OEM+ Coupe 16v (1.8t on the way)

[bikerjim]

Ok the story so far, this is all inserts from a project thread on another forum.

LINK to original project

Old posts from other forum:

12/12/08

Hi everyone

As some of you may or may not know i have been gathering parts to have a go at getting a little more from my little four pot.

I have finally managed to get a bit of time to use a corner in my dads garage, so i started on it this eve.

It all started last febuary when i bought the car. The guy i bought it off suspected it had a headgasket problems so i got it at a bargain price, as it turned out it didnt have headgasket problems afterall Alhought it did require quite a bit of TLC to get it right.

Anyway i have been using the car for the last few months and love driving it, it handles great and goes pretty well. However it has been using alot of oil :evil: I have come to the conclusion that it is very likely to be the valve stem oil seals.

So i thought wilst i had it in bits i might as well have a play and see if i can get a little more out of her.

Parts i have collected:

5 branch tubular manifold
Heat shield
VW Golf KR inlet and exhaust cams
Full headgasket kit
New genuine audi cam chain

And a few other bits and pieces





Soo...

Tonights efforts consisted of running the car with the oil and coolant flush, draining the fluids and starting the dissasembly.

Tomorrow i hope to get a full day at it and get to the point where i have the old manifold off so i can have a good look at what needs doing to mod the tubular one to fit (if it will fit) :?

This is all fairly new to me although my dad is a self employed mechanic of the last 40 (ish) years so i have grown up around engines, cars, motorbikes and a little engineering so i am quietly confident in my abilities and know when its going over my head ops:

Feel free to comment, offer critisism, help or advice.

P.s. i'll try keep the pics coming





13/12/08

Balls balls balls :x ..... Major disapointment today, got it all stripped down to the point i could try the manifold in place. Slotted in lovely..

Origional


Tubular


Started loosely fitting bits back in to see how things fitted



Seemed tight but feesable, then, notice the throttle body in the above pic, its probably hard to see but with the heatshield in place it sits about half an inch above the inlet manifold balls!

So i took the heatshield off and was left with it fitting but looked like this...



The throttle body is microns from sitting on the tubes of the exhaust manifold, as you are probably aware these run extremely hot and would almost certianly ****** it!

As this is a budget project i cant go any further with the tubular as it will require lots of expensive mods to make it fit. Either that or i do what aspro did and put it on a stand alone management system with throttle bodys but that will be expesive, take time and will make the car less street friendly.

Anyway, hay ho, the cams will still be going in and i will still be doing some home brew porting/polishing. Gona have a go at the throttle body too.

I'll keep you posted, head comes off on monday :twisted:


21/12/08

Ok latest developments......

Not been able to get o with this as fast as i would of liked. Our family dog of 12 years had to be put down on monday, was a pretty ****** day. He was a really great loving friendly dog, rest in peace Roly

Ok so i managed to get the head off on wed evening after work and also managed to get all the valves etc out, i was left with this...



It is a damn good job i decided to take the head off because one of the water ways in the gasket had started to leak towards the sealing ring around the back cylinder, dad recons it wouldnt of been long before it went.

Once the head was off i started work macthing the ports up on the inlet manifold and the head, i found there was a fair amount of material to remove. Spent most of this weekend finishing off taking all the casting marks out of the ports (there was some quite heavy lines rinning right through). The head is now ready to be skimmed.

I also spent an evening last week messing with my throttle body and this is the result, not sure if im satisfied with it yet, i could go bigger but i dont want to mess with it too much, as it started off quite small, and dont want to end up with something undriveable at slow speeds.

before..



After...



Bits and pieces ready to go bak on the car, head is getting skimmed 2mora....







10/01/09

Ok, she is up and running again 8) wahoo, finally!

After much deliberation about cams (see my other thread in the series 3 section) i ended up putting my origional cams back in. I have not had chance to drive the car yet to see if the home brew porting polishing job on the head and throttle body has made any difference.

Finally got her fired up tonight about 6:30. Took ages for the tappets to pump up, bet eventually they did and she ran sweetly

Here are a few pics, i did a little tarting up in the engine bay while i was at it, also modifyed the cool air intake too, it still draws warm initially but it went through a very small hole in the plastic headlight shroud so i cut the hole out a bit bigger and put in a slightly larger diameter pipe, what effect this will have (if any) i dont know but i wanted to avoid drilling the airbox.

Painted Rocker Cover


All back together




So the engine is now back togeter but as with any project it will never be finished. After i get it back home and give it a wash i will take some pics of the other bits i been messing with

[bikerjim]

18/01/09


Afternoon everyone

Well this happened last week as i thought it would:



Completely rotted off its joint.

So 2 things stopped me fitting the remus

1 salty roads
2 someone has had the exhaust replaced in the past but with a 50mm system (probably an 8v). This means the remus (60mm fitting) wont fit. so i did this :twisted:





Im actually supprised how quiet it still is, someone has removed the smaller silencer after the cat at some point too so its only going through the mid box . Sounds great when you set off from a junction :twisted:

So im saving my pennys for the rest of the 60mm stainless system and the remus box i have.

This is how the car sits at the mo:-







Need to get some better paint to re do the grill too.

[bikerjim]

20/04/10


Ok after not updating this for over a year now i think its time i did.

I started uni in september so i have been pretty busy with that but still found time for the car.

I had been toying with all sorts of ideas do i sell it, keep it, put a 1.8t engine in it all sorts was going through my head.

I have decided to keep it and make it how i want it. I am a student and money is tight but not quite as bad as expected so a few tasty mods to follow. I figure in my 3rd year of uni when i am having my year in industry i will maybe get an s2 or build something silly lol. I have a hankering to build a coupe quattro with a 2.5 tdi from an a6 in it.

Anyway back to the car.

I got the exhaust sorted in the end:





Here is a link to the origional thread about it: LINK Its not my thread but i had issues with the origional longlife system i had put on. The guy sorted it for me in the end.



I also had a play about with a spare grill and made this:



Its not currently wearing this as you will see in the next few pics but it is really nice. Im going to try it back on and see how it looks at a later date but might end up selling it.

Getting it stuck in the snow in our drive way was quite fun too lol




I also had a go at refurbing my fogs, this is how they looked before:



I got some more that were very yellow and set about taking the lenses off. I did this by heating them in the oven on a low temp for about 10 mins then prising the glass off carefully with a screwdriver. I then took all the light gubbins out and sprayed what was remaining with silver spray paint.
I used tiger seal to stick them back together. Really pleased with the results.



Sorry about the poor pics.

Inside i have also fitted a gearknob and gaiter from a later audi (A3/A4 or Cabriolet i think?) I really like this!



I have also fitted switches and blanks from the early A4/A8's which look great too (i dont have a pic yet, sorry)

This is a recent(ish) picture taken at center parcs. Here you can see i have painted the light surrounds black and have a fk automotive grill.



Not long after this some more fun began..........


I was searching around on ebay one day and spotted these wheels, i have always liked them so had to get them:



I also got a set of audi center cap stickers for them:



I decided i wanted to lower the car too. After doing a bit of research on here i got a set of springs from venom motorsport (Supersport springs). It turned out they were wrong for the car. This was not a bad thing because i found out the rear shocks had about had it too so i sent them back and upgraded to a full Supersport suspension kit.



I refurbished my fronk struts while i had them out. I used some of Halfords rubberised enamel paint so hopefully this will last a while. It went on nicely and gave a great finish:



So this is how the car stood before it went in:



And when i had finished it:



I am really pleased with the results. I was dreading the first drive in it. I thought it was going to be like driving a brick! It was ok actually, its not too bad. The wheels have the wrong size tyres on so when i get some with slightly bigger profile this will help too. Also think the suspension will bed in some more too.

I also bought a heat gun and gave the black on the bumper some treatment. I took this on friday:



This is how it stands now.

I am still working on getting the exhaust manifold to fit. I got a scrap head to work on it with and it is now welded up almost ready to fit. I have also made some custom intake bits to help squeeze it all in there. This will have to wait for another day and another update tho.

I also bought a v6 front bumper that needed some repair work doing, this is on going at the moment, im going to try di it all myself but if it goes wrong then i'll have to save some pennies to get it done properly lol 8)

Well thats it for now, hope you enjoy the updates. I'll be back soon with more i hope

[bikerjim]

26/04/10

Ok here we go just a couple of pics of the dash switches. This is quite an easy mod to do some of the switches are a direct replacement and some need the faces swapping, cant remember which tho ops: The heated rear window switch also has the nice function of switching itself off after 10 mins and also goes off when the ignition is turned off.

[bikerjim]

And todays post -

Ok been meaning to put this up for ages. Back at the end of may/ begining of june i finally fitted the tubular manifold. Unfortunately i dont have a lot of pics of the process as i was in a little rush to get it done. This was due to a planned holiday with the mrs and needing the car to be 100% right to get us to france and back lol.

I had to make alot of parts myself or modify bits to get this all to squeeze in.

First of all i needed to make a spacer to space the throttle body away from the hot manifold. I designed this using autocad then had it water jet cut at a local college near the uni i go to. Here is a pic of it being cut.





I then set too modifying the manifold to fit. I got a ******ed head to use as a jig and cut the pipes. I got a local engineer/fabricator/all round crazy guy to weld it up for me.

I knew that by adding in the throttle spacer i would need to make/find some one off bits to make it all fit together.

I got an intake set-up from a mk 2 golf and cut and shut the 2 halves of the rubber duct together to make one with a more acute angle.

I also had to cut and weld the throttle cable holder to sit the cable close enough to the TB.

Longer bolts were required an 2 TB to manifold gaskets to bolt the TB and spacer to the intake manifold.

a corrado TB was also used as this has a heat shield around it.

I have also Made an aluminium heat shield to cover it to stop any vital parts being melted. It was a shame to cover it up but it gets so hot!! :twisted:

Anyway here are some pics, sorry for the lack of detail.

Before





During















After













It was really satisfying to get this all sorted and fire the car up. I could tell the car sounded different on start up. Its not any noisier just makes a different noise, free-er breathing.

This together with the ABF cams and the matching of the ports and airbox modifications has made it a very nice drivable car.

A week later and the mrs and i set off to france in the car. It ran fantasic all the way there and back and retained a 33mpg on the motorway runs. We did 1200 miles in the 2 weeks we were away also getting to Le Mans to watch the 24hr race (which was a fantastic experiance 8) )
The day after the race was finished the public road part of the track was opened up so we went for a drive down the mulsane, managed to get my car round some barriers to take some pics on one of the chicanes -







The car is still driving fantastic and never misses a beat!!

[bikerjim]

As per another thread i started:- LINK

I am in the process of building a 1.8t to put into this car.

Im aiming for around about 250hp especially as its all going through the front wheels. Im sure alot of you will think this is a bad idea but i want a project that is a little different, and i already have a great base car.

Im also looking for economy so the little 1.8t will be good (ish ) for that too.

I have got the engine appart now and getting the internals checked over and cleaned/polished. New big ends and mains are on the shopping list and also piston rings. Im also getting the bores honed. Not sure weather to replace the rods, i hadnt planned on it as they are expensive and as i plan not going higher than 250 hp i dont think it will be an issue.

More on this to come

[Dan]

Nice write-up

Looking good

[speeding-g60]

good thing for you that you have a 4 cyl now. those motor mounts will bolt right on to the AEB block. should anyways..... external waterpump motor 058 family.

keep it up.....

[Error404]

nice little project
Are you going for K04 set-up on the engine? An upgraded front diff would help loads i'm sure

[bikerjim]

Thanks for the comments guys, appreciate it.

Yeah think im gona end up going for a K04-15 Although im not sure really. I need to look into other possibilities too.

If you guys know any better i would gladly take on-bored some advice. Im trying to keep costs down as much as pos although i want to do it right. Need to think about injectors and mapping too

[Skull]

hello bikerjim!

can you tell me how far from the manny was then the closest part of the TB?

i used a 2.3E TB, and this is how it looked.

[bikerjim]

The corrado TB i used was v close to the ex manni, but it has an incorporated heat shield. It still has the position sensor on the bottom but no damper like the original coupe one, so it want quite as close.

[Skull]

Well that position sensor is nothing special, i think, i ride normally with just the wot switch and idle switch (oldschool). i have found a way to move the damper a little away from the manny, so in the end it will be almost an inch from it. i will make a custom shield, heat wrapt the pipes, and i hope it will be ok...

[Acidburn]

Thanks for the comments guys, appreciate it.

Yeah think im gona end up going for a K04-15 Although im not sure really. I need to look into other possibilities too.

If you guys know any better i would gladly take on-bored some advice. Im trying to keep costs down as much as pos although i want to do it right. Need to think about injectors and mapping too

Since its a 4 cylinder look into evo turbo's you get some proper good one's for around £100, speak to jonny bravo about this as his mate can do manifolds or supply adapters

[bikerjim]

Since its a 4 cylinder look into evo turbo's you get some proper good one's for around £100, speak to jonny bravo about this as his mate can do manifolds or supply adapters

Ooo now that does sound interesting, i'll have to get some more info on this. I'll do a bit of research.