Gavin's cheapy but getting more expensive GTI ;)

[h100vw]

Just a few pics I took in the last week or so.

A bit of paint work on the filter mount. Some reassembly, just sat on a std sump for the moment but I have a wrinkle painted black one to go on after it has gone back into the car.

I gave the box a good clean off and a hit with the matt black too.

[h100vw]

Gave the under bonnet a swill off, blasted under the arches with the jet wash too. I replaced the inner CV boots too. One was spitting grease already and at $37 for the pair it made sense to do both.



Head goes on.



A few Samco water pipes and the clutch and flywheel bolted up.

[URL=http://s40.photobucket.com/user/h100vw/media/polo%20gti/IMAG1634_zps2fb87a90.jpg.html][/URL

New Gates Racing belt and IE manual tensioner back on and timing set.

[VWindahouse]

Gave the under bonnet a swill off, blasted under the arches with the jet wash too. I replaced the inner CV boots too. One was spitting grease already and at $37 for the pair it made sense to do both.



Head goes on.



A few Samco water pipes and the clutch and flywheel bolted up.

[URL=http://s40.photobucket.com/user/h100vw/media/polo%20gti/IMAG1634_zps2fb87a90.jpg.html][/URL

New Gates Racing belt and IE manual tensioner back on and timing set.

So close

[h100vw]

Yeah, could have been running except I don't want to pull the Frankenturbo off it a week later. Especially when I am enjoying the S3 so much after the tweaking I did the other week.

[Bullet Fast]

Hey buddy, love that you're doing this on the floor but seriously, go drop $100 on a bunnings work bench, Jesus!

Sent from my GT-I9505 using Tapatalk 4

[kendog]

Wow!....

I just read this thread from start to finish yesterday and today... this build has more drama than a whole season of Breaking Bad!

Gav, you are an absolute trooper!

Also, I'm keen to do the Seat Sport intercooler! So, if you hear of any cheap ones going... let me know
(I just got made redundant, so now have a lot of time to do a heap of golf things I've been putting off!) Although I still don't have a garage or even a driveway

[quattro5v]

Gav - can I ask what happened to your head locator/dowel closest to the front of the motor (#1)? It's not there in the first pic, but is in the second albeit 'wonky.' The machinist didn't smack down against the deck trying to punch it out, did they?

Also, did they tell you how much they took off the deck after re-surfacing? Same done to the head?

Mike.

[h100vw]

Wow!....

I just read this thread from start to finish yesterday and today... this build has more drama than a whole season of Breaking Bad!

Gav, you are an absolute trooper!

Also, I'm keen to do the Seat Sport intercooler! So, if you hear of any cheap ones going... let me know
(I just got made redundant, so now have a lot of time to do a heap of golf things I've been putting off!) Although I still don't have a garage or even a driveway

Thanks, I haven't ever seen a secondhand intercooler though mate.

Got no room in the garage for a bench Pete, with the Polo being in there all the chuffing time

[h100vw]

Mike, The dowel was a bitch to get out and bust the block at the same time. The guy at the engine shop said it's about 50/50 for getting them out in one piece. No dramas once the head is on and bolts in. I was really mindful of moving the gasket as I put the head on.

Not sure how much they took off, I can ask if it's good info for you? The head was skimmed when they did it earlier in the year.

Gav - can I ask what happened to your head locator/dowel closest to the front of the motor (#1)? It's not there in the first pic, but is in the second albeit 'wonky.' The machinist didn't smack down against the deck trying to punch it out, did they?

Also, did they tell you how much they took off the deck after re-surfacing? Same done to the head?

Mike.

[kendog]

Thanks, I haven't ever seen a secondhand intercooler though mate.

Aah, ok, so I'll need to find a 'new' one then?

Can't wait to hear when your beast is running again!

[h100vw]

darksidedevelopments is the place. Although you could do worse than a cooler that flows top to bottom. like this TRV185 Series Intercooler 720HP- TREADSTONE PERFORMANCE

[quattro5v]

Thanks Gav,

I'm not overly worried about how much they took off, moreso that they surfaced it for you according to the RA required (~5% off memory)... Either way, looks nice and neat. I noticed the dowel as I too tapped mine down but didn't have any issues whatsoever... but I can see your mech's point about the 50/50 hit/miss opportunity there.

Good to see it's coming along. Mine's nearing the honing stage. Got my connecting rods connected over the weekend which was a fun exercise. Managed to undo my crank bolt with a little bit of ingenuity so cracked open the main caps etc. Crank is just about ready to be pulled out... Still have a ~$900 order from IE to complete the build to go and then it's all systems go!!

Great inspiration from your build though - has been great knowing someone else is doing the same thing!

Mike.

[h100vw]

If you want to borrow the crank pulley tool I'll post it down when the time comes.

Take the oil squirters out for the hone. Be a shame to damage one.

Gavin

[quattro5v]

Re: Gavin's cheapy but getting more expensive GTI

Really appreciate the offer... Have undone the bolt so all good.

Re: oil squirters... The only reason I split the main caps off the block was to get to the squirters so I can remove them for the hone.

[kendog]

Just spotted this.. seems to mention your lack of oil and bearing damage issues.. thought it might be of interest..
Forge Motorsport | Alloy Fabrication

"The much loved 1.8T engine .... The key to this reliability is the lubrication system, which can quickly become overwhelmed when cars are driven quickly - or on track - causing oil starvation. Under extreme acceleration, braking or cornering, the oil can momentarily run out of the sump under centrifugal force, causing a temporary starvation through the oil-ways, putting critical bearings and bores at risk of damage. "