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Lëon OEM+

Discussion in 'The Project Room' started by jamiebennett81, Sep 1, 2013.

  1. jamiebennett81
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    jamiebennett81 Active Member

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    So I drove over to Nicks to pickup a set of lower arms and wheel hubs, top man! saves the car sitting on axle stands for months on end, and means its easier to do a straight swap when the time comes

    How I got them:

    [​IMG]

    Spent an hour cleaning them tonight

    de-greasing

    [​IMG]

    First scrub down with a wire brush and picking the old paint off with a screw driver, a bit to go yet

    [​IMG]


    These are going to need quite a bit of work to get like new again

    [​IMG]

    hanks to a few members off Edition today, they pointed out a 30% sale on euro car parts, so ordered two new lower ball joints and two new wheel bearings

    Next up is to scrape all the sound deadening out of the leon, take the roof lining out and as much weight as possible....potentially the air con as well as that weighs a ton
    #41
  2. jamiebennett81
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    jamiebennett81 Active Member

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    Bought some of this today....not cheap but will make it easier and get the job done

    [​IMG]


    and here's a picture of her next to my mates R5 before she was SORN

    [​IMG]
    #42
  3. jamiebennett81
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    jamiebennett81 Active Member

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    Been trying out the rust stuff today, it's actually really good, and has really stripped the rust off with very little work

    [​IMG]

    [​IMG]

    still some discoloration, but it has stripped the rust and some paint right back. I am going to leave it on over night, then clean it off tomorrow. Pretty much done and ready for painting then

    [​IMG]

    This was one of the worst arms. A lot of rust has been stripped but still a way to go yet

    [​IMG]
    #43
  4. jamiebennett81
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    jamiebennett81 Active Member

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    few bits arrived

    [​IMG]

    ordered some snow foam as well to clean the rear arches as I will be sealing these, shortly and ordered some butyl as well to sort out the leaky doors
    #44
  5. jamiebennett81
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    jamiebennett81 Active Member

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    in progress

    [​IMG]

    [​IMG]

    Bought these from AKS Tuning as well, OEM+ coolant and washer caps in black, look awesome. One problem with spraying the washer cap is the paint cracks when you bend the fixing point back onto the bottle. This doesn't happen with this washer caps as the actual plastic is black

    Coolant

    [​IMG]

    Washer

    [​IMG]


    Snow foam turned up also, so I can prep the arches and sills and get sealing these before the cold properly sets in

    [​IMG]
    #45
  6. jamiebennett81
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    jamiebennett81 Active Member

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    Had a fairly productive evening tonight

    Gave the arms a final coat of paint tonight, all done. Just need to drill out the bushes ready for the new polybush ones

    [imghttp://i253.photobucket.com/albums/hh67/jamiebennett81/Lowerarmsfinished.jpg[/img]

    Then I got onto the black sound deadening, was quite therapeutic doing this actually

    To the side of the footwell

    [​IMG]

    Then the spare wheel well

    [​IMG]

    A good 5kg of this stuff already, and got the whole of the footwells to go which is very thick, so a good 15-20kg I reckon of weight to come

    Got a shot of the engine bay, very dirty and bogging looking, nothing pretty about it

    [​IMG]
    #46
  7. ReDBull
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  8. jamiebennett81
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    Cracked on with working on the car tonight

    [​IMG]

    Sound deadening removed from under the rear seats

    [​IMG]

    Removed the drivers seat, and cracked on with removing more sound deadening

    [​IMG]

    first half gone

    [​IMG]

    [​IMG]


    full bag already of sound deadening, good 10kg's already

    [​IMG]


    Up in the air again

    [​IMG]

    Spot the difference and what is missing....

    [​IMG]

    Dirty arch

    [​IMG]

    Cleaned guard

    [​IMG]

    During clean

    [​IMG]

    Spotted three spots of rust, so I am glad I started this job now

    [​IMG]

    Lower arms all done

    [​IMG]

    Arch now sealed and left to dry

    [​IMG]
    Last edited: Sep 7, 2013
    #48
  9. jamiebennett81
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    jamiebennett81 Active Member

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    Decided to start tidying the interior up, and get rid of the old glue left over from the sound deadening

    Before

    [​IMG]

    After

    [​IMG]

    Rear patches tidied up

    [​IMG]

    spare wheel well (still a bit to sort)

    [​IMG]

    Made a brief start on the drivers side

    Before

    [​IMG]

    After

    [​IMG]

    Roof lining, grab handles, interior lights and plastic side pillars removed

    [​IMG]
    #49
  10. jamiebennett81
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    jamiebennett81 Active Member

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    The car was absolutely full of water, I knew it had a leak but didn't realise it was this bad....and we have had some pretty torrential rain

    Luckily I left some big cloths in there to soak up the water....I literally squeezed out two pints worth of water from them!

    The water is pouring in from the pollen filter housing. I removed this last night, and the seals around the pollen filter were soaked. So I resealed these and I need to reseal the plastic cover against the windscreen, but ran out of sealant

    Apologies for the poop quality

    So the evening started off like this

    [​IMG]


    Pollen housing...minging

    [​IMG]

    Screwed seals around the pollen filter housing

    [​IMG]

    Now resealed, so hopefully this will hold out for a while. Doing the rest of the sealant tonight


    I finally got round to sealing the last wheel arch.

    During cleaning

    [​IMG]

    Sealed

    [​IMG]

    Next up is finally crack on with reconditioning the hubs, removing all the old sealant glue, relocate the battery and start to design my custom housing to enclose the air filter.....
    #50
  11. jamiebennett81
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    jamiebennett81 Active Member

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    Got most of the old glue off from the sound deadening

    [​IMG]

    Pulled off the passenger cover tonight...trying to find the source of the leak as it's still leaking...and losing some more weight from the car

    [​IMG]

    Before

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]
    #51
  12. jamiebennett81
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    jamiebennett81 Active Member

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    Wheel arch refitted for the last arch which was sealed

    [​IMG]

    Finally got round to adding the last resistor to the removed SAI, so the error code stops coming up (Thanks to Mylo again for making this up for me)

    [​IMG]

    tidied it away since the pic.

    Sorry Bill....but I have rebuilt it since

    [​IMG]

    Old Vs new pollen filter

    [​IMG]

    Hopefully sealed the leak...but still don't think I have properly, as yet again the cloths on the passenger floor were absolutely soaking
    #52
  13. jamiebennett81
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    jamiebennett81 Active Member

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    These arrived (and still to be fitted yet also)

    [​IMG]

    3" Downpipe and decat off Nick

    [​IMG]

    Silica Gel, to soak up the moisture, as still got a small leak, and water collects on the inside of the roof (no roof lining)...also with it sitting around so much it never gets warm to dry up the moisture, so this will have to do for the mean time

    [​IMG]

    First set of polybushes arrived also

    [​IMG]
    #53
  14. jamiebennett81
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    jamiebennett81 Active Member

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    Determined to get my downpipe off ready for the 3" downpipe and decat....in the pouring bloody rain

    Downpipe off, not too difficult but made harder laying on the drive way

    [​IMG]

    Spot the restriction. 3" DP vs the restrictive supposed updated downpipe from Blueflame which is measuring in at just over 2.2"

    [​IMG]
    #54
  15. jamiebennett81
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    jamiebennett81 Active Member

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    So I got the spark plugs changed, which had not been changed since the turbo went pop.....they were very oily

    Old Vs New

    [​IMG]

    This was the plug nearest the turbo (something isn't right)

    Next was to pull out the sensors from the existing exhaust, but first I had to get this bolt out of the decat which was a pig...ended up putting the spanner and standing on it, which released it

    [​IMG]

    sensors out and then I put them in the 3" DP and decat....again standing on the spanner to undo the sensors!

    [​IMG]

    Then my outside light went pop!

    Inside of the old cat as well

    [​IMG]


    Next will be getting the DP and decat on, and changing the fuel filter
    #55
  16. jamiebennett81
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    jamiebennett81 Active Member

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    Time to replace the rocker cover gasket and the valve cover gasket

    Valve cover off, came off nice and easy too

    [​IMG]

    Bit of dried gunk on the 4th valve

    [​IMG]

    This is the old valve cover gasket, the 4th one which was where the oiliest spark plug was....I couldn't notice any splits or particularly worn gasket

    [​IMG]

    [​IMG]

    Fresh nuts also

    [​IMG]
    #56
  17. jamiebennett81
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    jamiebennett81 Active Member

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    Stage one to losing some more weight out of the car, this turned up [​IMG]

    Corbeau Pro Kevlar, weighing in at 8.6kg, compared a good 35kg+ for my leather electric seats. Only one at the moment as I couldn't afford two at the same time, so the second one will come later.

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    Other developments recently are my 3" Downpipe and decat are now on the car, and has made a big difference. You can really hear the turbo spooling even more now. Thanks to Nick.

    Getting the seat fitted on the 10th March, then next up will be ordering my water meth kit
    #57
  18. jamiebennett81
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    jamiebennett81 Active Member

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    Box steel arrived ready for the bucket seat being mounted

    [​IMG]

    Relocating the battery

    [​IMG]

    Bucket seat was installed. Started at 9 and finished at 18:00.....for one Seat. I did not realise the amount of work that went into this, but wow.

    Nick is an absolute legend, and his technical skills amazed me today.

    Today started off like this, at Prawn HQ

    [​IMG]

    Seat out

    [​IMG]

    Nick drilling out the welded OEM Seat rails

    [​IMG]

    Mess around the car

    [​IMG]

    Nick cutting out the 3mm steel for the box steel to be welded too

    [​IMG]

    Nick Tack welding the steel to the sides

    [​IMG]

    This was then removed, and sprayed up (to ensure this doesn't ever rust)

    [​IMG]

    All done

    [​IMG]

    Welding bolt eye into place

    [​IMG]

    Half done

    [​IMG]

    Lovely jubbly

    [​IMG]

    more welding

    [​IMG]

    Seat rails in

    [​IMG]

    Trial mounting seat

    http://i253.photobucket.com/albums/hh67/jamiebennett81/IMG_20130310_175802_zpsf4adaa74.jpg/img]

    AND fitted, sorry for the poor pic, but this was late, we were frozen beyond belief

    [img]http://i253.photobucket.com/albums/hh67/jamiebennett81/BucketSeat_zps0bf7697d.jpg
    #58
  19. jamiebennett81
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    jamiebennett81 Active Member

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    few better pics of the seat in daylight

    [​IMG]

    [​IMG]

    Ordered my water methanol kit, DVC30 progressive kit, with low level float warning and 4 quarts tank. This also comes with the sensor showing the pump is actually pumping to stop any issues with detonation etc which is pretty important!

    [​IMG]
    #59
  20. jamiebennett81
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    Bought a gauge pod, which is slightly angled towards the drivers seat

    Took the gauges out of the old Audi mounting brackets and trial fitted them

    Perfect fit

    [​IMG]

    Notice how the fittings are slanted also, so they point towards the driver

    [​IMG]

    Got myself a Makita angle grinder as well, as I need to cut up some steel plates to hold the alloy battery cage in and start making my custom heat shield

    [​IMG]

    [​IMG]
    #60
  21. jamiebennett81
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    jamiebennett81 Active Member

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    plan today was to get some more airflow to the FMIC

    Bumper

    [​IMG]

    Half cut out

    [​IMG]

    Done

    http://i253.photobucket.com/albums/hh67/jamiebennett81/IMG_20130331_134258_zps296914fc.jpg/img]

    I tidied it up a little bit after this as well

    hanging on after drilling the crash bar a bit as well, as you can see its quite a bit more flow to the FMIC with the number plate cut out

    [img]http://i253.photobucket.com/albums/hh67/jamiebennett81/IMG_20130331_145517_zps415df264.jpg

    Bits cut out

    [​IMG]

    Cut out.....actually looks wonky the holes cut but that's because parts of the bumper are sunken

    [​IMG]

    Took it off and drilled the back with a larger hole saw to maximise flow

    [​IMG]

    Naked again

    [​IMG]
    #61
  22. jamiebennett81
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    Tidied up the crash bar and finished off spraying it

    [​IMG]

    Decided to clean up the points where the crash bar mounts to

    Before

    [​IMG]

    Sprayed

    [​IMG]

    Dried and done

    [​IMG]
    #62
  23. jamiebennett81
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    jamiebennett81 Active Member

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    3m carbon arrived to finally do the missing bumper cover

    In yellow, but that doesn't matter

    [​IMG]

    Carbon covered

    [​IMG]

    Parts have arrived for the gauges today

    oil pressure sender

    [​IMG]

    Sump plug and sump plug oil temperature sensor

    [​IMG]

    [​IMG]

    nd my bits are ready from GStar wraps....SUPER excited about these [​IMG]

    Massive thanks to them. They can be found by searching for GStar wraps or www.gstarwraps.com

    [​IMG]
    #63
  24. jamiebennett81
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    jamiebennett81 Active Member

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    Few bits arrived for the car. Some of the cars performance issues is related to the stat and temp sensor as these are bringing the engine management light on, and this can really affect fueling etc.

    This figures because the mpg I get is piss poor even when coasting off boost and is effecting power top end as I don't think it can work out fueling correctly. Either running lean or rich

    Stat

    [​IMG]

    Temp sensor

    [​IMG]

    Boss to be welded into the intake pipe for the water meth

    [​IMG]
    #64
  25. jamiebennett81
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    jamiebennett81 Active Member

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    Superseize TIP arrived. This was a custom made one from SFS which fits to a K03 hybrid turbo, but goes into an 80mm MAF fitment. I wanted all one pipe, instead of having to use reducers from the MAF to the intake, as a hybrid runs an 80mm MAF

    [​IMG]

    MUCH bigger than the forge one
    #65
  26. jamiebennett81
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    jamiebennett81 Active Member

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    Battery relocation is a work in progress at the moment

    cut the brackets to pin the battery cage down. The lips on the end of the battery cage were to narrow and too thin to put bolts put through them, so I cut my 3mm steel left over

    cut and drilled the ends

    [​IMG]

    Started spraying them up, and the other black bracket is the top which goes over the top of the battery in the cage. The cage is too bling for my liking to its getting sprayed satin black also

    [​IMG]

    Trial mounted in the boot. You can just see the ends of the battery cage where they are too thin, so the metal bars will be clamping this down.

    [​IMG]

    I'm going to spray the white patch in the spare wheel well also at the weekend.

    Then all I have to do is drill the foot well and bolt it down, fit the negative cable then that's job done and I can start on the supersize TIP.
    #66
  27. jamiebennett81
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    I will just leave this here...

    [​IMG]
    #67
  28. jamiebennett81
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    jamiebennett81 Active Member

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    went down to Portsmouth today to pick up the replacement subframe, was in bloody good nick as well, rushed back.

    car jacked up and ready to go

    [​IMG]

    Subframe was changed in an hour thanks to the help of Nick, but while changing it over we noticed the dog bone mount was absolutely shagged....literally no rubber left in the mount at all

    [​IMG]

    now going to order a polyflex replacement one

    got the dogbone mount done today, as it was absolutely fecked

    Old rubber from the mount, absolutely soft as butter....an uprated mount from a supplier I won't mention]

    [​IMG]

    Old bush insert cut off, but had to drill a 15mm hole....and drill bits come in 14mm or 16mm....so out with the 14mm drill and widened the hole until the small insert came out

    [​IMG]

    Insert out

    [​IMG]

    Bush was then pressed in. This was a struggle, but managed to do it with a clamp I had. Took a few goes as it was only a small clamp and it kept sliding off the bush, but got there in the end

    [​IMG]

    Put the whole dog mount together. Next challenge was to press the two main bushes enough for the bolt to grip through the center of them onto the connecting nut, but got there in the end

    [​IMG]
    #68
  29. jamiebennett81
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    Fitted the dogbone mount tonight, hardly any engine movement now, and it's very stiff

    [​IMG]

    Then started with fitting the supersize TIP.

    Comparison (this is a custom made version as I run a K03 Hybrid, so it is a K03 fitment on the turbo end, but an 80mm MAF fitment the other end, as I run an LCR MAF)

    [​IMG]

    Fitted...excuse the absolute mess and wiring everywhere as I am in the middle of relocating the battery as well which is to be tidied up

    [​IMG]
    #69
  30. jamiebennett81
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    jamiebennett81 Active Member

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    small bits of progress tonight

    9.5mm bung's for the supersize TIP

    [​IMG]

    Started making the heatshield template tonight. Cut and ready, bit rough around the edges and a few bits to tidy up but on the whole it's sorted

    [​IMG]

    Looks like it sits very high, but that's because there is a bolt on the chassis so it's not sitting flush yet, and the bolt needs cutting off. It will sit lower once done.

    [​IMG]

    Shielding is going to be made from 1.5mm mild steel sheet, sprayed black, then wrapped in reflective heat material

    Ordered a few other bits as well arriving this week, more updates to come shortly
    #70
  31. jamiebennett81
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    Few things arrived today

    Methanol intake pipe, thanks to Bill Brockbank at www.badger5.co.uk

    [​IMG]

    6 speed quick shift as well.

    [​IMG]

    Just ordering 1.5mm mild steel now for the heatshield and magmashield tape for the heat shielding

    still sat on the driveway going nowhere...

    [​IMG]
    #71
  32. jamiebennett81
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    Since stripping the car, the buttons for the TCS and fuel cap are hanging loose in the car, so I have started to make the mount. The VAG com port is also going to be mounted into this.

    cut (maybe a bit too tall at the moment, but this is to be adjusted) and also small pieces to brace the sides of the mount

    [​IMG]

    This is how its going to look. It will sit lower than this as it is resting on the two bolts which is what it's going to be bolted onto. Will spray it black also to tidy it up

    [​IMG]

    Battery relocation done, but the boot is too thin to mount the negative wire too, which is causing a weak signal, so I need to get a longer piece of cable and mount it to the seat belt point

    [​IMG]

    Final filter relocation bits arrived

    [​IMG]
    #72
  33. jamiebennett81
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    jamiebennett81 Active Member

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    Started on my heat shield properly, cutting it etc

    From this

    [​IMG]

    To this

    [​IMG]

    fits perfectly, needs trimming more, and the holt cut out for the filter then its almost done
    #73
  34. jamiebennett81
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    jamiebennett81 Active Member

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    Did some more work on the car tonight, only had an hour or so though

    Battery tray

    [​IMG]

    two bolts in the way, out comes the angle grinder..... (earth for cable is going onto the engine mount where the hard pipe is)

    [​IMG]

    quick clean

    [​IMG]

    The issue with catch can as you can see is its a complete mess and in the way of the TIP, and the pipework is also in the way of the DV.

    [​IMG]

    This needs to be relocated. I have taken it off its mount

    Mock up of how it will look, and the catch can which is going to be mounted to the side of the heat shield. Other pipes need trimming down of course

    [​IMG]

    Got the day off on Thursday and Friday so I aim to finally complete it all then
    #74
  35. jamiebennett81
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    jamiebennett81 Active Member

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    Also just ordered a 5m roll of magmashield, to wrap the heat shield and to wrap the pipe going onto the filter (will also be sprayed satin black)

    Example picture:

    [​IMG]
    #75
  36. jamiebennett81
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    Magmashield turned up today

    [​IMG]
    #76
  37. jamiebennett81
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    jamiebennett81 Active Member

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    So finally finished off my custom heat shield yesterday, really pleased with how it has turned out!

    Hole cut out and filter mounted

    [​IMG]

    Trial fit

    [​IMG]

    Rubber mount

    [​IMG]


    Sprayed satin black

    [​IMG]

    Here it is finished

    [​IMG]

    [​IMG]
    #77
  38. jamiebennett81
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    jamiebennett81 Active Member

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    ll in and done. Relocated the catch can as well and mounted it to the heat shield

    [​IMG]
    #78
  39. jamiebennett81
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    jamiebennett81 Active Member

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    Finally got the car up and running today with help of Nick.

    It was such a stupid problem as well.

    when I originally took apart the battery fuse box to fit a new cable, I only did up four of the nuts...leaving the other four loose

    We scratched our heads for a few hours this morning. We went and bought a volt meter tester in the end, 4 of the nuts were good and showing good current, but when testing other areas of the fuse box, the signal was very weak.

    We only figured this out because when applying pressure from the volt tester, we faintly heard a few sparks....then we realised the four nuts were loose....

    tightened these up and hey presto.

    SO frustrating because everything I had done with the battery relocation was right, and it was all undone from 4 nuts loose on the fuse lid

    I can't believe it was something so stupid!

    I then went for a test drive...almost straight away the car died on me and the EPC light came on and the car was struggling to run.....something had popped off

    found that the charge pipe to turbo had not been tightened

    Limped home, tightened it and all good
    #79
  40. jamiebennett81
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    jamiebennett81 Active Member

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    Few pics of the battery install in the boot. Need to cable tie the main cable to tidy it up still

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    You can see the LCR spoiler in the passenger footwell I picked up the other night as well, going to fit this when it stops raining, much bigger than the standard LC spoiler

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    and because race car

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    finally got my hands on a facelift rear spoiler. Much bigger than the LC one.

    Pic doesn't do it justice, but when fitted it looks a lot bigger and much deeper as well. very pleased with it

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    #80

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