GrahamU's 2.0 TFSI with DSG

[GrahamU 5]

Plenty of poeple on here and on your local dub site ;) that could give advise if you get stuck.

[GrahamU 5]

Well it was on the road for a whole 3 months....... then the end of the gearchange cable broke and fell of, had to manually stick it into third and drive home.

 

Time for some changes:

 

First is the mk4 golf gear shifter upgrade

with the engine run in its time to fit the k03s

When driving it sounded like the diff bearing was noisey so an gearbox change aswell

Uprate the exhaust as I'm still running the standard 16v exhaust

Couple of changes to the cluster 😉

Maybe re-upholster the recaro seat centers (I have 2 spare mk5 GTI rear seats with interlagos material to use)

mk4 golf rear calipers and gonna look at rear bushes

 

 

My first thoughts on the gearbox were to fit an 02s 6 speed and I thought I'd got one till I got it home and found it had a gear missing, bloody ebay seller swore blind it was a 6 speed and would not pay for shipping/transport costs to have it back so I have a 2011 mk6 Golf LHE 5speed diesal box - decided to give it a go unless I find a 6 speed before I fit it all back in.

Got to make the speedo drive come of the ABS but hopefully that wont be to much hassle.

 

this is the broke cable

and here she is looking all sad and in bits again

 

Just a couple of jobs and have it back out for summer

Edited January 27, 2023 by GrahamU

[Hofmiester 10]

Mate, I have been looking high and low for a bonnet in Black berry for 5 months and there you go.....cheap as chips off eBay ;)

 

Seriously though, if you haven't painted it yet (and it is in good nick paint wise) then if you want to sell it to me for a profit and buy another, let me know.

[GrahamU 5]

Hi Hof,

 

Unfortunately the bonnet has a few scratches which didn't bother me as I intended to spray it. I do now have a red bonnet so I will be selling the black berry one

[GrahamU 5]

Got another chance to get an afternoon in the garage today.

 

I've given up for now trying to find a 6 speed 02s for a price I want to pay so here is the 0a4 5 speed I have from a 2012 golf

built 02/11/11, nice...

Had to make a braket to fit the rear mount, took a little while as I hand cut it from 6mm steel but it seems ok.

now fitted to the engine along with the k03s

 

Gear ratios/revs/speed for this box are

 

Final-----1st Gear 3.778----2nd Gear 1.944----3rd Gear 1.185-----4th Gear 0.815----5th Gear 0.625

3.64-----Revs----Speed----Revs----Speed----Revs-----Speed----Revs----Speed----Revs----Speed

 

-----------500--------2

-----------1000------5

-----------1500------7

-----------2000------10-----------------------------------------------------------------------1959-----60

-----------2500------12

-----------3000------15-------3251-----32

-----------3500------17-------3500-----34-------3902-----63

-----------4000------20-------4000-----39-------4000-----64-------4434----104

-----------4500------22-------4500-----44-------4500-----72-------4500----105-------4964----152

-----------5000------25-------5000-----49-------5000-----80-------5000----117-------5000----153

-----------5500------27-------5500-----54-------5500-----88-------5500----128-------5500----168

-----------6000------30-------6000-----59-------6000-----96-------6000----140-------6000----183

-----------6500------32-------6500-----63-------6500----104-------6500----152-------6500----198

 

1st, 2nd and 3rd look to be ok but 4th and 5th may be a little tall.

1959 rpm @60mph will mean no more reving the nuts of it on the way to work (better than the old 3000rpm @60mph)

 

Got to wait till next weekend to carry on.

Edited January 27, 2023 by GrahamU

[GrahamU 5]

More playing in the garage today.

 

So, stage 2 of the speed drive, now I think I know how many pulses it takes to run the speedo I have found a sensor that will do the job niceley

 

http://uk.rs-online.com/web/p/magnetic-pickups/2355706/?searchTerm=235-5706&relevancy-data=636F3D3126696E3D4931384E525353746F636B4E756D6265724D504E266C753D656E266D6D3D6D61746368616C6C26706D3D5E5C647B337D5B5C732D2F255C2E2C5D5C647B332C347D2426706F3D313426736E3D592673743D52535F53544F434B5F4E554D424552267573743D3233352D353730362677633D4E4F4E4526

 

As my rado doesn't have ABS fitted, my plan is to fit this sensor in the hole for the ABS sensor then modify the ABS ring so give the correct pulses to run the speedo.

 

Started by working out the spacing for the ABS ring and removing the bits I dont want

Then weld up the holes in the remaining tabs to make solid areas for the sensor to pick up on

Finally, drill the hub I have and fit the ABS ring to it

I now need to paint it and get a bearing to refit the hub (Thought I had one in the garage but it turned out to be for a Mk1 😞 )

With that done I thought I'd start making my exhaust, when it was on the road last year I was still running the 16V exhaust but with the bigger turbo I thought it needs to be bigger.

 

Had a few bits lying around from the many exhausts I tried on the old Bora so cobbled this together

 

old 16v next to the larger bore

 

 

Still need to finish of the tail pipe when I decide how I'm gonna do it

Edited January 27, 2023 by GrahamU

[VW_OwneR_85 1]

good job! im likeing this.

[GrahamU 5]

Well the engine is back in

Been playing some more with the cluster, almost there now:

 

cut the tracks that went to the speedo and tacho motors then re-wired them to swap their positions

Then downloaded some images of standard dial faces, resized them to fit the new positions and printed them onto some sticky backed photo paper. Stuck them to the dial faces and got this:

During the time the cluster was in bits I managed to break one of the needles so I converted the needle from a mk4 to fit by gluing part of the corrado needle to the underside of the mk4

then fitted it all together

 

 

Not 100% sure on the needles and the fuel/temp gauge is now a different colour but its almost right

 

Next will be the SWG scuttle cover panel when it arrives 🙂

Edited January 27, 2023 by GrahamU

[GrahamU 5]

After doing a bit of decorating today I had a bit of spare time so I fitted the oil cooler sandwich plate I'd been waiting for, filled it with liquids and turned the key and it started straight of

 

was quite impressed and happy.

 

Just a couple of jobs left and it will be on the road again

[GrahamU 5]

The rado hit the road today, did its first 50 miles of the year

 

And it looks like a got my calculations for the speedo drive correct I'm glad to say, just need to align the speedo needle a bit better as it reads 10mph to high instead of the standard 5mph.

[GrahamU 5]

Fitted the SWG scuttle panel from the group buy

 

Edited January 27, 2023 by GrahamU

[GrahamU 5]

Decided today I would change the colour of the rear number plate panel from red back to black, whilst I was doing it I thought I would also paint the corrado emblem

Then onto the polishing, got one side done-ish

 

who says you cant polish a turd...

 

 

Plan to paint the wheels white next

Edited January 27, 2023 by GrahamU

[GrahamU 5]

Painted the wheels today 😄

 

Don't think they look to bad, was only done with cans but I like it so will get it powder coated when winter comes back

 

Edited January 27, 2023 by GrahamU

[MarkFoster 0]

Wouldn't have thought white RCs would work to be honest, but they look good. Certainly against the red at least....

[GrahamU 5]

Thanks Mark,

 

I wasn't 100% sure it would work myself but when I bought them the wheels had been rubbed back by someone using his teeth and sprayed black, I sprayed them silver for a while but thought I'd try white.

 

I can get them prept and coated properly now I know what colour I want.

[GrahamU 5]

Well 500 miles is all the diesel gearbox lasted....

 

Broke the syncro on 3rd on my way home tonight.

 

Knocked it down from 5th to 3rd to give a little squirt of power and there was a loud crunch, now it crunches everytime I go into 3rd in both up and down the box unless I let the revs drop right down.

 

I wasjust beginning to have fun aswell.

[GrahamU 5]

Right then, got myself another gearbox from a mk4 1.8t (EVS code) the gearbox has now had the driveshaft cups changed to be 100mm, the linkage on the tower is now changed to be the pin style rather than the ball joint type and its been filled with oil.

 

Its now fitted to the engine and back in the car.

 

I spent a couple of hours yesterday in the rain going to a breakers on the other side of Norwich and looking at all the shift cables and different brackets to fit the cables before realising all the stuff I'd read about a 6 speed cable shift not fitting a 5 speed was bollox and all I needed was the right mounting bracket.

 

The bracket and cables are now fitted but this causes an issue with the 3" tip I have fitted so tomorrow I'll be making some spacers to move the cable bracket to the side a bit and then removing the metal cooling pipe that feeds the heater and cutting it down.

 

then its just a case of fitting all the ancillaries again and hoping it all lasts longer than a few weeks.

 

At some point in the future I plan to strip the 16v box I have and the mk6 golf diesel box and swap some gears about. I've never stripped a gearbox so that will be interesting :)

[dragon green 4]

Good luck,

Get some pics up when the gearbox is working !

[seanl82 23]

Excellent work! Well done for getting stuck in and all the best for the gearbox strip down. I think that would be beyond my skill level fiddling with that, although I can't say I've ever attempted it. Got nothing to loose if its a knackered one worth not much at all anyway I suppose, so good luck and look forward to the updates! :thumbleft:

[GrahamU 5]

Bloody Corrado's........

 

Spent the day putting it all back together then I try to start it and nothing...........

 

Ignition switch is knackered now.

 

 

 

And to top it all I found a hole in the Sill under the wing

[GrahamU 5]

Got a start button today so I can start it when the ignition fails, fitted it and the thing started of the key again, typical

 

Then went to a family BBQ

 

Got back home and went straight into the garage.

 

Had it running for a while and it boiled up, bit of an air lock I thought, so let it cool and tried to get the air out, run it again and it boiled up again.

 

Had a closer look and found the small inlet into the expansion tank was blocked.

Unblocked that and tried for a third time. It lasted quite a while longer before boiling up again

 

It was 10 o'clock tonight by then so I gave up before the wife ripped my balls off.

 

I have a couple of hours to get it sorted in the morning before going to watch the BTCC

[GrahamU 5]

And the problems just keep coming.....

 

Now it turns out the gearbox I put in jumps out of 3rd gear as the clutch engages unless you hold it in place, seems to stay in gear once the clutch has engaged.

[GrahamU 5]

Here I go again

 

Engine, suspension and subframe all out

 

Edited January 27, 2023 by GrahamU

[GrahamU 5]

This afternoons progress

 

 

Virtually everything from under the bonnet removed and one wing and door off

 

Next is the other wing, door and the dash out but that will have to wait as I off to watch the truck racing at Snett tomorrow

Edited January 27, 2023 by GrahamU

[GrahamU 5]

Some more pics

 

Bit of a hole at the bottom of each A pillar/sill

Other wing off

and the dash out

 

Edited January 27, 2023 by GrahamU