Dubster's 1.8t conversion build

[blackers10]

wow looking good mate!!
needs angry eye bonnet lip!

but more importantly how do I get ahold of said interior trim pieces?? mine are all roasted(the door handles)

[dubster99]

Cheers blackers! Yea im keen to get one when its running sweet and ive got everything else sorted lol

The trim pieces i got from ebay uk. Im fairly certain you can find the net optic over here from some boras.

[dubster99]

So after I replaced the timing belt/ water pump, ecs stage 1 with lightened flywheel snd new throw out bearing on the 20V the engine I installed it into the golf. Pretty straight forward. Same mounts as the 1.6 and majority of plugs matched. The only concern was the miss matching plugs that plug into corresponding plugs under the wiper motors. Ended up leaving a black plug which never actually affected the car. I pressume its for climate control and sunroof controls.

I did have a problem actually starting the engine. Car would click but not pop and bang. Had the gearbox off numerous of times to check if flywheel was fouling on bellhousing as some of the casting are a few mm smaller in diameter and need to be grinded. Turns out the throw out bearing and clutch fork was back to front. Doh!!

After a while of running it it had a missfire issue so new plugs went it but did not fix the issue. Then on the day before new years this rattle came from the engine and pulled it right off the road. Thought maybe the miss fire issue was due to a defected ignition amplifier and maybe have done further damaged. Sump came off and found a piece of plastic was in the oil pick but no metal shavings. Pulled of end caps snd the bearings were fine so its off to Volksfactory this week for them to diagnose the problem.

[kimmeh87]

Been researching about interior trim, as mine was standard is was all peeling and was too plain. Couldnt justify the price for R32 trim so after a little bit of searching on ukmkiv and found out about net optic trim. Can sand it down to look like aluminium trim but so much cheaper! Found some on ebay uk and bought it straight away!

It arrived and went straight to work with the wet and dry sandpaper.













Also gave the handles a coat of paint to freshen them up



All done! Clear coat to seal if and installed it.

Any chance you have the link to the trim? My mk4 is in desperate need



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[dubster99]

Just type in net optic on either ebay.com or ebay.co.uk

[kimmeh87]

Nice. Thanks for that. Pretty pricey hey


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[dubster99]

Because of the falling Aus dollar its all expensive! Cheaper than R32 though

[RolfGolf]

Is the car at Volksfactory now Anthony? Any news on what the issue is as yet?

[Conradianaski]

Mint MK4 mate. Really like the look of the porsche wheels and the fresh paint looks gorgeous!

[dubster99]

Cheers mate! Unfortuneately I have been advised today engine is toast! its either rebuild or buy another engine!

[dubster99]

So after a little research I decided to take off the gearbox once again and check to see if the noise was a flywheel or clutch loose. So after wrestling the gearbox out the flywheel and clutch came out and well the bolts for the flywheel were loose as! And the pressure plate looks shot even after only 4 weeks!
Also the flywheel must gotten stuck on an angle because it wasnt easy to remove




So looks like a new clutch kit and flywheel! Any ideas? Matt from Candem GTI mentioned a vr6 kit with G60 flywheel?

Also went to supercheap and got myself an air orbital sander and more coolant as it was all on special!

[blackers10]

Wow that sucks mate!! Glad you checked it tho as a flywheel through the firewall isn't a good outcome when they let go at decent rpm!!

The he one from Camden or ECS sell are decent. Plan for the power you want not the power you have otherwise it will be another nother clutch.

Good luck!

[dubster99]

Whilst the car is still not running I decided to pull off my intake manifold and sand/polish it.
First I took off the manifold and cleaned behind it. So much build up!





Then degreased the manifold and cleaned off all build up and then commenced the sanding, for this I used an orbital sander with some 60 grit pads.





Todays progress



Cant believe how sanding was needed just to get a flat surface with no little dimples. Will try and get it finished and fitted before I have to go back to work!

[dubster99]

A couple of hours and it starting to look good now! Getting the last of the imperfection out and the deep scratches out.

[RolfGolf]

Good progress Anthony