spraycanmansam build thread

[s4mmie]

Another one on the SEAT cooler bandwagon --






It better





<EDIT> Just thought I'd add it was a total biatch doing it in this :O --

http://www.couriermail.com.au/news/gallery-e6frer9f-1226518633361

..I got the core on before it started pissing down, thank goodness it dried out this afternoon to finish it off.

Took it for a test drive before I bolted the bumper back on; It holds 17psi as normal through 2nd, no leaky
I wouldn't say it's increased performance, but I got my powa back! It feels like driving on a winters night.

Only thing I don't like is the stupid plastic OEM pipes still there...I'd like to grab a peice of 2" alloy pipe and another 90 deg bend and replace it to put my mind at ease.

They weren't wrong when they said there's a lot of plastic to go in the bin! :O The bumper required serious trimming, none of which is visible. The lower drivers-side fog grille also need cutting down at the back, but I replaced it with my thinner honeycomb grilles. It still fouls a little but I'll see what I can do...





Anyway, happy with how it feels
Onto the brakes...

[s4mmie]

No worries Jimmy, I mustn't have tightened it up and it's worked it's way out
Yeah I'll play around with the struts some more, I still have a feeling it's the KW rubber bushing at the top of the strut. It's definitely coming from the top and there's nothing else it can be!

G'day Sam, you have inspired me. I sold my WRX this week and turned my attention to the Polo. Rear Sway bar installed same night you dropped them off. Having had to get a safety certificate reminded me that the Cone filter open in the engine bay could be defected by Qld Transport. As soon as I saw your Cone In A Box I knew it was the solution. So on Saturday I got the tools out and manufactured a lid to suit my cone and now all I need is the 90 degree silicon bend! Thanks for the write up on your sweet Polo GTi. Question: Where to get a 90 degree bend? Cheers Al

Yeah mate, that's the main reason I did the cone in the box, keep Mr. Plod off my back! When you start getting big power levels it gets restrictive but see how I go later on.
Depends what size your filter is but I bought a 2.75-3.5in bend. I had to cut off a little bit on the MAF end which made the hole a little larger, I think a 2.5" might fit tighter. EBay should have plenty

[sssstew]

I cut the offending pieces out on all four guards. It's amazing the amount of crud collects in behind the plastic arches --

Yep, this is common on all VW group cars it seems, found this on my old Audi i got last year and cleaned it out, see below. Its much more of an issue in the UK where these things fill up with mud and road salt which just sits against the paintwork for years being wet and damp and causes rust issues, here in Aus you are lucky you dont salt the roads and its much drier.

[Polo GTEye N9]

G'day Sam, you have inspired me. I sold my WRX this week and turned my attention to the Polo. Rear Sway bar installed same night you dropped them off. Having had to get a safety certificate reminded me that the Cone filter open in the engine bay could be defected by Qld Transport. As soon as I saw your Cone In A Box I knew it was the solution. So on Saturday I got the tools out and manufactured a lid to suit my cone and now all I need is the 90 degree silicon bend! Thanks for the write up on your sweet Polo GTi. Question: Where to get a 90 degree bend? Cheers Al

[Jmac]

Jimmy, tried to spray some silicone spray everywhere around the struts, no luck mate The CEL came back too
You didn't happen to see if the grub screw for the coilover adjuster was missing the other day did you? It's disappeared...



Well, I had a great productive afternoon! Love when you can spend no money and make a huge improvement on the car. Reading Anthony's thread gave me the motivation this weekend to get off my bum and fix the scrubbing. I had suspected that they weren't actually scrubbing on the metal, but rather the plastic guards. After removing the arches it was pretty obvious where the tyres where scrubbing --



I cut the offending pieces out on all four guards. It's amazing the amount of crud collects in behind the plastic arches --



I also pumped my front guards out a bit more with my specialist guard pumping tool (hands). Slowly and carefully pulled them out till I was happy with them. The metal is so thin on the front it's terribly easy.
After our recent discussion on rear bumpstops and Ben's success, I finally got around to modifying mine also. I cut out the middle knob in both bumpstops to give the shocks the proper travel --




I still need to figure out what I'm going to glue them together with...
Results: No scrubbing! At all! Our street is a terrible bumpy street and the car would scrub in the rear doing 50km. Now doing 60-65, no scrubbing



Afternoon well spent

Na mate i only had a peep in there and saw there was no spring problem so didnt even pay any attention to your grub screw sorry and had no need to be near it. Next Cel, shame that your resistance and resistors must be the problem, well have to be, its only relating to SAI flow so its the pump resistance. Shame silicone didnt quiten it, i still think the noise is the struts though and must be internal mate. .Heard that very noise too many times on other Coilies.
good to hear you have no rubbing must be happy with that, yeah its hard to get motivated at times hey but great when you do. .
Cheers
Jmac

[s4mmie]

Jimmy, tried to spray some silicone spray everywhere around the struts, no luck mate The CEL came back too
You didn't happen to see if the grub screw for the coilover adjuster was missing the other day did you? It's disappeared...



Well, I had a great productive afternoon! Love when you can spend no money and make a huge improvement on the car. Reading Anthony's thread gave me the motivation this weekend to get off my bum and fix the scrubbing. I had suspected that they weren't actually scrubbing on the metal, but rather the plastic guards. After removing the arches it was pretty obvious where the tyres where scrubbing --



I cut the offending pieces out on all four guards. It's amazing the amount of crud collects in behind the plastic arches --



I also pumped my front guards out a bit more with my specialist guard pumping tool (hands). Slowly and carefully pulled them out till I was happy with them. The metal is so thin on the front it's terribly easy.
After our recent discussion on rear bumpstops and Ben's success, I finally got around to modifying mine also. I cut out the middle knob in both bumpstops to give the shocks the proper travel --




I still need to figure out what I'm going to glue them together with...
Results: No scrubbing! At all! Our street is a terrible bumpy street and the car would scrub in the rear doing 50km. Now doing 60-65, no scrubbing



Afternoon well spent

[Jmac]

Thanks Sam appreciate that, im doin it, cool look. Yeah i think its your struts my friend but please let us know if not. .
Cheers for now
Jmac

[s4mmie]

Thanks Jimmy.

Maybe I misunderstood.. did you mean try and spray lube the piston seal, or spray around the rubber strut top mount? Or something completely different.. Yeah it's definitely not the springs. But it is coming from around the top of the strut tower, which leads me to believe it's something related to the mounts, bearings or that little rubber insert I mentioned.

<EDIT> You can see the little insert here --





I primed the valve cover with the VHT engine primer and then prob 4-5 coats of the VHT red wrinkle-coat.

http://www.vhtpaint.com/products/wrinkleplus/

Part #'s are down the bottom.

[Jmac]

I did mention that i think its the struts too mate, heard this noise heaps of times, some only do it from cold and some not, def not springs, checked that.
Ive also replaced blown out 70 bushes sold as APR in the passed too, but those customers may have misunderstood so not going to get into that. They got 70 again and all well.
Your car is shaping up well mate
Im a massive fan of your tappet cover, ill def be doing that to my 6N2. Can you confirm what you used again mate??
Cheers
Jmac

[s4mmie]

Ah yeah I remember the Powerflex ones now, they all had 85 in the part number
For some reason I thought I bought the diesel version...
The Purple/Blue APR bush that I had and kaanage now has had a little sticker in the pack that said it was an 85K competition bush.






Hmm had another look at the front struts this afternoon.
I had thought the coils were binding, giving me a consistent low speed 'whump-ing' noise. It's not.
It had Jimmy scratching his head as well, he suggested it might be a dry seal, chuck some silicone spray around the strut piston try and lube it up. No fixxy...
I also tried jacking the car up and then levering the wheel up and down to move the strut. All moves and sounds perfect.
After looking around, pushing things, spraying things, turning things, I remembered that the KW's have a little rubber insert that goes in between the strut top bearing and the piston. I didn't lube it up when fitting so I'm thinking it's the dry rubber rubbing against the piston. It sounds like it's at the top of the tower where the insert is too...

Thoughts?


I cbf taking the struts out so I'll live with it until they need to come out again.

[Deadpool]

Awesome build, keep it up Sam!

[Catfish]

I've tried a few different dogbone bushes, and as far as I can work out the hardness goes like this:

Powerflex red (diesel) <70 - but cofusingly with 85 in its part number
Powerflex yellow (petrol) 70 - but also with 85 in the part number
Powerflex purple (track) 85

Superpro purple (sports) 70
Superpro purple (competition) 80

APR purple (sport) 70
APR yellow (motorsport) >80

Happy to be corrected tho.

[s4mmie]

Haha it sure is!

At the time I wasn't aware of there being different 'shore' bushes, and I don't think most other people are either. After some research and a bit of discussion, the 'it's fine, harden up' vs the 'it rattles my teeth out' argument seems to be down to people fitting different shore bushes. I found out the APR one is an 85K. Superpro make 3 from memory, starting with the 70 shore diesel version. The 70 shore I have fitted looks identical to the 85K competition APR mount

I was iffy on whether to fit the Superpro as I wondered if the vibrations were just inherent to fitting a PU bush. The Superpro is barely noticeable vibration wise.. there is more, but not much. The APR I found very noticeable. I think I mentioned it a while back, but I probably still would have kept the APR mount if I could've found the 1 bloody rattle in my dash. The APR felt great when driving, but like you say, bit rough on idle. Got to keep the missers happy tho!

[kaanage]

The biggest surprise for me is the Superpro 70K dogbone bush. I was nervous about getting Jimmy to put this in and I asked him to keep the stocker jussst in case! The APR version (85K) was much too stiff for my (and the missers) liking! Turn the key and you could instantly feel the vibrations through the cabin. The Superpro on the other hand is b-e-autiful! Tightens everything up how it should and it might sound funny, but I think it transmits a nice low grumble through the cabin. And by grumble, I don't mean vibrations at all, I love it, it makes the car feel.. meaner.

So the purple one I bought from you was the APR race mount? No wonder it rattles my eyeballs at idle
What colour is the 70 D Shore bush?

BTW I believe that SuperPro actually makes the ones sold by APR.

[team_v]

Good to know about the 70k dogbone mount.

I had the APR one and the vibrations were far too harsh for me to keep it in.