WA: Back doors 'Boring'

[leighaus]

Your rocker cover wasn't that dirty. Looks like a good example. How long till it's running?

[Back Door Shenanigans.]

Really? I thought otherwise haha.

Ah not sure. Main issue at the moment is the old money. Got mostly everything just need the exhaust pipes but thats once tax is come through so hopefully before august....

Your rocker cover wasn't that dirty. Looks like a good example. How long till it's running?

[Back Door Shenanigans.]

Little update.

Painted the manifold.

Before

After


Just needs to bake

Also painted the mounts which came out average but hey not too much of an issue


Got my package from Germany. Woo. I can start putting it back together soon

R8 cap for $30

Timing pieces and 14 exhaust studs woo!


Final of cover (will get a better shot on the weekend)

[dylan8]

Looking good

[work]

All that extra power means lots more heat of course, so I guess you considered getting that manifold ceramic coated. Too expensive?

[Back Door Shenanigans.]

All that extra power means lots more heat of course, so I guess you considered getting that manifold ceramic coated. Too expensive?

Yep really wanted to do it and the turbine. Maybe later on. This was just for a bit of rust protection. Dam money being a problem...

[Back Door Shenanigans.]

Little lazy with updates so heres a big one.

Turns out the guide i got from germany is the wrong one so yay! Had to bite the bullet and go to VW to order the correct one. $50 wasn't too bad still glad i got the chain at $200 from VW. Was told 4-6 weeks to get here but took just over a week which was awesome, picked that up monday. All im waiting on now is a clutch and the engine can go back to its rightful place and i can get on with making up the exhaust.


Engine wise just sorting out the pressure sensor relocation and turbo oil feed line.


What i have been doing tho is working on the boot.

Starts with some wood. Chopped up just right.


Glue the wood together


Then trace and cut the wood


To get the basic result


Now there was no way that is going to hold the battery down securely so i had to add some thickness.

Missed some shots but heres the earliest i got. Four bits of jarrah cut glued and sanded together.


Holes drilled for water tank and battery box. Little section made up to aid in securing the water pump.
Shot of it all mounted up and circuit breaker in rough spot. Wood not finished yet.


The difference a bit of sealant makes


And finally the (almost) finished peice


Heres where i need some help if anyone has some
Only problem i'm facing now is how to get the water pipes and battery cable to the front engine bay in a clean matter. The section under the left hand side (see below) is the chassis rail and i'm trying to avoid drilling through that. Anyone have any ideas on where i should route it?

[work]

Carpenter, plumber, electrician, mechanic ... is there anything you cant do!

[JustCruisn]

You could run the cable and water line through the cabin. There is heaps of room around the door sill area.
I ran a gauge 0 line from the battery through firewall then under the door frame trim all the way to the boot of my golf on the drivers side, then ran vga,usb,audio on the passenger side.
Once you pull the plastic off the door frame you will see the channel.

[dylan8]

There is also a grommet at the rear of the sill on both sides.
I ran my air lines out the drivers one then tucked it up with the fuel lines. Did the same on the passenger side but don't recall what I held the line up with...

[JustCruisn]

Yep the grommets in the rear are an option, less messing about, how strong is the water line would it last being exposed under the car ? You can see one in the photo above, also in the spare wheel well there is a big one.

[Back Door Shenanigans.]

There is also a grommet at the rear of the sill on both sides.
I ran my air lines out the drivers one then tucked it up with the fuel lines. Did the same on the passenger side but don't recall what I held the line up with...

Is that at the back seat? Or right at the end of the boot? I will have a look but the one near the seats is the one that runs into the chassis rail which is fine but need to get the lines out which is the hard part.

You could run the cable and water line through the cabin. There is heaps of room around the door sill area.
I ran a gauge 0 line from the battery through firewall then under the door frame trim all the way to the boot of my golf on the drivers side, then ran vga,usb,audio on the passenger side.
Once you pull the plastic off the door frame you will see the channel.

Yeah ran the power cable for the amp down there but dont think ill get the water lines to fit. Also trying to avoid running the power cable down there due any interference problems but it may be the way to go. The water lines are quite big.

Yep the grommets in the rear are an option, less messing about, how strong is the water line would it last being exposed under the car ? You can see one in the photo above, also in the spare wheel well there is a big one.

Yeah should be its heater hose equivalent. Definitely trying to run it under the car just got to figure out where. Will figure a mounting solution as well. Mm thats a golf though bit different. As above that one runs down into the chassis rails.

Carpenter, plumber, electrician, mechanic ... is there anything you can't do!

Body work! well im not game at least.

[Back Door Shenanigans.]

Another time between installments but a lot of progress made.

Starts off on thursday when the UPS man was "kind" enough to leave this on my front door...all day.


Inside is these lovelys. (H&R sways)

Good old merica (yes thats a sticker)

And these, ARP rod bolts, throwout bearing and slave cylinder, another rear main oil seal, aux water pump and mounting


Then this on friday. Brought off a vortex user.




Decided id get straight to work. Heres the old throwout with the new throwout

Flywheel mounted

Clutch and pressure plate mounted


Old and new aux pump.

Putting the new one in is a bit of a paint in the ass due to having to take the bracket off to get the rubber mounts on.


But the main part is that i finally got the engine back in the freaken bay. Only a couple of months to get the bastard off the floor! Woo! I installed the gearbox whilst the engine was still on the floor. Much better idea, only took around 15minutes of screwing around to get it on compared to the 2 or so days last time. Might have something to do with taking the prop shaft off aswell though.


Did a mock up of the turbo mounting to see what needs to be moved. Such a good sight to see. Feel like there's an ending to this project now.



Seemed awfully quick to put it back together though which is nice. Still quite a bit of fab work to do but all fairly easy just need some time.

Todo:
034 044 surge tank install and plumbing
AWIC mounting and plumbing
Heat exchanger mounting and plumbing
Exhaust
Intake piping
Those bloody water lines and power cable (still have no idea where to run them)
Other little pieces
Rear anti roll bar
Ecu tuning once everythings done.

[work]

Hows things progressing? I bet you'll be glad to get off that bike with all the rain ... probably just in time for summer

[Back Door Shenanigans.]

Hows things progressing? I bet you'll be glad to get off that bike with all the rain ... probably just in time for summer

Getting there not too far off. Don't think ill make german car day but should make Day of the VW. Yeah im almost 100% sure that when i finish it will stop raining. Took a week off to do the exhaust so ill see at the end.

Missing alot of photos but will take tommorow and update.

Update of to Do list
Todo:
034 044 surge tank install and plumbing (finished need photos)
AWIC mounting and plumbing (finished need photos)
Heat exchanger mounting and plumbing (finished need photos)
Exhaust (working on)
Intake piping
Those bloody water lines and power cable (still have no idea where to run them) (bit the bullet and finished)
Other little pieces
Rear anti roll bar (finished)
Ecu tuning once everythings done.

Lots of stuff coming in
Fuel pump surge tank


Exhaust parts 1



Exhaust parts 2




Finished the most uncomfortable part of drilling into the sump for the drain port



Surge tank mounting and pipe routing. Not very comfortable of it being above the exhaust but eh


Small update on what i got finished on the exhaust today. Got to the cat so downpipe and next part finished



Main issues i have so far and to come
Downpipe tubing. Very hard to find tight radius 3 inch pipes without spending $300 on a stainless donut. Made do with two 90.

Intake manifold. Don't make your own it sucks. I should be able to make it work but would have been a lot better to just buy one.

Minor tidbits here and there. Issues with wiring and coolant hoses just changing one thing has a good knock on effect of changing everywhere.