First of all apologies for lack of pictures during the early stages.
Well it all started on 21/06/2011. After months of searching I finally found the Golf on eBay. After exchanging phone calls and e-mails and almost losing it we settled on a price and we went to Coventry to fetch it. The car had barely turned a wheel since 2007 so the hand brakes were stuck on and it didn’t start which made maneuvering it in line with the recovery truck fun.
Couple of pics when we got it home.
Some temporary wheel dolleys were made to make shoving the Golf around easier.
Attention then turned to getting it running to assess the condition of the engine. After putting an old battery we had lying around and dropping some oil in the bores, I soon found out the starter was seized solid. A second hand starter was sourced and fitted, it then fired up flick of the key on christ-knows-how-old fuel.
However the oil pressure light refused to go out, which was sorted with a new FRAM oil filter and some oil my Dad got from work. Upon restarting and after a combination of holding fast idle/natural idle for a while the engine kept rattling and smoking.
My options were; rebuild the 8v or go for something with a bit more power. Naturally power won[:$] So after researching the choices I settled on the 20v conversion, over VR6/ABF/2.0TFSI, due to the combination of tunability and also ease of fitting.
A donor car(1998 Audi A3 1.8T) was found on The Bay and the tear down began.
After getting the engine back home in the garage, i removed the turbo to inspect for signs of wear before putting it in the golf. What i found was Crack-tastic[8(]
Plus there were unacceptable(sp) levels play of in the shaft so the tiny K03 was destined for the box under the workbench.
Now considering the K03 is unserviceable i toyed with the idea of fitting a K04/Garrett item. I found though that generally for a secondhand and potentially damaged K04 the prices, in my opinion, were too much and Garrett's, in either GT28RS/GT30 form, secondhand were rare as rocking horse sheit and too expensive to buy brand new.
So, long story short, I found Jonrandom's build thread on another forum and settled on a TD05 16g6 10.5T from a Mitsi Lancer Evolution 8 if i remember correctly. With a manifold/downpipe to be fabricated by myself.
With the increase in power in mind, i decided that upgraded internals were essential. Having spoke to Bill@Badger5, some Brute rifle drilled rods and shells were bought and the engine strip down began.
Off with it's head!
Quick inspection of the head and all seemed okay so it was sent off for a skim/pressure test and to also have the valve guides and seals replaced. Work then began on removing the pistons ready to swap the Brutes in.
Another nasty surprise was waiting for me when piston #2 was removed.[8(]
Then end of compression ring 2 had broken off, but thankfully there were no marks/scratches on the cylinder wall:thumbup:
A new set of piston rings were bought. With the bores honed and the rings gapped, I set about swapping the rods over. Annoyingly i can't find any in progress pictures.
Well here they are in their new home
The engine was then put back together with new timing belt&tensioner kit/new water pump/new thermostat&housing/new oil pump&pick up/new coolant flange for the N/S of the head/new camshaft seal/new cam chain tensioner gasket&half moon.
Also while the inlet manifold was off i flatted back the plenum and gave it a couple of coats of high temp black spray. Didn't turn out too bad i don't think.
Fitted to the engine
While the above was happening a TD05 was sourced & collected from a chap on eBay
Sitting next to the K03
A twin scroll turbo flange and a 1.8T exhaust manifold flange were bought from JBS and i began to start mocking how the turbo will sit on the engine. Flanges have been tacked together with some scrap rod just until i can fit the engine in the car and check clearances etc.
As it currently sits
That's as far as i have got on the engine at the moment, an ABF flywheel and VR6 are going to be bought as soon as time allows me to get to GSF/ECP.
While work on the engine has been progressing/waiting for parts i gave the front suspension/brakes/engine bay a mini overhaul.
Pictures of many stages on the front end are lacking due to me forgetting mainly :thumbd:
- The front subframe removed and cleaned up with a wire brush(not fun) then paint with some good ole Hammerite Smooth Black
- I bought some new bottom arms and balljoints from GSF. The rear bushes in the arms lasted all of 30mins before they were pressed out and new genuine R32 bushes pressed in their place.
- I found some old but new Eibach front & rear roll bars on eBay for a nice saving, so they were duly snapped up and fitted along with new drop links and Powerflex top bushes
- The steering rack was sent away for a refurb/check over and refitted with new track rods ends.
- Knowing the standard 239mm brake weren't going to be much use with the up in power, I bought some 16v hubs/calipers/carriers from Hotgolf. However wanting more braking power i bought a 280mm setup from D4LFR.
- Cleaned the engine bay and gave it a lick of paint to freshen it up a touch.
- Ford focus master cylinder fitted along with Corrado pedal box and clutch master cylinder. Also replaced all engine bay brake pipes and now re-organized the pipe work so that i have a T-piece either side of the bay. To finish off front end brakes i fitted new Goodridge braided lines.
- I cut all the old loom wrap stuff, as it looked turd and had gone hard, and have re-wrapped the loom in some cloth tape
- I do have some coilovers waiting to go on, but the higher suspension makes underneath access easier.
Front wheels back on
Started on the back end.
The rear axle currently has been sent away for blasting/powdercoating. When it comes back I will fit the rear antiroll bar and also fit the polybushes. I will also be upgrading to the Polo stub axles and will be fitting MK4 calipers off of the donor A3.
Should hopefully have some updates this Thursday when i fetch the stub axles.
Cheers for reading and sorry for dragging on lol