies for the rear.

 

I bought some AVO no progressive springs to go on them so I have a matched set of springs front and rear so have taken the cups from a set of shocks I got given to put on the front coilovers.

 

They seem to sit ok, I just need to get the correct top plates (the shocks I was given were from a caddy van so different top plates) then form a way to lock the cups to the adjusters.

 

 

old caddy shocks for cups

 

 

cups and springs on the coilovers

 

 

New springs :)

 

 

 

P.S. if anyone has a good reason as to why this spring / coilover combo wont work, please tell.

Edited July 22, 2014 by DriverVR6

[GrahamU 5]

What's the deal with the zinc plating and blackening over powder coating?

 

I believe it has a higher resistance to corrosion than powder coating and you don't get the build up either so you don't need to worry so much about threads.

 

Also, its dipped so the coating goes in everywhere.

[Jim Bowen 1]

Suspension setup looks interesting. Will be watching to see how they turn out on the car. I do find the lower spring plate/cup can end up very close to the tyre. Is ok on coilovers as the springs and plates are so narrow. I just wonder if at certain ride heights the plate might interfere with the tyre.

 

 

Or it'll all be fine and I'm just over thinking it all.

[oneohtwo 8]

I believe it has a higher resistance to corrosion than powder coating and you don't get the build up either so you don't need to worry so much about threads.

 

Also, its dipped so the coating goes in everywhere.

 

Yeah, zinc provides both barrier and sacrifiial anode protection, but powder coating is barrier only. if the zinc coating gets scratched the zinc will continue to protect the exposed steel, whereas if you damage the powder coating you can be sure rust will be getting in there eventually!

[GrahamU 5]

Suspension setup looks interesting. Will be watching to see how they turn out on the car. I do find the lower spring plate/cup can end up very close to the tyre. Is ok on coilovers as the springs and plates are so narrow. I just wonder if at certain ride heights the plate might interfere with the tyre.

 

 

Or it'll all be fine and I'm just over thinking it all.

 

You make a good point about the spring cups and I hope now that I don't have that problem. I don't run silly low and the front wheels have a spacer aswell to cope with the brembo's

[GrahamU 5]

Got this off ebay tonight

 

 

bit tarty but I love it :)

[Jamie 1]

Got this off ebay tonight

 

 

bit tarty but I love it :)

 

 

Really like that - is it W8 Passat?

[GrahamU 5]

Really like that - is it W8 Passat?

 

It certainly is :)

[Jamie 1]

Cool. Nice find :)

[GrahamU 5]

Progress has been a bit slow lately, got out to the garage for a couple of hours today and found another hole in it :( this time on the inside of the car, just on the sill area.

 

So welded that up, not the nicest repair but it will be hidden under the sound proofing and carpet.

 

 

Bolted the gearbox back onto the engine, then sprayed up the steering rack and bolted that to the subframe, need to decide what I'm doing with the fluid lines before I can bolt the subframe back on the car.

 

Started spraying the inside of the car aswell, only scuffing and spraying with a rattle can, but again, it will be hidden.

 

And before I can spray the outside, I need to remove the rear quater windows, so had a go at that aswell. Managed to get the bottom of one of the windows lose but it seems to be a long hard process of running a blade along it to cut it out. Gonna try using a cheese wire next time.

[GrahamU 5]

Oh yeah, and I picked up a set of late leather door and rear cards, little bit of damage but nothing I cant fix :)

 

So another little project will be leather seats with mk5 golf tartan centers (cos I have a couple of mk5 gti rear seats to play with)

Edited August 25, 2014 by rado20vT

[Andy-H 0]

Just read through the entire thread. Great work and nice to see the transformation

[GrahamU 5]

Thanks Andy.

 

 

Todays task, get the side window out........

 

After spending a couple of hours with a knife running around the inside of the passenger side rear window, I ended up with this

 

 

 

Luckely no rust in the corner like I've seen on so many others

 

 

Then after a clean up it looked like this

 

 

Then I coated it with rust treatment to be sure it will be ok

 

 

Dont know if the window can be used again though

 

 

 

 

Just the other side to do now

[GrahamU 5]

So, people may think I've gone a bit mad but I got myself the set of black leather door cards so I need to do something about the seats.

 

The plan is for black leather seats with tartan centers but I'm gonna have a go at doing it myself.

 

So I was sat in the living room think 'how can I get some leather' when I looked at the sofa, ping, light bulb moment.

 

I'm now the proud owner of an old leather sofa that a guy at work gave me, here it is being dropped of

 

 

Today I stripped of all the leather so I have some good large parts to use.

 

Just hope the old sewing machine I have can cope with it.

 

I have covered a complete interior before back in the day when I had an XR4i, I put a set of RS1600i seats in it that I covered with original ford grey velour and escort cossie black hex material, used to have pics but seem to have lost em :(

 

Just hope these go as well as the ford seats

Edited September 6, 2014 by rado20vT

[seanl82 23]

Wow, look forward to seeing this! Good luck, I'm sure it'll come out well. :thumbleft:

[odub 0]

Go for, , I'm looking forward to seeing how they turn out. Or could you just mount the whole sofa in the car?

[16VG60 0]

Great thread, it completely embodies the term, enthusiast. I love the way you just get stuck in, and get results. Clearly you are an unstoppable force. Good luck with the DFS back bench install :)

[GrahamU 5]

Thanks guys,

 

I really need to make a list of stuff to do and stick to it instead of jumping from job to job depending on the ammount of time I have :)

 

Anyway, today I cut up the frame of the sofa so I can dump it then spent some time cleaning the power steering pipes up, painting and fitting them to the subframe assembly

 

 

Need a clip to hold the pipes in place as the original clips are broke then I have to do the ARB when I find the one I want

[odub 0]

That's looking really smart. Which arbs are you after?