Project: 2001 1.8T Golf IV

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Rabbit Farmer
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Project: 2001 1.8T Golf IV

Post by Rabbit Farmer » Fri Jun 15, 2007 1:19 pm

I still have a bit to do to make it perfect. Engine build-up coming within the next 8 months to give me full boost on the turbo.

Here it is from the beginning to get everything caught up to the present....

Steve

Here is where the car started...
(I Spy... Black Rabbit in background with '702' in the window... last time we had ice time trials, I guess)

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Summer 2006:

Safety
FIA Cage (Done)
FIA Seats (Done)
5-point harnesses (Done)
2.5 LB A-B-C fire Ext. (Done)

Suspension
Bilstein Sport shocks/struts (Done)
Shine Racing coilovers and camber plates (Done)
Shine Racing anti-roll car (Done)

Tires/Rims/Brakes
EBC Yellow brake pads all around & new rotors (Done, thanks for Fast Addiciton)
Waiting for my Mintex pads to arrive.
17x8" rims (Done)
Toyo RA1s (Done)

Plans over winter 2006-2007:

Engine
Turbo GT2871
Performance intake manifold
3" downpipe and side exit exhaust
034EFI Stand-Alone Engine Management
APR fuel pump
57 lb injectors at 3 bar
Adjustable Fuel Pressure Regulator (FPR)
Cooler spark plugs
Might change oil pan (add baffles and trapdoors)
Fuel injectors
Cam shafts
FMIC
Sprayer for coolant radiator since FMIC will block some of its air flow.
Oil pan (trapdoors/baffle)

Transmission/Clutch
Lightened flywheel and performance clutch.
LSD

Body
No plans other than some minor body work.
Last edited by Rabbit Farmer on Fri Jun 15, 2007 1:46 pm, edited 2 times in total.
Steve #702
Go Fast VW & Audi parts at FastAddiction.com
It takes hundreds of nuts to hold a car together, but it takes only one of them to scatter it all over the highway. - Evan Esar

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Post by Rabbit Farmer » Fri Jun 15, 2007 1:20 pm

1st of two coats. All painted with a brush. (friend Nick helped tonight)


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Buring the midnight oil....

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A little progress this weekend.

(1) Determined solution for sunroof hole. Going to Rathe's on Friday to cut some sheet metal from a Golf/Jetta III. This is just a temp. solution to plug the hole until much later when the body will be the concern. For now... getting it on the track/hill and going fast will be my priority. Won't look pretty for a while. :oops:

(2) Wiring: Just have to weld a tab in for the fuse box and then plug everything together that is on/around the steering wheel. Everything else is hooked up.

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(3) Plug the air vents in the dash where the dash was cut for the cage and then installed the vents a little further up-stream. :D

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(4) Did some cutting of the dash and glovebox to make it fit. Still a work in progress.

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(5) "Fixed" front bumper (essentially it looks like Frankenstein) and test fit bumper and fenders. Ordered part that was broken on fender (goes between fender and bumper). After the part comes in the front end body work will be done.
Steve #702
Go Fast VW & Audi parts at FastAddiction.com
It takes hundreds of nuts to hold a car together, but it takes only one of them to scatter it all over the highway. - Evan Esar

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Post by Rabbit Farmer » Fri Jun 15, 2007 1:20 pm

Another busy night.... finished a bit earlier than I had been this week.. midnight. :oops:

(1) Spoke with Pete down at VW to attempt to order little plastic tube that goes into the vacuum in the front right fender well... not really sure what it does, but it sucks air when the car is running so it must be really important. Anyway, Pete said that the little tube I need does not come separately and that I would have to purchase the entire tube for $50. :shock:

Here is the vacuum blue-ball thingy with the broken (half of broken tube is still in the flexible tubing) black connecting tube.

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At lunch I decided to figure out what alternatives I had and came up with a brake line (the flared ends were a perfect fit)

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Did a little cutting and sanding...

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And done!

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I did put tape between on the brake line so it could not slide inside of the blue-ball thingy (the lines are secure and shouldn't move around, but I still didn't want to take chances).

(2) Next, working with Eli at Shine Racing Services (www.srsvw.com) we are trying to determine the best suspension setup (done) and to see if camber plates will work on the strut towers with the cage there. Eli faxed an outline of the camber plate to test fit it on the car. Not looking good.

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(3) Finished the dash with the exception of the trim at the driver's feet and steering wheel. Waiting on those until my brother Andy welds on a tab for the fuse box that is normally located at the end of the dash.

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I cut off the back of the center section to make it easier to change/inspect the e-brake lines in the future. I don't want to have to remove interior trim.

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(4) Trimmed the door panel (just one thus far) to fit around the cage. Not perfect (need to slam door) so I will have to tweak a little more. I might use alum. sheet at a later date, but this is what I have for now.

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(5) Starting to look like a car. Fenders mounted, bumper mounted, broken grill mounted. All panels are a little bumpy, but body work comes later after the performance step has been completed. :twisted:

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Steve #702
Go Fast VW & Audi parts at FastAddiction.com
It takes hundreds of nuts to hold a car together, but it takes only one of them to scatter it all over the highway. - Evan Esar

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Post by Rabbit Farmer » Fri Jun 15, 2007 1:22 pm

Andy (my brother) came over today so we could get to work on the roof and fuse box. HE can fabricate.... I can't even come close. If it doesn't involve cardboard, a couple of nails, pop rivets, zip ties or duct tape, then I'm lost.

Anyway, headed to Rathe's to cut off the roof of a MKIII Jetta. Thanks to Chris (vtGTI) for the loan of the cordless sawsall.

Short and quick.

Put the new roof on top of the old roof, traced the sunroof hole....
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Andy (love his shirt!) grinds off the paint to prepare the surface for welding.

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Cut out and grind edges to match new roof to old hole.

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Weld in new roof (including one brace from the original roof). Didn't come our perfect (a bit of warping).


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Grinding down the welds....

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Later... filling the holes and painting the roof.

Welded in bracket for fuse box.

It is coming together.... slowly.
Steve #702
Go Fast VW & Audi parts at FastAddiction.com
It takes hundreds of nuts to hold a car together, but it takes only one of them to scatter it all over the highway. - Evan Esar

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Post by Rabbit Farmer » Fri Jun 15, 2007 1:22 pm

Spent all day on the car and didn't seem to accomplish everything I wanted.

Cut off the top of the glove box so that it could be accessed from above by going through the airbag opening on the passenger side. The glovebox won't open because of the cage, so I figured out a way to access the box another way. Of course, I suppose I could convert the airbag hole to the euro box and call it a day, but that purchase doesn't make the car go faster or handle better.

Anyway, Did another door today. Reinstalled window and interior door trim... cut the heck out of it to fit around the cage. I will take a picture of it with the door open so you can see all the cutting that was needed. My goal was to make it look complete when the door was closed.

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First coat on the roof.

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Some misc. shots (new wheels are on)... needs to be washed very badly:

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Since the first event for the Golf is coming up very quickly, I took today off to work on the car.

A present arrived today.....

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Steve #702
Go Fast VW & Audi parts at FastAddiction.com
It takes hundreds of nuts to hold a car together, but it takes only one of them to scatter it all over the highway. - Evan Esar

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Post by Rabbit Farmer » Fri Jun 15, 2007 1:23 pm

Well, I took enough pictures of the whole process and will make my own tutorial for the VermontRacing site.

Rear shocks/springs are in. Ride height was reduced by only 1/2", but I can lower it 1" more. We will see how the front comes out. It is all about performance.

Here is the reason I couldn't figure out the rear... I had to remove the retaining clip and plastic washer, install the perch, and reinstall the washer/clip. I had to purchase a new retaining clip spreading tool (whatever it is called) since the one I had spent more time going sideways instead of spreading the clip. (junk!)

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Installed....

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Smoothed the roof out some more.... there are a lot of wrinkles.

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Life on "the farm"... too many projects, not enough time!

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Took Sunday off because I worked on car from 9am (Sat) until 2am (Sun).

Had a real fight with trying to get the camber plates aligned. For now, they are held in with 4 grade 8 bolts per side until we can get it on an alignment rack to check the caster. I'm not worried about camber since the plates are adjustable, but caster is not adjustable once welded in. We will weld both the top of the plate and underneath to make sure it stays together.

Did the finally smoothing of the roof and plan to try the paint method posted by Rob (Elmer Fudd) since it is just white and the roof. Bret at Rally Grafix will take care of the graphics for the roof. :wink:

Anyway, Nick and Tim came over and helped with the drilling of the 4 1/4" holes to remove the original strut towers. The drill was so powerful that it took Nick for a ride a couple of times when it caught. :shock:

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Hole in the strut tower.

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Camber plate installed....

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What it looks like underneath....

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It is kinda of strange taking a cutting wheel to a new strut

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Installed.

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I am still working on sourcing the brake rotors, but put it together for now (the brakes are easy on this car!) so it is mobile.

Short and sweet. I'm really looking forward to getting this on the road.

Dealer is coming over on Monday night to determine the actual value of the car for registration. NADA lists this car at $9700.... yeah right. Was that before or after it landed on its roof?
Steve #702
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It takes hundreds of nuts to hold a car together, but it takes only one of them to scatter it all over the highway. - Evan Esar

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Post by Rabbit Farmer » Fri Jun 15, 2007 1:23 pm

A big thanks to Casey for coming over tonight with a rear brake tool to reset the rear caliper, help put the car together, and get it down to the shop (and me back). Plus, he didn't show up empty handed. :)

Pictures as promised.

Chris scuffing roof to prep for paint.
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Me painting the first coat.
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Roof when done.
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Present arrive from Fast Addiction!
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Rears before...
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Rears after...
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Fronts before...
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Front after...
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Seats are in. Harnesses are partially in right now.
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Camber plates installed...
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Thanks to Bret at RallyGrafix.com
(covering over a really bend roof)
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(end 2006)
Steve #702
Go Fast VW & Audi parts at FastAddiction.com
It takes hundreds of nuts to hold a car together, but it takes only one of them to scatter it all over the highway. - Evan Esar

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Post by Rabbit Farmer » Fri Jun 15, 2007 1:24 pm

And now you are all caught up. Welcome to 2007.....

Tranny is out. What a pain. The actual removal of the transmission was easy. Big bolts on the axles, easy motor mounts, lots of big bolts all around the tranny (instead of those 10mm head bolts from the Rabbit that hold the sheet metal cover to the transmission to keep water out... and that little piece in the back/behind the passenger side tranny flange), easy to remove parts underneath, and it just slides out soooo nice. The pain was the hours we had to spend on the top of the engine trying to figure out how to remove all the crap.

Transmission goes to Fast Addiction tonight (11pm) to start its journey towards enlightenment (e.g. LSD).

The issue I did have with the removal is the bolt that holds the back of the dog bone to the subframe snapped off (I just barely started to turn it with very little force). The bolt looked more like chalk instead of metal. And, in my efforts to remove the dog bone (the bolt broke off leaving a stud still in the hole) it looks like I broke the back of the dog bone. So, I will need to get a new one. Doh!

This week: front bumper off, exhaust off, DP off, exhaust mani off, clutch/flywheel off, SMIC off, power window control in. That should do it. Then start ordering parts.

Still looking for a hood and front bumper. I believe I have a lead in NH for the front bumper, but local would be better.

No pictures... figured you know what it looks like to remove a transmission. I have to say that I do not like the Bentley for the MKIV. Funny part of the removal, there was one like that stated (in a nut shell) to go to the electrical section for removal instructions for the starter. Okay, looked at the section on how to remove the starter... zipped to the step near the end since all the previous steps were completed until I realized the ONLY step that I needed to follow in the starter removal process was to remove the lower bolt on the starter. Um, they could have told me that in the transmission removal section.

ohn at FastAddiction.com has the transmission and is installing the Peloquin LSD. Want a go fast modification? This is a great thing to get!

I recent purchased a MINT front bumper from a fellow Vortexer (I had to drive to the intersection of 89 and 93 to pick it up... and then on my way home stop by at FA to get some parts).

Here are the 'some parts'

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I am still lost on what I should run for for electronics. I have an e-mail out to Unichip. APR is a no go. Revo is a no go. I can't find a product that will run a big turbo (short of engine management).

I finally got to dig into the engine today to swap out the plastic water pump with a metal one. Doh.. it already had a metal impeller. Such is life. I guess I needed the practice. 2.5 hours start to finish. :) It did make it easier with the fact that the transmission was out of the car so I could hang the engine more in the middle of the engine bay giving me more room to work.

Progress continues.....
Steve #702
Go Fast VW & Audi parts at FastAddiction.com
It takes hundreds of nuts to hold a car together, but it takes only one of them to scatter it all over the highway. - Evan Esar

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Post by Rabbit Farmer » Fri Jun 15, 2007 1:24 pm

Car still isn't faster, but I now have all the body parts I need and the transmission is back in. I wanted to drive it around a little tonight to make sure everything was good (plus I'm supposed to put 450 miles on the clutch before any hard launches... I don't drive that much in a year with that car... LOL). But, since I didn't completely bolt the DP to the turbo it was loud as hell. Don't worry, it is just hooked up for moving the car around (get on the trailer, etc.) and the ol' foot won't punch the throttle creating a lot more boost that it can handle.

Anyway.... a little progress.

Thanks to John at FastAddiction.com, I now have my new flywheel, clutch, and pressure plate (I installed this on Saturday) and the transmission back with a nice toy installed inside. I also purchased a set of Driveshaft axles (good for 400 HP). The MK4 axles are soooo much easier than an MK1.

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Clutch installed..... (bolts not tightened yet)

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Something to keep me warm when the heater ran out of gas.... a little bit of apple infused vodka thanks to a friend.
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The stock axle vs. the driveshaft axles.
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Spent most of my time researching the internet for ways to make the car faster. Thanks to John at FA, he was able to give me some direction since I am new to the whole leaf blower mounted on an engine thing.
Steve #702
Go Fast VW & Audi parts at FastAddiction.com
It takes hundreds of nuts to hold a car together, but it takes only one of them to scatter it all over the highway. - Evan Esar

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Post by Rabbit Farmer » Fri Jun 15, 2007 1:25 pm

Spent the last few weeks making it look pretty. Waiting for go-fast parts to arrive.

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Steve #702
Go Fast VW & Audi parts at FastAddiction.com
It takes hundreds of nuts to hold a car together, but it takes only one of them to scatter it all over the highway. - Evan Esar

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