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LR5V

GTI Upgrades

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Treated my Gti to some new plugs & new ignition leads

Really pleased with the build quality of the leads, they are half the price of Magnecor leads, choice of 3 colours and are British made from Formula Power

Compared to the old cables they look to be twice the size, this means it is bye bye to the cable tray - shame about the rub line in the rocker cover.

e2m8BG.jpg

Got to say I am really pleased with the roadkill taught cable tie spacers 

nse7rX.jpg

Edited by LR5V

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Gearbox rebuilt.

Flywheel was 6.4kg

T6ZwFf.jpg

Refaced

ctLhB0.jpg

 

New pins and slimfast money shot:

OEeNtD.jpg

Quaife

4TYZHg.jpg

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finally, someone has the quaife.

where are you at?

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Interested to see how you get on with the quaife. 

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Rich - Actually I'm up the coast from you in Edinburgh, but the Lupo was from your neck of the woods

cj1 - Yes I am eager to see the difference it makes to the handling.

But this will be delayed my control arm bushes need replacing, so no point just swapping the box, it will have to wait to be done with rebuilt hubs, rebuilt control arms & rebuilt drive shafts.

Oh and my radiator weeps, rather than fitting another massive VR6 rad I am going to fit a smaller alloy rad and in the liberated space fit an oil cooler -plus shed some weight with AC delete

Question - Does the Lupo front end come off in one lump - i.e. lights / bumper / slam panel all together - like on Golfs??

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yeah, bumper off and it explains itself.

arch liners first.

hub rebuilds are fun.

 

 

NewImage_600_1066_90(2).jpg

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nice to see someone doing something interesting... :)

how are you setting the bearing preload on the quaif? do you use the same crown gear and what are the complications? do you need to shim it or is it in exactly the same position as stock for the crown gear mounting flange? more pics please!

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On 04/05/2018 at 3:35 AM, mk2 said:

how are you setting the bearing preload on the quaif? do you use the same crown gear and what are the complications? do you need to shim it or is it in exactly the same position as stock for the crown gear mounting flange? more pics please!

Thanks for the replies

When it comes to gearbox's I wouldn't trust myself with anything more taxing than a clutch change!

I sent it off to a VW gearbox specialist, unfortunately he is all the way down in South Wales.

He is well known in the VW community, does dog boxes, sequential all sorts. I believe he does so many diffs he must get discount, for mine he beat Awesome & Darkside price wise by a good margin. 

he actually mills off the crown wheel rivets of the existing diff and bolts it onto the Quaife. I am getting my old diff back.

He did an over the phone un-boxing, he has not done one of these before, made some interesting noises and said it was good that they provided the shim.

Bolts are genuine VW Verbus 12.9 - I asked for ARP, but suspect they would have been over kill

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On 04/05/2018 at 1:29 AM, Rich said:

yeah, bumper off and it explains itself.

arch liners first.

hub rebuilds are fun.

 

 

NewImage_600_1066_90(2).jpg

But the bumper stays on the golfs! - Thanks I will do it your way when the day comes.

Yeah - I have a bad habit of getting a pairs of used hubs to rebuild ready for the day they get swapped out, I have in my collection M3 Mk & some LCR hubs to go onto my Mk4

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i have an SDI box to collect at some point (which needs some welding). i'm going to pull out one of my worn boxes and swap over, then get the removed one rebuilt- with a camera present.... i can't wait. it'll be the ultimate how to! no point having a quaif though.

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the golf 4 bumper has to come off tp get access to the bolts underneath.

the golf 3 front comes off with the bumper on.

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Nice thread! I like the dbilas intake manifold, I want one for my 1.6 bby build but they are really expensive. Do you know if there are any other alternatives out there? What throttle body are you using? 

Thanks

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Hi Nacho  - The manifold was on the Lupo when I got it - yes those dbilas manifolds are very expensive. the previous owner said that it wasnt built that well & he had to do a lot of work tidying it internally + port match.  He even had the dbilas remote air filter - this kept blocking so he  swapped it for the cone. For the price you are a few hundred away from bike throttle bodies, a manifold  & stand alone management. I have not looked, but I assume it is just the standard throttle body, but with all those bends removed. its still on remapped OEM ECU

Gearbox is back, unfortunately the speed sensor was destroyed on the trip down, so need to get another - cant seem to find a part number online -I am hoping these may be easy to find in a scrap yard?

This where some of the weight was lost in the fly wheel:

nlZoTE.jpg

Hard to see, but the pressure plate ihas also been ablenced to the fylwheel:

om37Nx.jpg

Quaife stuff & my old diff back:

zm0MDk.jpg

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lots of shopping & stuff back from powder coating

pM5FkM.jpg

And the polybush haters can look away right now...

JrhzbF.jpg

 

 

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Thanks Guys

Huibs rebuilt:

aiLjxp.jpg

szeV4k.jpg

The slightly rusty drive flange was replaced only a few months before they broke the lupo up. Threadlocked stainless bolts hopefully wont weld themselves into the hub

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I put stainless bolts where my dust guards once went on the hubs and the abs sensors.

good choice although i didn't go for hex bolts. 

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Cheers Rich

 

Got to cleaning the box - wasnt happy with investing so much for it to be crusty.

Took 5 hours to go from:

6viRWr.jpg

CH5UfM.jpg

 

To:

xvLmAk.jpg

VvqkFM.jpg

I used Alubreight to clean off the oxidisation and Jet Laq paintless lacquer finish - it dries to a satin finish, above was it just applied 

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Finally got some time to work on the Lupo, I hope it wont be in this state for too long

8Yqsgj.jpg

 

Rear beam out - I did'nt try keeping it attached to the brake pipes as had resigned my self to re-building the beam. 

PI6ro4.jpg

Surprised to see the built in ARB is hollow, every other one I have seen is solid - is this part of the factory weight saving?

RH rubber was peeling off the alloy inner of the bush, probably caused by the spring seat on that side having wound itself down lower:

GuwLr2.jpg

No idea where to get replacement ARB U-bolts, just hope its an off -the shelf size

The adjusters look very crusty, not looked at them.

ABS sensor just were not coming out - had to use a press to get them out - are they usually that bad?

Still have to get the bushes out of the beam, currently using drill, hacksaw, pad saw and hammer.

Found something weird with the rear calipers - they are pretty much brand new, but for some reason the PO decided to attack the mint powder coating to grind off something and then did a crappy job painting:

GnKPSe.jpg

Any thoughts? wondering if it was a Seat logo - the area is square or could they be non VAG?

This is the only PN I can find on the RH caliper

7sV7B7.jpg

 

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Poor AC system.

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I just took my bumper off to change mine.

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On 8/24/2018 at 9:05 PM, LR5V said:

 

Found something weird with the rear calipers - they are pretty much brand new, but for some reason the PO decided to attack the mint powder coating to grind off something and then did a crappy job painting:

GnKPSe.jpg

Any thoughts? wondering if it was a Seat logo - the area is square or could they be non VAG?

This is the only PN I can find on the RH caliper

 

 

I bought new calipers all round a couple of years back and they were exactly the same.

the guy I use for servicing is a VW Master Tech and when he compared them said they are identical to the old.

i was thinking the same as you, SEAT, Skoda, or another manufacturer’s branding.

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