Jun 14, 2012
this or its fooked...
So, over the course of last week I received various bits in the post eventually amounting up to this lot...
Wanted to try fit it this weekend, was going to allow 2 days for installation as there were a few other things I want to do at the same time and just in case there were any complications but unfortunately I was working Sunday.
On my way home from work on Sunday I popped a boost hose off so first things yesterday morning she was up on the axle stands... Didn't want to attempt the IC but I took it as an opportunity to do a bit of prep work ready for the IC and to get some of the other things done!
So,yesterday I removed the SAI pump and installed the resistor that frenchman had given me. Couldn't be bothered to remove the combi valve as I didn't want to drain the coolant, I'll do that next weekend when I tackle the IC, should be a simple job. I also removed the air-conditioning condenser to give me the best possible chance of keeping my fogs, no great loss as the air-con didn't work and by the way things are going it wouldn't come in handy this year anyway!
While she was in the air I thought I'd have a look at this knocking exhaust. Turns out it was knocking on the heat shield to the fuel tank. The next rubber down from that was near enough completely perished but by the looks of things if I had replaced it it would have only pulled the exhaust closer to the heat shield, NOT what I was looking for! So I turned my attention to the hanger on the back box, attached a couple of strategically placed cable ties and now all appears to be in order no knocking!
Apart from that it was good just to have the bumper off to get a better idea of how the IC is going to fit. I now have every confidence with the job at hand and rekon I could probably get it done in half a day... Hopefully a job for next weekend!
So, been fairly busy over the past few weeks... Not only with work and a small event in a field called Glastonbury but also managed to make some headway with the car.
First up, the intercooler's in! Was a tight squeeze but really pleased with the end result:
Can just about see the alloy cooler poking through, had to trim a fair bit of the bumper by the fogs but you can barely see the pipework and most importantly I've kept my fogs in tact!
Pretty much exactly how I wanted it!
Obviously I removed the air-con condenser so I could set the cooler back a bit, had to trim a fair bit of the plastic surround so I could set the cooler back but the end result was that it clears the crash bar and more importantly I was able to keep my fogs but it is still tight. Here's a shot of how much it clears the crash bar by and how close it is to the rad... 10mm either way and it wouldn't have worked.
I didn't really have a clear plan for the DV take when I went into this, just had the idea of mounting it above the cam cover near enough where it is as standard but space was tight and I had to get a little creative. Luckily, with a bit of trimming, I managed to reuse the pipe that was already there and it all worked out pretty well!
Perhaps not the prettiest job in the world, but it works!
One thing I'd completely over-looked at the time was the MAP sensor... So i ordered one from forge (50 f-ing quid, thanks forge!) and a TB to IC hose from creative motorsport. Upon arrival the hose was instantly butchered to pieces, seemed a shame seeing as I'd just spent £50 on that as well but needs must! I then wedged the map sensor pipe in the, bit of a fiddle but does the job nicely.
So that all done, went for a little drive Pleased to report that all seemed very well indeed! Seemed to pull a lot stronger all the way through the range and power deliver just was just a lot smoother and better in general. AIT's were dramatically reduced! Before you really didn't have to do too much to get AIT' into their 60's. Now, as long as there's air flowing over the cooler then they wont get much above mid 20's... Result! Now all I need is a trip to Niki to get that all fully mapped in and I'll be laughing!
While I was messing around up there I also whipped out the combi-valve, and plugged up all holes/hoses... Makes the bay look so much tidier!
Not long after that someone started a post about short shift kits for the 5 speed box and got me thinking about the B&M kit I had on my old A3 and how DAM GOOD it was!.. It's not the cheapest bit of kit in the world (circa £170) and I wasn't exactly minted at the time but I couldn't resist. . . before I knew it I was on the phone to venom-motorsport, debit card in hand. I'M SOOOO WEEAAAAK!
As soon as it arrived though, no regrets... Such a well made bit of kit!
Following weekend got straight to work on fitting that... Fairly fiddly to be honest: need to get the car in the air and remove the centre section to gain access to the linkage cover under the car. Once you've done that, disconnect both linkages and get back in the car to fiddle round at the the top end of things... Right hassle as everything's all lubed up and spring loaded, any way, got it done in the end.
Overall, couldn't be happier, not only with how it transforms the feel of the change but also it looks SOOOO OEM+ on the inside:
IMO this is by far the best short shift option as it keeps the VAG weighted linkage on the gear box end, gets rid of the weakest link (the shoddy standard stick it's self) and converts to "pull up" reverse... Ever missed second cos it gets stuck in that little notchy bit between 1st and 2nd where reverse is? This will completely eliminate any possibility of that!
Almost done rambling, promise!................
So the other day I noticed it sounded a little gritty from the turbo, had a look and there was air leaking from around the turbo/down-pipe area. Assuming it was the gasket there I ordered a new one and got to work on removing the DP only to find this:
Massive crack along the weld! . . To be honest I think it may have been a result of me being a little too heavy handed when trying to remove the centre section, it was a right pain to get off tho! Didn't really have many other options...
Oh well, hopefully get that all welded up this weekend. And in fairness, it doesn't exactly look like the strongest weld in the world to start off with.
Apart from that I've had a think and I don't think I'm realistically going to be able to afford to get to any track days this summer, not reliably anyway!.. Just going to concentrate on preparation for next year when hopefully I'll be able to hit the ground rolling.
Hope you guys like what I've been up too... Cue advice, opinions, questions and abuse......
P.s excuse the shoddy pics/state of the car... Being honest slightly reluctant to wash her until I get the flaking on the rear arches sorted. Which I believe I have Prawn to thank for!?
P.P.S can a mod please change this so it says "VAG-slags dailytrack all rounder"?
Maaaaaan that cooler looks sweet hidden away like that! Wish more people did the same!
Nice work mate. Impressed how you have got the fmic in with the lower valance intact and also the crash bar! I have the larger IC to go on soon, but I can't live without my AC....
Love love love this car.
Great work on keeping the old girl tip top, I've got a lot of memories in this thing and its lovely to see you going for it.
Keep the updates coming
Can I have my car back now please?
I miss it!
Good work Lewis. Impressed.
For me mate, it was the only way to go! . . As I said, pretty chuffed with the results my self exactly how I'd imagined it!
Will try mate but being honest I often struggle to find the time/patience for my dyslexic little brain to piece together anything worth reading... Hence why it generally all comes in one big lump of cyber vomit!
Mwhaa ha ha haaa! she's mine now! ! !
Glad your impressed mate, will have to pop by some time, hopefully post mapping sesh! . . Oh, and do you still have those weitec adjuster cups? Need more lows on the rear me thinks, specially now I've taken most the rear half out
Right... Obviously not updated this post in a while, being honest, not really had anything worth shouting about. But what have I been up to?
Well, changed the discs and pads a while back (not exciting at all, i know. Bear with!). As good as the DS3000 pads are I will not be using them again... They're very noisy, they absolutely chew through disks and they've made a right mess of absolutely everything. Not worth the hassle/expense on what is essentially an everyday car.
The calliper was completely crusted in a thick break dust build up that I literally had to chip away. The rims aren't looking too clever either and they even left a layer of bronze/black sh!t down the side of the car that was very hard to clean off. So I just went with the OEM brembo pads for the moment, aren't bad at all and were only £50 for the set.
So all was well and good. Happy motoring! Went out for a little summer drive (I know, seems like a life time ago now!) and was having a bit of a tare up with this little Renault 5 GTT. The guy was a proper petrol head, was chatting with him inbetween lights, the usual exchange of compliments for each others cars etc and how they compared in a straight line (obvs I had the edge tho
At the last set of lights I enthusiastically said "yea, check this out. I got launch control!". . . Famous last words or what!?
Lots of horrible noises, not a lot of drive... Bet he was well impressed with my launch control! lol
Anyway, to cut a long story short the diff basically exploded sending shards through the bell housing...
New clutch and gearbox it was then!
Took me a while to sort that all out. Got a cheapish gearbox second hand and fitted new clutch while I was there. Happy days, back on the road again!
And so followed at least a couple months of hassle free motoring... I even managed to get round to cleaning her! Here is some photographic evidence of that twice yearly (at best) event. Was loving her stance at this point as well, had been playing around with her ride height and the size of the spacers on the rear:
Then, just before Christmas, this happened:
I wont bother explaining again but basically more drama!
So, where am I now and what's the plan?.. I've got a low miles APY head here that needs a couple of valves so I'm gonna plonk them in and get the car back together. CAN'T WAIT to have her back on the road!
While the head's been off I've taken the opportunity to have a go at porting the exhaust manifold my self. (I'll get some pictures up soon) so long as the car is in good health once she's back together I'll be ordering a 12 psi actuator off beach buggy Dan then it'll be up to see Niki @ r-tech for a final few tweaks to the map... I'm hoping to hit 245bhp
So that's what's been going on/the plan from here. Hopefully slightly less drama ahead! I'll try and keep this updated more regularly as well to try avoid more large, scatty, nonsensical posts like this.....
As promised here's a few snaps of my mani porting "skills"...
I think I've taken off about as much metal as I would like (and possibly a little more in places, oops!). Just need to give it the once over with a flap wheel to smooth it out a bit and she should be good...
Really hoping to have the car back in one piece this weekend but realistically it's more likely to be next weekend... Fingers crossed all will be good after that and ready for BBT actuator & final mapping!
I love this car Lewis.
Keep up the good work. I am so glad you stuck with it, once you get boost again I promise it will be worth it.
P.s, I've farted in your seats.
Looking good mate
I'm really glad you've decided to fix and keep it!
Porting looks fun! Not something I've done for years!
Ahhhhhhhhhhh, that explains it... I was wondering why it smells a little cummy!
when are you going to fix this, and bring it back to it's rightfull home? so we can park it next to it's elder brother and take another pic like this, for old times sake?
Or take it to Bruntingthorpe to play with bad-ass mid engined kit cars?
I never managed to beat 6s dead to 60 on the liquid:
This is where it belongs
Properly miss my old wagon!
Best car on ASN I reckon
More wheels than hot dinners
Ok, just one more set, for now.....
How much alcohol free beer have you drunk?
I got home early, so this evening has been Reeeeeeeeeeeealy long
Bed time now. haha
This is why i want some chunky flat faced wheels.....this looks the nuts!!
Soon mate, SOON! . . With a bit of luck I'll have her back together by the end of this week. And mate, if you ever feel the need to sell the rota's, hook me up!
p.s thanks for for the spamming :thumbsup:
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