WA: Back doors 'Boring'

[geoff_gti]

Awesome work mate!! Have just caught up on the last couple of pages, although I've seen some of this in the flesh it's good to see the build notes as you've been going!

To get the section between the head and cat off the sub frame needs to be dropped and the steering rack removed. I think this is VW's idea of fun.

The Germans are a perverse bunch I've decided. Just enough of a sense of humour to drive other people nuts while still maintaining strict efficiency

To get the basic result

That paneling has turned out so well!! You had it mocked up in the boot I think last time I saw it ready to cut to shape.

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

It's sickening, isn't it Phil? Wish I was this practically minded & able! I sit in front of a computer all day doing numbers :/

I do like how so many photos of your feet there are haha. Go OHS. And also the obligatory can of Coke! That explains why your stereo carked it yet you still work with coke in confined spaces

Yay you've finally got the clutch done and engine back in!! I was gonna say if you wanted to take a look in mine to see about running the awic pipes you could, ie where there are grommets etc if it was any help, but I see you've got it sorted already.

Turbo power soon!

[Back Door Shenanigans.]

Time for random update.

Kinda slow progress recently. Got the exhaust sorted that week but then flew to melbourne for work and had another 2 weeks off the car so went a lot slower than it should have. Good news is that is all coming together fairly well and it should (hopefully) be running in a couple of weeks, hopefully before DOVW. Just need to get the intake manifold welded up and put everything together. Anyway progress pictures cause everyones lazy.

The exhaust all welded up and finished. Took most of the week. Good fun and not too much trouble. I really like welding stainless with a TIG, far easier than arc welding anything.






Wrapped the downpipe to reduce underbonnet temps. Pain in the ass that stuff and itchy as hell! Looks good though


Downpipe and wastegate all installed.


Latest problem is getting the intake manifold sorted. Originally brought it with the runners already welded on using a MIG welder. Basically took it to someone who said that the welds a crap and would need to be done again. This was kinda good actually as the angels were all wrong and i was wondering how the hell i was going to get it to fit. Took it back to him after cutting the runners to shape and size (aluminium is crap to work with, scary as hell cutting it with a table saw) and he tacked it all up. Just need to make a few adjustments figure out the throttle body flange and vacuum fittings and get it all welded up. Then the car can go back together and run!!!!!!! Woo. Shouldn't hopefully be too long.

(will get some more photos of it)

[geoff_gti]

new tips look great! does the valance fit back on?

[grtuned]

Pics of valance would be great. What's your ideas? I've fitted the r32 exhaust to mine and I've just adjusted the exhaust tips to point slightly down away from the valance for the time being. I fitted a standard valance which has no cut out for the moment. I've searched but can't find anything stock that will allow twin setup.


Sent from my iPad using Tapatalk

[geoff_gti]

......and ???

[Back Door Shenanigans.]

Pics of valance would be great. What's your ideas? I've fitted the r32 exhaust to mine and I've just adjusted the exhaust tips to point slightly down away from the valance for the time being. I fitted a standard valance which has no cut out for the moment. I've searched but can't find anything stock that will allow twin setup.


Sent from my iPad using Tapatalk

Not sure. Ill probably cut the same shape out on the other side making a template and then cutting with a dremel. Ill let you know how it goes just had to sort the exhaust out as it had shrunk since last time....

......and ???

There is no pleasing you is there geoff?

Not much has happened. Should have been finished 2 weeks ago if it weren't for some problems.... Ugh problems. Cable i bought to read the map doesn't work so i've ordered 2 more to see if they are the issue (hopefully). And the intake manifold should have been finished but my fabricator decided to go to china without telling me.

Few things though.

Was having trouble with the sway bars hitting the control arms but sorted that out using adjustable swaybar links from gruvenparts.

Had to cut and reweld the exhaust as it has somehow shrunk an inch from before. Fits very good so not too annoyed.

Cleaned the interior of the car which is looking good.

Still to do:

Not much. Fit and spray the intake manifold and cut a piece of pipe in between the throttle body and intercooler. Then fit the front bumper and a few trim pieces.

Biggest issue will be sorting out the tune i guess but hopefully it should be good to go for DOVW.

Few update pictures ill try and get some better ones of the other various pieces that i keep forgetting. Pretty happy with how the engine bay looks. Should be very little lag as the piping is almost dead straight.

[dubster99]

Hey mate sweet build! Did you have to rebuild the brembo 4 pots or were they new?

[Back Door Shenanigans.]

Hey mate sweet build! Did you have to rebuild the brembo 4 pots or were they new?

I brought them new from England.

[geoff_gti]

There is no pleasing you is there geoff?

:'(

Nah jokes aside, you've done really well mate Hope you get it there on Sunday!

[Back Door Shenanigans.]

Soooooo Happy. Sooo very happpy. very little sleep but totally worth it!.

SHE RUNS!!!!!!



So a few days off and a hectic schedule that i didn't think would get the car working but it all came together and came up milhouse.

Wednesday was down to claybar and waxing the car as thats all i could do. Luckily the guy welding my exhaust managed to get it sorted wednesday night after a month or so but oh well all good in the end.

Finished manifold


Thursday was around installing the manifold and finishing the rest of the car off so vaccum lines etc. Ended up getting the first run in on thursday night and boy was i happy sounded awesome. Managed to have a fuel,coolant and oil leak though.

Friday didn't go how i expected. Managed to get the new cable at 9:30 and read the ecu first time with no dramas. Was ecstatic after that. Sent the tune off to vince from stealth racing and waited for the tune. Spent most of the rest of the day fixing the leaks and tidying up. At midnight i gave up and expected not to get the tune sorted, however at 1:30 i woke up and checked my emails, to my surprise vince was working on the tune on a friday afternoon. Sooo happy.

Woke up this morning after very little sleep as i was so excited. Uploaded the tune no problem and tried to start it. But it wouldn't. Turns out the 044 pump in the surge tank had seized... oh well thats a bad buy, at least my stock fuel pump will work for now. So took all that off and boom! she started no dramas. Took her out for her first spin with a grin from side to side. Managed to blow a boost hose and a coolant hose but fixed them and took it for a decent spin. Soooo very happy!! Just a few leaks etc to sort out but it should be all good from here out. Had a minor freak at the chatter coming from the gearbox thinking something hugley just went wrong but nah all good.


Uploading tuning this morning



Exhaust (cut out not finished more a temporary one as i kinda screwed up need to get a professional to sort it)


Finished Bay (surge tank missing now due to pump failure)


Best part is i get to drive it to DOVW.

Big shoutout to vince from stealth racing who went above and beyond to help me out and has been nothing but a good communicator and tuner since i first contacted him.

[tinto]

Nice work!

[popeclement]

[QUOTE=Back Door Shenanigans.;1100114]Soooooo Happy. Sooo very happpy. very little sleep but totally worth it!.

SHE RUNS!!!!!!

http://www.vwwatercooled.com/forums/images/icons/icon6.png

Best part is i get to drive it to DOVW.


Saw the beast at DOVW and have to say this is an awesome build. The attention to detail is a testament to BDS's skills & when I heard it rumble into the display bay, it sounded magnificent - suggest an audio clip is loaded

[Back Door Shenanigans.]

Saw the beast at DOVW and have to say this is an awesome build. The attention to detail is a testament to BDS's skills & when I heard it rumble into the display bay, it sounded magnificent - suggest an audio clip is loaded

Haha it was good talking to you! Hold off judgement on my skills untill you see what happened to my brake booster vacuum line.

[trickysimon]

Awesome work buddy! So happy for you! Looks awesome!

Only thing I'm worried about is that surge tank location :/

[Lito]

Awesome work buddy! So happy for you! Looks awesome!

Only thing I'm worried about is that surge tank location :/

I agree with this. Car is awsome but the surge tank location is tempting fate. I have the same surge tank and mounted it where my stock intercooler was. I know this is a vr6 but knowing vw the mounting holes for the intercooler bracket are probably on the frame rail. Check my thread if you want more info but I really think you should rethink that surge tank location