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adzer's mk1 leon 4wd conversion


Adzer
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thought i would share my other project i have at the moment along with the lupo, there is a heap of pics etc i'll copy and paste from another forum so if you could kindly not reply to this thread untill i get it all copied id be greatful thanks

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thought id post up a quick post about my leon, wont be anything too compex tho

i bought the leon about 3 months ago now, traveled down to birmingham to look at a yellow one, turned out it was totally rafted so i had a look at a few others on the way home, ended up buying a black leon cupra r from carlisle.

when i went to look at the car the guy had cleaned it and she was gleaming inside and out, had a few mods but was mainly left unmolested. had a book full of paper work and service history, was serviced every 1000 miles by the previous owner and had a new clutch and flywheel the year before.

only mods it had was a front mounted intercooler and an induction kit.

got the car at what i thought was a good price so ended up buying it.............and this is where it all went wrong lol

me and seats dont get on i should never of bought another but couldnt resist the power.

anyway got it home and everything was fine for a month or so, bought a liquid guage for it £200, fitted some hids, wrapped the chrome grill and badge black

few days later turbo was making a weird noise then bang no power and oil everywhere??? turbo shaft snapped and split the turbo pipe.

so £600 later for a turbo and luckily i had an uprated tip it was back on the road.

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the gearbox had a whine since the day i bought it and its a common problem but it drove fine so i just dealt with it but a week after i fitted the turbo the gearbox started to feel tight and struggled to get first gear so i ordered a second hand box £380!!

after spending all that i decided id be aswell keep the car so went and ordered a full turbo back decat miltek system £745 (what an absolute **** to fit)

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painted the wheels white this week and ordered a 3" turbo intake pipe, jetex air filter and heat sheild and forge 007p dump valve £350

once thats all on its ready to get a stage 2 remap then some coilovers to drop it.

ill get some pics up with the white wheels soon

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last of the toys before the remap rolleyes.gif

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picture of the tip, heat sheild, jetex filter and forge 007p fitted, now just to clean up the engine bay which ill attept tonight

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some more new parts for the leon and i have a rolling road session this sat to see if she runs ok before i remap

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ill never polish up anything again, its took me a week to get it to this standards and still aint perfect

mehhh this cars pissing me off!!

last night i set about fitting timing belt kit and new water pump, whilst doing that i thot id change my inlet mani and rocker cover.

upon removing the inlet i found 2 split breather pipes, seat want £33 each for a 3 inch bit of pipe, and plastic pipe was also cracked £25!!!

also set about removing the air con system and carbon canister and reroute a water pipe out of site instead of running along top of the rocker cover.

polished up the throttle body to match the inlet, will get some pics up soon

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safe to see this project has came to an end

from this

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to this

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once i removed all the bolt on sections the damage to chassis isnt that bad, think im lucky i kinda tried to steer around richie otherwise my radiator, intercooler and whole front end of engine would of been smashed.

if only there wasnt a focus coming towards us i could of swerved around both of the cars in my way and none of this would happen

well i made a bit of progress today after getting my hands on a mig welder, hopefully ill get a new front section tomorrow and be able the get the engine bay put back together so the engine can run which will just leave body panels.

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Well after getting the car fixed and ordered a new bumper my bottom

End has decided it's had enough at 108k :-(

So looks like im now into a new engine build. Gonna go down similar route as Cammy with forged rods as when I get it stage 2'd I will not need to cap the boost incase I bend rods :-) might look into a hybrid turbo too ;-)

Well that's me ordered all parts needed to rebuild the entire engine. Hopefully get most of the parts tomorrow. Will take some pics of the progress of the engine build.

Well she lives again after a full engine rebuild.

On first start up it was running rough and sounded bad. Turned out the crank sensor wasn't connected properly coz I broke the conector once I plugged it in properly she idles sweet as a nut. So I'll fit a new sensor then get bumper back on :-D

well thot id post a couple more pics of my car while i was repairing the crash damage and engine rebuild nowt exciting

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had a bit of progress today..........took my car to my mates work after hours to paint my wing............ended up doing a bit more than his boss thinks lol

prep up the panels before paint

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stealth is everything ;)

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well seeing as the judge had BUM GRAPES! i think its time to up my game.

4wd conversion, full roll cage, bigger turbo and MORE POWER

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Edited by Adzer
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Right guys really toying with idea of 4wd conversion but is it really worth It :-s

Right time for an update, your all gonna think I'm a crazy lovely person!!

Bought myself a 1.8t quattro a3, daryl1205 gave me and my mate a lift to pick it up from Kinross (cheers Daryl)

Car is remapped and had a few extras like induction, dump valve, boost gauge and 18" alloys. Guys original price was £1350 and I managed to drive it away for £600 which I think was a steal fir a running 1.8t, anyway this is where this whole thread gets interesting.......

Car as I bought it

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Started stripping interior to chop floor out....

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Rear setup....

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Rear diff setup removed....

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Petrol tank removed.....

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Next update will be removing the rear floor pan

I must be a crazy lovely person :-s

Watch this space :P

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Small update got home from work and removed the front seats and sold them to Jay for his polo so thats a boost, once Jay had gone I Thot I'd start on the removal of the rear floor, drilling out

150+ spot welds is a right pita!!

Think this conversion Is alot more complex than first Thot but I shall see

This thru.

Here's some pics of today's progress

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Hopefully have the floor removed

Tomorrow just get around the

Seat base to drill out now

Well that's another night spent on the Audi, managed to get it out eventually after burning out my grinder and a helping hand from John Webster. Must admit now I've removed the floor from the a3 I'm having second thoughts :-s

Anyway here is some pics of tonights progress

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Well that's another night spent prep'in the floor pan not really much to show for 7 hours worth of work. All I need to do now is chop the side rails but I won't do that until I've removed the floor from the Leon so I can measure where to cut them so I can make sure they will butt together so I can weld it to mate the a3 rail to Thr Leon rail.

Anyway here's some pics of the floor pan

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Well guys this is where **** gets Nasty :-s

Audi went to scrap yard today freeing up some much needed space to start on the Leon, so first things first was moving the BMW out into the street and placing the Leon in it's final resting place for the next feck knows how long.

Take one last look guys coz you might never see it again lol

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Well as I've got a bad case of ants in my pants I couldn't help myself and go start the Leon.

First step was to strip out the interior

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After Removing all The trims I have noticed a big difference in the rear wheel tubs as to how the rear seats bolt in. I'm still undecided if I want to go down the stripped out route or refit all my interior and keep it practical for my wee boy and just make it a fast road car.

At this point I actually stepped back and asked myself if it's actually worth the hassle.

Anyway I decided to start removing the

Brackets for the rear seats incase I need to weld them in

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Then thot I'd slam the front coilovers

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Only joking just jacked up the rear ready to strip the underside of its running gear

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Then set about removing the rear axle

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Next up was removing the old petrol tank which is tiny compared to the one I need to fit

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Next up was removing the rear bumper

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Then finally remove the crash bar

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Say hello to my new toy!!

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Cheers for comments guys, spent another 4 hours on the car tonight and

Managed to get 90% of the floor removed so tomorrow all I need

To do is clean up all the joins ready to weld and meassure up the side rails and chop them to mate with the new floor.

Not much in the way of pics today

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Was hoping to offer up the floor pan today and maybe tack weld it in! No chance with this rain :(

Well didn't get much done due to weather but the shell is now all cut and ready for new floor, just need to chop the side rails on the new floor to butt with the shells side rails.

So if this rain fecks off tomorrow I should have my floor mounted and tacked welded into place

Pic of my friend helping me carry the new floor from the shed to my car ready to be offered up tomorrow

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Well got a fair bit done tonight, managed to offer the floor up and get it into place, them just tack welded four corners into place, before I weld it fully

Into place I'll refit the rear diff setup and make sure everything lines up

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Didn't get much done on the car

This weekend due to having the

Wee man and having a night out on Saturday, but managed to mount the rear diff and Hubs to measure that the floors sitting straight before I fully weld it into place, got everything sitting pretty much bang on so I was happy enuf welding up the floor at that, started welding the side rails and seam welded passenger rear arch, well chuffed with my welds too, don't think they could get any better

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Hopefully I'll have the floor welded by the end of tonight

Small update, finally got The floor fully welded in, welded seat mounts in, fabricated a rear panel, painted in inside and undersealed the entire underside.

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I then got the rear crash bar bolted back on followed by the rear bumper

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Rear end off the a3 was looking scabby so Jordk offered to bead blast the parts and give them a lick of paint at his work, then two days later my mate tells me his boss is away on holiday and says he can powdercoat all my parts cheap,since I have 2 rear ends I decided I'd just get them both done, so here is a before and after of the parts he has done so far

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Some pics of the goodies for the rear end

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Before I could proceed any further with

The chassis I had to make up front to rear brake pipes which I couldn't be assed doing coz 1- the rain didn't **** off and didn't wanna lie in the wet and 2- I had no idea how long they had to be at the rear until I get the trailing arms back on so I just flared one end of

The pipe and shaped the pipes to the rear so I could refit the petrol tank. Once The trailing arms are

Fitted I'll cut the pipe shorter and flare them on the car.

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Now that the pipes was done I could start rebuilding the car. So cracked on with the petrol tank

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This is pretty much the stage I am at right now, ordered my standalone diff controller last night from Germany £800!!!!!!! Last of the chassis parts will get powdercoated tomorrow hopefully and I've ordered new bushes and clips that I had to strip off the rear subframe to get powder coated which will also be Here tomorrow another £200!!!!!

Once I get all these bushes from seat tomorrow that's me pretty much ready to mount the diff onto the car :-D

All parts now powdercoated and cleaned

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Some more parts

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Well 2 parts I ordered was wrong and two bushes was on back order so these was holding me up...........but the nice manny from seat came today and delivered them

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So all I need to do now Is press the bushes in, fit the disc shields, press the hubs into the bearings on the trailing arms and start building woop woop.

Might be on it's wheels this weekend if I push

Built up the trailing arms today and pressed the last of the bushes in, cars officially ready to bolt back together, just awaiting on Wallace performance to make up some nice hel brake hoses and await the arrival of my diff controller from Germany

Small update, started bolting the running gear back on today, managed to get the rear Diff and cradle on, then the 4 control arms and rear shocks.

Just need to get the trailing arms on now

Some pics

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Well progress has been slow lately.

Got the trailing arms on ready, then got the rear anti roll bar fitted too

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I then started to get the rear brakes back onto the trailing arms and have ran into a snag! The caliper carriers are different from my Leon! Callipers are same as the s3 but carriers on a 4wd are different so again im waiting on parts to arrive!!!

Picked my brakes hoses up from Wallace today, but the ends are slightly bigger so I'll need to bore out the hole in the mounts for them to slide thru.

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I also ordered a lightened flywheel and fast road clutch for when I come to swap over the gearboxes

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Some more progress made, finally managed to get the rear brake hoses to fit and flared the pipes to suit

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I also got the last of the welding done and welded in the mounts for the propshaft and got the rear half of the prop mounted ready for the gearbox to be fitted

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The rear arch liners off the Leon no longer fit so I had to use the ones from the a3 but they was slightly different as the Leon bumper sits wider so I had to chop up the Leon arch liner and do I bit of plastic welding to make 2 liners into one around the rear bumper. Nowt fancy buy it's functional

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I also got the skirts back on today but are a bit scuffed up from storage grrrrrr

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Well after spending most of today on my arse staring at the rain I Thot I better go out and press on with the Leon regardless

Because I'm stuck waiting for parts for the rear end ive had to start work on the front end, first off I had to hack off my locking wheel nuts coz I Lost The key :-/

Anyway to fit the new gearbox with transfer box I Thot it would be easier if I removed the subframe and polybush everything at The same time.

Anyway subframe off

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Old gearbox out

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Boxless bay

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Well progress Is flying now that I'm onto the mechanical side of the build

Removed the old clutch and flywheel then fitted the lightened flywheel and fast road clutch

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Gearbox looking pretty and ready to go

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Well about an hour later I got the box in place and bolted up

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Well as I refused to pay the price seat wanted for rear brake pipe/hose Assy and no companys seem to make them either I decided to ask if Wallace could custom make the hose with a normal female end so I could make up the pipe myself and screw it into the hose, where as the originals are a complete unit where the hose and pipe cannot be separated.

Whilst doing my clutch I noticed the feed pipe also has a rubber hose so I Thot **** it and dropped the original off at Wallace this morning and they made the 3 hoses for me.

Just back from picking them up so I'm away to make up the pipe to complete The rear brake lines whilst the suns out

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Simple and easy, fitted the clutch hose and made up rear pipes and fitted to the hoses, just need to wait for my new carriers and the rear end is finished woop woop

New rear pipes getting made

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Nowt worse than getting rudely awakened on a saturday morning! Unless of course it's the postman with presents

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Bit more progress tonight, I thot I'd start installing the diff controller, plan was to wire it all up behind the stereo as thats where all the wire seem to be, plus I need to make a surround to hold the screen and the control switch, seeing as the wires between the module and the screen aint long I've decided to do away with my middle air vent and house everything behind it. Some pics of my progress.........

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Finally it comes to life

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Ah ha the final piece of the jigsaw to finish up the rear end

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Even better........more goodies arrived today

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Well got the new carriers painted And went to fit the brakes to the rear, driver side went on no problem

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But for some reason the passenger side carrier fouls the disc :-/

I have a feeling that the bearing isn't pressed in 100% which is making the hub/disc sit just out of place

Well finally managed to get the passenger rear caliper bolted on, turns out the fixing points on the trailing arm was slightly bent pullin the carrier too close to the disc, quick blow with a hammer and a hand from John (astrasxi) soon sorted it out, cheers John ;-)

As I was feeling a bit better yesterday I thought I should try get some progress made

So I jet washed and stripped the front subframe and suspension arms ready to Be painted and poly bushed.

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Very good progress tonight, managed to

Get the Audi tt downpipe fitted so I can run a temp exhaust that won't hit the propshaft until I decide if I'm going big turbo or not.

Once downpipe was on I could finally get the front part of the prop shaft fitted, I had to fit both downpipe and prop before I could get the subframe back on.

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Once that was done I had to fit my lower engine mount and arb back onto the subframe

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Then I set about Bolting it back onto the car and bolt steering rack back onto the subframe

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Then I fitted the wishbones and fitted the drop links

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It's alive and launches well!! My old mother wasn't too pleased about the noise it was making

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Starting to look like a car again

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Well as im still undecided what turbo I'm going for I am still unsure what downpipe I'll be running so ive just mocked up a **** exhaust so the car can be run until such times the turbo gets swapped. As I didn't have an exhaust to fit straight on I butchered the old system of the a3

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Anyone wanna buy a cupra?

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its kinda complicated, i took the car 300-400 yards from my house to my garage to drop off all the tools and test the brakes, when i was pullin out the garages i could see her coming down so i stopped but my nose was sticking out and she just wasnt looking at the road and i knew she was gonna hit me.

next thing i know my bumpers all over the road!

Well Chaps it's been a while since an update, not really had much time to touch it in the last 3 weeks as have been flat out doing homers from lowering numerous cars to doing a clutch on an rs4 :-D

Any way I had to fabricate my centre vent to house my diff controller and am very pleased with the end result, every one that's seen it thinks I cheated and bought this vent until I flip it round and they see the rear ;-) pics will do the talking lol

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The diff controller switch looks **** and I plan to make it look better and less out of place.

And if anyone is wondering why I've placed the switch to one side, all will become clear in due course when the second part of the project starts ;-)

Small update old turbo set up has been removed

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Well progress has been slow, ain't touched the car for weeks, just been gathering a few parts so I can blitz the next part of the project.

While doing the new turbo I plan to rip out as much shiz as possible to clean up the look of the engine bay, so I'll be removing most of the pcv system as half the hoses are split anyway and replace it with a simple catch can system, Also got an uprated inline fuel pump and exhaust pieces to build my own downpipe

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also eventually bought a headlight lol

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Well project can start moving again..........

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Well I finally decided to start pulling my finger out and start doing odd jobs on the car while I wait for parts to arrive.

Last week I finally got round to fitting the exhaust heat shields that will separate the prop from the exhaust.

Finally fitted the new headlight after that **** smashed into my car

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And latey I've just been buying in parts really, bought myself a cylinder head off an early 1.8t which has larger ports on the inlet side of the head which will help flow air quicker.

Only problem with a large port head Is my inlet manifold is designed for small port heads which means I'd need a new inlet but all large port inlets the throttle body sits on the left where as my engine it sits on the right............so more money wasted on a sem high flow inlet manifold which suits large port heads and houses the tb on the right ;-)

Whilst ordering the manifold I got a deal from the company and got a larger tb at the same time so I'll now be running a 75mm tb.

With all this I thought I'd be as well get the head worked on, so it's going to be sent away to get ported and polished next week hopefully once I receive my inlet as they are going to port match the 2 manifolds to the heads.

Once all this was running threw my head I then somehow got it into my head I needed updated cams and decided to go fork out for some catcams lol.

Once all these parts arrive, hopefully next week I shall get some pics up ;-)

Well it's only took about 3-4 weeks but it's here

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Well it's sat night I have the wee man and x factor ain't started yet! So I'll update this thread lol

Well my manifold eventually came along with the throttle body

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And seeing as I've bought a few grand worth of goods from this guy he said he threw a surprise into the box..........

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A number plate surround for an American plate???? Nae much use to me pal but I may use It somehow

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