Bora R32 Build Thread

[beale187]

I was almost going to go down that route with the BDE 2.8, port / polish the head but I didn't want my car off the road that long waiting on workshops. The dimpling is interesting though haven't seen that done before, might watch a few more videos to see how they effect the flow. I would have thought a smoother surface would have achieved better results flow wise.

The zhorst I hit soap water and scotch brite and metal brush to start with, followed by a 400grit wet, then an 800grit wet, then a polish, then a quick wash to remove any excess polish. The thing was filth I could have spent all day on it. Come up better than expected.

[dylan8]

Cleanup made a huge difference!

[beale187]

Busy weekend on the 4mo. After spending 8mths tripping over the body kit in my shed I thought it was time to fit it up. I couldn't fit it up earlier as the lower skirt at the rear doesn't clear the tail pipes. The meant I had to do the body kit and exhaust at the same time.

Stock:


So once the bar cover was off it was time to split it. I left it out in the sun for an hour or so to soften up then got to it. So to split the rear bar it's basically all clips in



Then once it's split, with the Oettinger rear skirt.



And a few final pics once it was fitted along with the BBE exhaust.







Unfortunately I had misplaced my phone earlier in the day (later found it in the engine bay of the R32 wedged behind the expansion tank , must have slipped of the skirt and fallen) so I didn't get many photo's of the skirts or front splitter getting fitted OR the exhaust. The front splitter clips in the same as the rear skirt but from my previous experience if you scrap it then it can come unclipped so I used a few small dobs of Sikaflex, 1 at each end and 2 in the centre only about the size of the 5cent coin.

The side skirts, 3M double sided tap again 2 dobs of Sikaflex at each end of the skirt, then they get screwed in at the ends.

The exhaust sounds phenomenal! Nice burble under about 2500rpm but sounds nice and throaty at anything above 3000rpm.

[beale187]

Not much happened over the weekend, usual domestic crap got in the way. I did however take delivery of this, ladies and gents welcome to the place where MK4's come to die... My backyard haha

[ATTACH=CONFIG]33541[/ATTACH]

This quote has come back to haunt me.... So after having my Oettinger bodykit on for about 4 days! This happens....





I'm yet to strip it down and see the extent of the damage but one of two things is going to be the outcome.

A - Buy another one (AGAIN, my VWW signature is getting longer)
B - My R32 conversion just got a whole lot more in depth.

Needless to say I don't think there will be much progress for a little while.

[RolfGolf]

Oh that's devastating! Looks like a big hit - what happened?

[dubster99]

Thats gut wrenching mate! Hope its only minor and fixable!

[beale187]

Stuck my nose where it doesn't belong unfortunately, my bad.

[beale187]

Stripped some of the front off over the weekend and as I suspected she got hit right in the sweet spot (hence why the bags popped)







Tiny little bend in the rail. Spoke to my smashy at worked and he has told me it's an easy fix panel / rail wise, it'll pull right out. Only problem is the motor has to come out to do the job right... Which was going to happen anyway to fit the R32 donker.

[beale187]

So originally the plan was to swap out the

R32 motor & gearbox
ECU
Cluster
Ignition barrel (this way I could use the R32 key with minimal reprogramming or immo defeat)
And other suspension goodies...

Now to add to that

Seat belts (my front ones deployed)
Dash with airbag (or at least airbag)
Steering wheel airbag (possibly clockspring also)
Airbag module
Rad support and basically everything forward of the engine minus bar cover and headlights.

In theory it should all bolt right up.. Can anyone think of anything I've missed??

[IanPGonzaga]

No need t o stuff around with the key barrell and make new keys. Just change the coding in ecu/cluster to be your current data.

[beale187]

Ah but what is my "current data"? If I swap the ECU and Cluster, wouldn't it be easier to just do the barrell and ignition module as well?

How'd you go with your swap Ian? Did you swap the ECU as well?

[IanPGonzaga]

I just thought getting to the barrell was difficult and then switching it is a delicate task?

I’ve swappwd the ECU (me7.5 > 7.1.1), harness and engine. Everything coded to match. Works a treat.

[beale187]

Progress has been slow over the past months but FINALLY ready to pull the donk out. Images are mainly for my own reference for later on when I go to humpty dumpty this thing back together.

Step 1. Get the front off, CHECK! Accident took care of that.



Many hours later mucking around trying to work out how to jack it up safely, a hazard of living on hill and doing this on the grass. As you can see the drop across a 1-1.5m is a good 50mm... It was pretty sketchy at time.



Started assessing the damage. Few little things broken but nothing major.


Bracket for air pump, air pump was cracked at the mounting point as well.


Oil cooler, dented


hi/low A/C compressor lines were completely busted up. Which saved me from degassing the system a small win.

[beale187]

Started disconnecting all the coolant lines.


thermo housing




return lines at the rear of engine, on both sides.


And this little bugger for the secondary coolant pump.

[beale187]

Fuel lines, disconnected and sealed.


unbolted downpipes.


cable ends for the gear selectors and speedo sensor.




clamped and disconnect clutch bleeder assembly