wire bundles arrived for replacement of a few loom wires end to end, extending the MAF was the big one but deceided to replace some tired wires anyway.
carpet under lay also got picked up, its a backed wool, so it should do the job nicely
I took the manifold off, ported it a little and then put it back with a new gasket. while i was there i ckeaned up the rear of the engine and painted it with engine enamel. nobody will see it, but i know its been done and is tidy.
I stripped out the interior one evening wen the kids went to bed:
I broke a couple of the clips that hold the heater controls in place, i took the wires off to lubricate them, this has always been a bug bear of mine that its all so stiff.. Some dry lube for the bicycle chain was a good thing to use. not greasy and messy, leaves a teflon type coating and its now nice and free.
There is no intrustion of water into the cabin :
I breathed a sigh of relief when i took the window out:
Yes, theres rust, but it looks like just superficial rust, so i would not need to have a pannel put in! should save on bodyshop costs.
I took the ECU apart to have a nosey inside:
06A 906 018CG
They did a nice neat job off the Immo off. the ECU is accessible through Vagcom and the port i installed in the cabin, so maybe just bolt a K03s onto it and get that mod done while the engine is out.
I took the change on Saturday morning to get busy and start prepping the car for some work:
Took the wings off and cleaned off the wax with a hot gun and some paper towels, then wiped down with brake cleaner to remove the remaining wax. I have not tackled the sealer with anything, i am tempted to wire wheel it all, epoxy prime and then spray it with raptor black for a long lasting durable weather proof finish. I dont care if it doesn't look factory in that beige colour, more worried about it lasting and looking clean and tidy.
A couple of rust spots found on the near side, i guess this is typical as this is the gutter side and more prone to salt intrustion?
Well i picked up the new used box from a seller i have known about for a long time so that gave me some confidence in what he was saying... So many people have tried to sell me duff box's or just come across as such cowboys.
Photo from the seller below. pretty oily and grimey but came out of a running Octavia VRS and the gearbox was running smoothly.
got busy with the oven cleaner and some other cleaning products and it really did a good job on removing all the grime! the only issue was some surface corrosion that i've began cleaning off before clear coating the box.. i don't want to paint it silver as it just looks wrong... black would be good but keep it original looking and clear it.
half way through clearing it up my second Dremel died.. thats 2 now in the space of 2 years... going to buy a cheap one this time as im sick of the cost of a dremel against the length of life
Finished cleaning up the cam cover, masked up ready to paint
Idle pulley bearing was rough so took that apart, cleaned up all the aluminium, chemically treated it and then cleaned again and clear coated it... i also did this with the bracket on the front of the engine for the alternator
Took the bearing out thinking i could just replace it... looks like its easier to just replace the assembaly
Stripped the alternator to check the bearings as it sounded a bit gritty..
Outer shaft bearing in the casing is all good... inner is gritty..Part number for it in pic. ordered a new bearing and will replace that.
did loads more cleaning up of the alternator casing, i will clear coat this when done.
and put some of it back in to get an idea of how its looking.
Intercooler out (need to make up some good brackets for that again as i didn't like how it was sat at an angle before)
cooling system out - getting completely replaced
Alternator and bracket - out to be refurbished.
This is the offending pipe!
The near side of the engine has a coolant housing that the temp sensor goes into, so i whipped that off while i clean up the engine of all the muck and grease, as it came of, the rubber o'ring came away in 2 pieces..so that's likely where the little dribble of coolant has come from and possibly not the pipe in the pictures above, but that needs replacing anyway.
Going to fit a catch can so whipped out all the oil breather pipes, the one that goes into the block obviously split as it came out..just brittle. so ordered a new part there, that will go into a silicon pipe to a catch can and then one from the cam cover to the catch can...then delete the PCV (puck) valve.
then took out the alternator and the bracket behind it that supports the power steering pump. I'll sand them back and clear coat them... not sure how to restore the alternator yet though but just want that back to OEM looking and clear coated.
loads of cleaning to do! should be a good week for progress
Stripped down the rear ARB to bare metal as it seemed to have some worming under the powdercoat, painted with etch primer then Upol-Raptor, let it all cure for a week and i re-fitted it all with all new bushes.
I used to be on the forum but then it changed and i think my content got deleted, so thought i'd just share the latest on the project.
The car was originally a 8v GTI but that was dead boring / slow / old and i wanted something to keep up with more mordern cars. So i decided to install a 20v turbo engine.
I drove it about for some time and then decided on some maintenance and a change to 20v. i've skipped a lot but here's some of the journey.
The front drivers side wishbone joint was looking a bit sorry for itself
so ive added on some S2 twin pots
changed the charge pipe setup for that of a k04
new genuine mounts:
got it all in the car
a couple of nights of work and its back like this:
just loosly put in the new subframe while i clean up the engine bay and the old power steering rack
also ordered a new trackslag exhaust , the slanty tip one to look OEM.
its no longer my daily driver but also not a show car
painted my intercooler pipes and fitted a new larger radiator. Just waiting on the fan bracket so that i can add the fan and fill it up with coolant again.
Cooling sorted, plumbed, bled..ready to drive! now for some dry weather
i replaced the fuel tank straps with new stainless ones :