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Discussion Starter · #1 ·
Been working on this on and off for the past year now, its been coming together in recent weeks. There is still plenty to do on it but most of the messy stuff is out of the way.

I only have a few pics of the progress to date most of which is before.

Breakdown of things done on it to date

Suspension Brakes & drivetrain
New front wishbones & bushes
New front ball joints
New anti roll bar link rods and bushes
New anti roll bar bushes (front center)
Steering tie rod left and right sides
New rear axel bushes
H&R coilovers & top mounts
OMC upper/lower and rear strut braces
Goodridge Braded rear brake lines (conversion lines for mrk iv calipers)
Sparco Braded front brake lines
Zimmerman rear disks
280mm Zimmerman X drilled front disks
Mrk iv rear callipers + pagid road pads
New rear wheel bearing sets on both sides
S2 2 pot front calipers
Pagid fast rd pads for S2 calipers
New VW front brake plates
DOT 4 Brake fluid

Engine & fuel injection
Skimmed and polished head
New gaskets all round water flange/throttle body inlet/out manifold
New head gasket & valve seals
Flushed ISV and cold start valve to clean out dirt
New bosche spark plugs
Polished rocker cover & inlet manifold & alternator
Ported & flushed throttle body
Flushed inlet manifold
Trimsport power rhor
Braded fuel lines
Blue Ignitor HT Leads
K&N air filter
New oil filler cap
New coolant temp sender for ISV
Oil pressure switches (4)
Alternator/water pump belt
Power steering belt
New distributer Bosch
Bosch starter motor
New VW Timing belt tensioner

Wheels & tyres
16' BBS with Perelli P Zero 195/55 tyres
New locknuts and deep wheel nuts all round

Cooling system
New oil cooler
16V Samco sport hose set
New water pump & thermostat
New Expansion bottle + cap
Braded water pipes *2
Replaced radiator fan + wiring

Interior
3 spoke VR6 leather steering wheel
New polished seat handles
Parcel shelf
VW Gamma head unit from mrk iv golf

Exterior
New O/S door
Replaced door haldles
New 4 bar grill + red VW 16V badge
Replaced spoiler mechanism
Lupo Gti wiper conversion

Electrics
New switches oil pressure switches and sensors
Spoiler control module + motor
5-6 fuses
New wiring for head unit
Uprated headlight wiring loom

There is a new oil cooler on the way with sandwich plate and braded lines, going in after Christmas. As well as one of these


 

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you have done a top notch job on it barry, the engine is sweet!

here is a pic of the car before baz got it
 

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all sounds top notch barry
best of luck with it
 

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Well fair dues to you. You really got stuck into it didn't ye.

Nice bit of paint work by ol James I see. Your only man.
 

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Discussion Starter · #9 ·
That pic is about a yr old Mark, it was buffed up over in James's place but he didn't do the bopdywork on it yet, Im leaving that job till last, Ill prob get it done in the spring at some stage.

There is also a new VW 22mm brake master cylinder and new VW brake pressure regulator to go on in the new year..

I got the 4 branch from a place in Belgium [email protected]

Im having a bit of trouble with a spongy pedal at the moment I think it may be down to air in the system.

I'm replacing all main brake components as a precaution anyhow all GENUWINE VW parts going in.
 

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i hear the twin pots are fluid hungry bastards, there is a bigger master cylinder out there than the 22, there is a 24 from a 6n polo/seat cordoba i think and some thing bigger on some audi
 

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it all looks good Baza, im really liking thoes rear brakes

nice job done
 

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Discussion Starter · #14 ·
Do you have a part no on it?

Audi coupe
893 611 021 A ?

Polo
6N0 614 019 A ?

These all seem to be for ABS tandem master cylinders?

6N0 614 019 is without ABS
 

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Brakes will feel a little soft as there is new pads and disc's front and rear. Shoud be ok when there is a few miles on them.

John
 

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Discussion Starter · #18 ·
I've no new pics at the moment but a few things added recently the new rad has made a huge difference dropped my running temps a good 4-6 degrees. Thanks for dropping that over Rich.

The new oil cooler also helps but to be honest the rad made a bigger impact on the temps the old one must have been well blocked.

I've finally managed to get a decent brake pedal the 2 pots with the mrk iv rears are a good upgrade well recommended once you are patient with the bedding in process. Its just a case of bleeding and bleeding and bleeding them, the new rear valve helped a bit also.

I got the rear axel reconditioned and painted also and new brake pipes on the back axel as well as a new rear brake valve. I replaced the rear bushes which was a bitch of a job but not as bad as fitting the rear axel on my own that nearly killed me.

It was hunting for a while there when warm but since the new rad went in this has seemed to even out. I still think the timing is slightly out as it can be a pig to start in the mornings. It could also be down to fuel mix either.

It tends to drop well under 800rpm when coming down from 3000+rpm when warm I'm going to try another ISV and replace the idle control switch on the head as I think this could have some bearing on the issue. I've checked for an air leak and clipped all the pipes and its still dropping below 500rpm occasionally cutting out.

I finally got around to clearing it! paid the VRT this week there wasn't much point up to this stage cus it was off the road from the time it was brought in, more or less J

Ill post up pics soon I have to book it in for the NCT next week a few things to tidy up before that
I need to get the horn working again.
Slight oil leak near the sump
Tracking is still out pullin to the left a bit
Could do wit 2 new tires also
 

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Its looking good Barry, now hurry up and finish it, then decide you want a new project and I will kindly take it off your hands
 

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Discussion Starter · #20 ·


Managed to get that cutting out sorted with the new ISV, put it on yesterday and its much better revvs don't drop below 800 now and its more even with the revvs dropping.

Ill replace the rocker cover gasket during the week as a couple of the lads reckon its the cause of the slight oil leak. I had the cover off a while back to tighten the head, it prob started weeping after that.

There's a messy oil switch on the cooler plate that could also be the problem ill pick one up while im at it.
 
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