alan.m 10 Posted April 6, 2013 Ok so i have been meaning to make a thread about this for a while now so here goes.... I bought the car at the beginning of December it looked a bit like this It wasn't perfect had a few dents, some rust and had been resprayed (badly) It had a running 1.8 16v which i soon removed after buying the car dont have any photos of this. so i decided smoothing the bay was a good starting point ill let the photos do the talking Mocking up the plate Plate all welded in Starting smoothing the bay of both sides soon started to remove the un needed brackets it is not much further on than that as i wanted to get the lump in to make sure i had covered all areas and sort a few things out so in the new engine goes Also as you can see from this photos the wheels and suspension have been removed Quote Share this post Link to post Share on other sites
seanl82 23 Posted April 7, 2013 Why didn't you paint the firewall and other areas that are the original colour when everything was out? Looks a bit of a mixiblob of colours now............... Quote Share this post Link to post Share on other sites
alan.m 10 Posted April 7, 2013 Apart from engine side of things i have been doing some body work started on the door looks like people liked opening there door on to this side of the car first layer of filler went on It seems really hard to get it all smooth so i have left it like this for now today i started to fit and mount the intercooler and also run the boost pipes there wasnt a lot of room to fit the intercooler but worked out the best place and started grinding, tried to do it without removing anything structural main two points are show here Not finished as i want to tidy up and weld a bit of support onto the second cut but it now fits As for running boost pipes i have mocked this up but i want to make a few changes but as for now it looks a bit like this First i used the original pipe and cut to make it work Used a reducer of the turbo Sits a lot higher than id like but as i said i may change this next time mocked up like this for now Just need to order some bends to mock up the other side I did want it to show a little through the bumper but this is the best i could get it for now with this intercooler you can just see the bottom of it (not a very good photo) Thats about as far as i have got so far, im going to take more photos of the stuff i do along the way and will update after cheers Also in reply to the question above the bay was only sprayed with black to protect it, it isnt finished yet thats why its red and black Quote Share this post Link to post Share on other sites
alan.m 10 Posted April 7, 2013 I have done a little more to this today was not happy with the way i had layed my boost pipes so decided i would change them, i need to buy 3 bends and some clips to finish it but it should look something like this now :D Its a little tight to the starter motor but nothing is clamped up yet As shown in the photos the boost pipes are a lot closer to the engine and now run in a straight line so i am a lot happier i know there is two bends at the bottom but i dont think it will restrict air flow to much? Still got plenty more to do and will update again soon :) Quote Share this post Link to post Share on other sites
ross k 10 Posted April 7, 2013 looking good mate nice to see someone else not getting scared from bad paintwork Quote Share this post Link to post Share on other sites
alan.m 10 Posted April 7, 2013 looking good mate nice to see someone else not getting scared from bad paintwork Thanks, yeah the paintwork is really bad but im hoping some welding, filler and time will put it right Quote Share this post Link to post Share on other sites
alan.m 10 Posted April 16, 2013 So friday i got a good few hours on it, looks and feels like going backwards but hopefuly when i have done all i want to do the engine can go in for good so i first popped to local dealer and picked up some brand new flywheel and clutch release plate bolts Also got a rear ashtray and a maf sensor from the forum Im running a standard g60 flywheel with a luk vr6 clutch, i will be lightning the flwheel and upgrading the clutch at a later date. ok so engine back out with the gearbox removed Going to clean and paint the gearbox had a little go at it but still looking pretty dirty Ok so where i modified the lower crossmember to fit the intercooler i wanted to put a bit of strength back into it i have painted this but it didnt turn out to well so i didnt take a photo ok so with the engine out i wanted to spray some bits and bobs just going for a matt black finish Also did the front pannel pretty happy with how it tuned out before: After: It was still a bit wet thats why it looks a bit shiny, ok so thats it for now i want to do loads more but im away this weekend so will update when i have more Cheers Quote Share this post Link to post Share on other sites
GrahamU 6 Posted April 16, 2013 How much do you plan to lighten your flywheel by? The g60 fly is already alot lighter and I've heard it can cause problems with tickover going to much lighter Quote Share this post Link to post Share on other sites
alan.m 10 Posted April 16, 2013 How much do you plan to lighten your flywheel by? The g60 fly is already alot lighter and I've heard it can cause problems with tickover going to much lighter Well i have heard the same, slight hunting when at idle but a friend of mine is running 4.0KG and another 6.5KG neither have any troubles so im not sure. Im not planning on doing this for a while yet Quote Share this post Link to post Share on other sites
alan.m 10 Posted April 28, 2013 (edited) Ok so a big update had the engine out for the last time to do some final little bits, changed the flywheel bolts and clutch pressure release plate bolts to brand new vw parts, sprayed some parts and cleaned the gearbox, also managed to spray the bay and joff came down this morning to get it running so here are some pictures and a short video. Also modified and painted the lower front cross member for my intercooler to fit Final work before engine bay was sprayed The result was something like this Hand balling the engine into the car as we didnt have a crane at the time All in well sort of Last bu not least a video of the car running, isnt very long as there is no water in the engine no boost pipes connected and as you can see/hear no downpipe but you get the idea :lol: More to come soon :D Edited April 28, 2013 by alan.m Quote Share this post Link to post Share on other sites
VW_OwneR_85 2 Posted April 28, 2013 looking nice bud, like your smoothing ;) Quote Share this post Link to post Share on other sites
alan.m 10 Posted April 28, 2013 looking nice bud, like your smoothing ;) Thanks mate, wasnt the best job in the world but with it being matt it turned out ok :smug: Quote Share this post Link to post Share on other sites
alan.m 10 Posted May 2, 2013 Ok not a massive update but i have managed to plum in the whole water system and fit the radiator in its new home, just need to mount the expansion tank or fit an in line filler. How the rad sits now nearly the same but just had to drill a few holes The original mounting points i kept the same Then drilled a new hole at the bottom where i have moved the rad over to allow for my intercooler pipe work notch Just need to make some sort of fixing for here Then the top pipe was made up As said before i have done all the pipe work now but dont need pictures for it all I will be doing loads over the weekend i will update when i have more :) Quote Share this post Link to post Share on other sites
alan.m 10 Posted March 2, 2014 Hi guys so its been a very long time since i last updated this, i dont have many photos of well anything that has happened between the last update and today but basically, i took the car for its mot and it failed on a few little bits so i was ready to fix the issues and get it on the road when my turbo decided it wasnt having any of it so long story short the k03 came of and a 70k k03s went on then i had an issues of no oil at the top end and leaves me to about where i am now so i will be making updates again but i wont have as much time as i did back then anyway the front mount has changed along with the pipe work, exhaust is all bolted on (hate the back box but that should change soon enough) so an odd few photos between the last update and now cheap downpipe i got hold of changing the front mount (yes its very bit but i like how it sits) the car heading back home from the unit to its new home a few sneaky pictures of the color change so far (not yet completed) making use of the missus patch i had to weld in ok so today im currently getting the engine ready to come out to remove the sump try and find the fault clean and paint everything as it looks a bit of a mess and maybe a top end rebuild depending on time and money, anyway so pictures from todays progress this is the mess and what id like to tidy up aswell as putting an 16v box on instead of the tdi box Also the slow work on some wheels So thats where i am now like said before progress will be slow but ill try to keep this more up to date Cheers Quote Share this post Link to post Share on other sites
carrots 1 Posted March 3, 2014 who did you get to do your loom and ecu imob Quote Share this post Link to post Share on other sites
alan.m 10 Posted March 3, 2014 who did you get to do your loom and ecu imob A friend local to me (Norwich) did it all with a stage 1 remap dont think his on this forum though, after seeing what was done apart from the imob its pretty easy and theres plenty of online help about now you should look into doing it yourself its a lot cheaper :thumbleft: Quote Share this post Link to post Share on other sites
alan.m 10 Posted March 9, 2014 Hi there another update from the weekends activities, borrowed a crane of a friend of mine as i wanted the lump out to clean/spray everything and do some work on the lump. First job was to remove the sump as i was having issues with oil at the top end so the sump came off. Not sure ow bad these can be but i think this could of been my culprit? After a very good clean i think this should be better? As spoke about before thought id take a photo of the k03s that i got hold of Also made a start at removing th **** from under the bonnet, need to finish this off soon Wont be much to update this week or next weekend but when i do something i will post it Cheers Quote Share this post Link to post Share on other sites
alan.m 10 Posted March 31, 2014 I havent done all that much over the last few weeks, main reason for this is my race season starts in 3 weeks and the engine still looks like this... Anyway onto the rado.... With the lump out and sitting in my shed....again i begun to strip and clean up the parts looks a mess atm but slowly getting there throttle body filled with liquid metal All sprayed up not brilliant but look a bit cleaner also made a start on the rest of the body work again not my best work but aslong as its smooth i can vinyl wrap over it Also started yet to complete the bumper It is a little further now but forgot to get a shot :wink: Hopefully will be able to do a bit more in the next few days Quote Share this post Link to post Share on other sites
alan.m 10 Posted April 1, 2014 looking good Thanks ill keep updating as much as i can Quote Share this post Link to post Share on other sites
carrots 1 Posted April 3, 2014 So friday i got a good few hours on it, looks and feels like going backwards but hopefuly when i have done all i want to do the engine can go in for good so i first popped to local dealer and picked up some brand new flywheel and clutch release plate bolts Also got a rear ashtray and a maf sensor from the forum Im running a standard g60 flywheel with a luk vr6 clutch, i will be lightning the flwheel and upgrading the clutch at a later date. ok so engine back out with the gearbox removed Going to clean and paint the gearbox had a little go at it but still looking pretty dirty Ok so where i modified the lower crossmember to fit the intercooler i wanted to put a bit of strength back into it i have painted this but it didnt turn out to well so i didnt take a photo ok so with the engine out i wanted to spray some bits and bobs just going for a matt black finish Also did the front pannel pretty happy with how it tuned out before: After: It was still a bit wet thats why it looks a bit shiny, ok so thats it for now i want to do loads more but im away this weekend so will update when i have more Cheers hi have you got the part numbers of your clutch bolts and flywheel bolts.cheers Quote Share this post Link to post Share on other sites
alan.m 10 Posted May 2, 2014 Sorry i dont have parts numbers written down any more if you go to your local vw dealer they will get the parts numbers for you Hi guys been a while again since i have updated this but progress is still going well and im getting close now so heres a few pictures from the last couple of weeks so i gave the rado a clean mainly the parts i have already wrapped came up pretty good Next on my list was front rubber brake lines, both failed on the mot so i stripped down replaced hoses and gave everything a lick of paint nothing special just to tidy things up a bit Both sides are done but you get the idea Been ordering a few parts still waiting on some to come, changed the pagid front pads to ebc red stuff just waiting for them to come in engine parts starting to go back together new/cleaned/painted still a bit more to do but getting there Also cleaned the gearbox ill get some pictures of this up soon Last thing was some work to do on the body heres what it looked like before i started Ill post the finish project this weekend hopefully Cheers Alan Quote Share this post Link to post Share on other sites
carrots 1 Posted May 6, 2014 getting there mate,i need to get my engine built up Quote Share this post Link to post Share on other sites
alan.m 10 Posted May 7, 2014 Ok so a little more progress over the weekend, slowly gfetting there now :) Pannels repaired primed and top coated didnt get many photos of the progress though Door half wrapped All done now :) Rear section Rear quarter Its all done and tucked now but dont have a photo as of yet Also prepped some parts ready for paint :) More to come soon Quote Share this post Link to post Share on other sites
alan.m 10 Posted July 27, 2014 Been a while since i have updated the thread but a lot has changed the car is now mot'ed and has been on the road 3 weeks with a total of 300 miles on the clock. Since putting the car on the road i have had a few issues intercooler was to big pipe work was to long so i have changed all this now and im still having some issues so im having the map changed by jof to see if it makes a difference. anyway on with the pictures. Before the front mount intercooler change it looked like this (ignore the headlight tint it was a protective film) Then the new to me but old intercooler during mock up This is how the car stands and looks now More to come soon Quote Share this post Link to post Share on other sites
