Project Golf

[audiman]

You'll have to make yours fast first Chris

[jogi730]

Tom,
Just getting her on the road will be an achievement at the moment .
Reckon might be okish once ready though.
Cheers
Chris

[Bram]

Any news?

[audiman]

LMAO, well, new turbo went pop after 1500 miles due to a freak oil starve!? Had to pay for a rebuild, also decided to fit an external WG as the internal one was just too small and wouldnt control boost. I hoping to pick it up form the fab shop on saturday so i should be back on the road (i hope).

During the turbo repair i have changed to hotside housing for a larger one to reduce the surging problems that i was having. Hope it works!

[gnutz2]

Did you run an oil restrictor?

Were the compressor blades damaged? maybe overspeeding was the cause of failure because of the small hotside A/R?

Any pics? As you can see im very intrestd in turbo failures and how to prevent them

[audiman]

Oil restrictor was used, now it isnt. No damage to blades, i didnt let it get that bad. No overspinning, all it did was damage an oil seal and burn oil. Seal was replaced and a new bearing for good measure.

The car suffered from surge, becasue the hotside was too small (0.63) now gone up to 0.80, that hopwfully will cure the surge. I had to really limit boost as at came in and then due to the crap internal WG, i had to set the rev limit to 5400rpm to stop the boost going past 1.5-1.8bar.

Will report back when i know what the difference is with new setup.

[Rusty]

Sounds like fun Hope you get it all sorted soon. I'd guess it was rediculously fast... when there was grip.

[audiman]

Update :

Well, the plan of changing to external wastegate has proved to be a lengthy one as its still off the road!!!

To cut a long story short, RS fabs had the car for months, they first made it all wrong so it went back, they fixed it 4 weeks later i drove the car, did 10 miles with Doug trying to map it, then the modded exhaust manifold split open like a grenade in a bean can! Nice work. So it went back to them and this time it comes back not running and wont idle.

Water and servo pipes on back to front - water in engine - engine ruined :O

So now i have after months of insurnace claims etc etc, got a new 2.0l Eurospec enigne, came complete with forged crank, rods, pistons, main bearing girdle, extra water cooling in deck and a nice lowish 8.5:1 CR. Some new eurospec 268 cams finish the engine off.

All i need now is the exhaust manifold to be repaired correctly and i will be back in business. Hopefully the new enigne should produce somewhere in the region of 450-500bhp

This has to be one of the most annoying and stressful builds i have ever done. I hate its guts, and once running i will punish it.

On the plus side, it has given me the chance to fit a few nice things. I now have a nice shiny fuel swirl pot in the boot, fitted with my 10 bar '044' Bosch pump. Also have now 280mm rear brakes so the 900kg monster should stop ok

will update again once RS Fabs sort there work out

[Acidburn]

This has to be one of the most annoying and stressful builds i have ever done. I hate its guts, and once running i will punish it.

love that, your have to do that with mine once its rebuilt and goes for mapping

[audiman]

I dont thrash customers cars. You will have to run it in before mapping. You can do your own thrashing!

[Rusty]

Sounds like a right 'mare Tom, hope things go your way soon!

[Jamo]

I love this car! bought an LSD yet? or is tyresmoke going to be the norm?

[Ross]

Tom,

Fair play for sticking with it! I knew about the turbo failure, didn't realise you'd had so many other problems.

I know only too well about repeated rebuild failures

Look forward to seeing this beast in the flesh some day,

Good luck!!

Ross

[audiman]

This project has been a mare, but thankfully, NONE of the failures have been anything to do with the work that i did in the first place. They have been caused by letting others work on it. Thats the most annoying bit. The part of the job i cant do myself and entrust others to do the same quality of work. Live and learn.

LSD hasn't been ordered yet, I want to get the engine sorted first and the general running of things. However i have just landed a mk3 golf TDi gearbox with some stupid diff and gear ratios. I have seen them used before with good results, but normally only used on low end torque G60 engines, that dont rev high.

With the gearing in stock trim, it should in theory hit 220 mph in 5th @7400 rpm. However, with the 80's brick like styling, i doubt i will get there. 175 would be nice tho.

[Rusty]

...it should in theory hit 220 mph in 5th @7400 rpm. However, with the 80's brick like styling, i doubt i will get there. 175 would be nice tho.