Few pics of my mk1

[schwartza3]

ok,
So after having a better look at the front bar decided to build one from the front as well just like 2L TSI cars, although I borrowed the idea of a scoop from BMW. I’m sure designers intended this opening to be the intake on 1.8t cars like on 2L TSI, anyway here are the pics



Some more modeling



Opened up the front grill a bit as well for better flow



Painted and installed the scoop.







Started fabing up the rest of the intake after the scoop.





Took my time with this one since its in the engine bay.
Made some other custom parts to bolt to this





All done, painted with some black wrinkle paint



Installed in the engine bay, used all existing holes to mount the intake. No drilling needed. Ignore auto meter sticker





Pipe to be finished and painted, just making sure it all fits good



Model air box, haven't done the pipe from the front intake at the bottom of the bumper yet.



S2000 stock air filter



Just started the air box.
Made a mounting point for the final stage ignition, trying to keep the location as stock as possible.



Half of box done

[Lito]

Haha don't I feel dumb, never clicked on this thread cause I thought is was about a mk1 golf lol. Just read the entire thing, car is looking mint mate! How those injectors going? Turned the boost up yet? Are you running a stock fuel pump?

[schwartza3]

Thanks mate.
Injectors are good, running rich at the moment.
I've changed back to a 3bar from 4bar fpr which made it a bit better, also using the VR6 maf housing.
Waiting to get the chip re-programed then I'll have a play with the boost. Still using the stock fuel pump, I'll see how that goes on higher boost. I might get an adjustable fpr to dial in the afr if it's still rich.

[Njay]

Loving the attention to detail, still thinking of upgrading the turbo?

[schwartza3]

Thanks mate, I think I'll keep the k04, it's been very reliable and goes alright.
I never ran it to its full potential, still have room to improve, installing 42dd tb and a few other bits.
Hope you get yours on the road soon.

[schwartza3]

Getting ready to install the exhaust...finally.
It's a 42DD TB (3"DP into 2.5" CB) with 3" dual tips - single wall, looks quality

[schwartza3]

all done, fairly straight forward job
checked for leaks, fitment and rattles while its still on stands, nice deep sound, can't judge how it will sound when driving but it seems like it shouldn't be too loud which is what im hoping. no rattles, hopefully all good once i start driving.
Took a bit of a gamble with the tips since my car is an A3, worked out good, had to open up my existing cutout just a little.
The only thing i noticed looking at the middle exhaust hanger is that the whole exhaust is sitting about 1.5cm towards the front of the car, this is probably because of my old engine mounts, still fine doesn't rub anywhere.

[Jarred]

nice, looks like a decent bit of kit.

[dylan8]

Tucked up nicely!
Those super RS though....

[waddz]

Cheers Ray, I'll have a better look into it.

Rear perches are done.
I haven’t seen of anyone doing this so I’ll post a couple of pics to illustrate what I’ve done.
I’ve heard of people removing the entire perch which looks very unsafe and makes a lot of noise with the spring not being properly seated and having room to move around the base.
Here is a standard rear perch with locking and spring collars.




If you removed the collars the spring wouldn’t sit centralised on the perch as the sides of the perch base are angled and that also made a lot of noise. I had this angled section machined to match the diameter of the spring collar, the spring sits nice and tight, no noise.





Here is the difference in height with the collars and without, I know it's not huge but it made a big difference how the car sits with another 20mm down.

exactly what i was after. Ace job schwartz !!!

fine selection in wheels btw

[schwartza3]

Thanks guys, it definitely is a decent kit and very well priced, just over 1K including delivery all thanks to Greg from Carformance.

On idle the sound is about the same as my previous exhaust but once you accelerate the sound is completely different, nice crisp sound and not too loud, no drone, seems like the boost picks up sooner and I have gained a few psi throughout the rev range, hitting about 18-19psi in 2nd and 3rd, car pulls very well and there is more room to improve. Luckily no rattles, doesn’t hit the heat shield on gear changes/acceleration and most importantly it doesn’t sound like I’m trying to race when taking off at traffic lights. Feels like it has lost a bit of torque down low (1.5-2k), it’s hardly noticeable but I can feel it probably because I’ve owned this car for so long, anyway it’s a small price to pay for a gain throughout the rest of the rev range. One other thing, I think the location of the flex joint would’ve been better closer to the engine to reduce to movement in the exhaust right from the start. Where it’s located it seems like its working in compression/tension more than anything.

Wadds, I was searching around for a while without any luck to find if there was any way of going lower without taking the rear perches out, I should probably copy that over into a DIY.

Super RS are my second choice, only got them on to change the tyres over on the Futuras. I’ll hang them on my garage wall & make a coffee table for my man cave.

[schwartza3]

back to finishing up the intake, i'm getting over the noise of the open air filter.
air box is almost done, still need to cut out the opening on the right hand side of the box for the pipe from the bottom intake (behind the bumper) and finish off the cover.

[schwartza3]

just sorting out the fitment, making sure nothing rubs, trimmed top of the airbox just a little bit and came up with a better solution how to bring the bottom pipe in past the battery into the box. Test drove it and to be honest it feels like the intake at the top would have been sufficient, anyway can't hurt to have another one. Here are some pics of the set up so far. i'll need to get different profile rubber seal for the cover and a different one for the new opening.
Just tried out the rubber seals i had at home and they weren't good enough

[schwartza3]

ok, so I finally decided to finish this off......here are the pics of the finished product.

















Inside the box




I'll snap a few photos of the engine bay, everything fits great, car drives great, it's now legal and most importantly the induction noise has been reduced.

[guile]

good skills mate, very nicely finished piece of kit. well done, you should be proud of that upgrade as it's all your own work...