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baker1983

The 1.8t build has begun aaarrrggghhh

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Hi all, starting a new thread with pics.

A word of warning if anyone is going to attempt this build make sure your either a qualified mechanic,skilled welder,naturally blessed at practical work and most of all patient!

Basically if your going to use mk4 golf engine mounts and gearbox mounts there's alot of cutting and welding to do, I had to cut a massive chunk out of the o/s chassis leg to fit, next time I would do engine mount first as would of been easier to cut n/s chassis leg for gearbox mount.

A good tip also is put the mounts on pissed as gives you better sump clearance and once stabiliser fitted you get a better driveshaft alignment.

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Forgot to say its being rigged up with a k04 ?

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A little update massive progress

Found out this morning in a trial and error test fit to see if lupo outer cv joints fit mk4 golf driveshafts, guess what

THEY DO ?

So got cvs fitted then trial fit shafts, both way to long, take to local engineering comp and get them to cut them in half with a bandsaw, then refit and load up suspension, line up driveshafts and use jubilee clips to mark, take back to engineering comp, bandsaw again and a **** load of weld

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Modified original golf engine stabiliser to fit these brackets, not going to be any sway on this one

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Few more bits done today

Mk4 hydraulic clutch pedal assy in

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Brake pedal box modified and fitted

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All turbo related parts here now so just got to build up engine, prep engine bay and then the joyous job of sorting out the wiring ?

Edited by baker1983

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Throttle pedal now mounted

40398233-36E2-4AD8-8CC0-1658E6AF9EA6_zps40398233-36E2-4AD8-8CC0-1658E6AF9EA6_zps

Wiring loom now being attacked! What a mess and my head hurts already!

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Throttle pedal now mounted

40398233-36E2-4AD8-8CC0-1658E6AF9EA6_zps40398233-36E2-4AD8-8CC0-1658E6AF9EA6_zps

Wiring loom now being attacked! What a mess and my head hurts already!

84D09766-3322-4E31-A03C-C7FE26B079F7_zps

Throttle pedal now mounted

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Wiring loom now being attacked! What a mess and my head hurts already!

84D09766-3322-4E31-A03C-C7FE26B079F7_zps

just a quick question mate how have you mounted the pedal??

also what about the fuse box does it not get in the way??

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I just got a piece of stainless steel, chopped it about, bent it and then riveted it to the wheel arch/bulkhead and put some riv nuts in prior to fitting so I can remove pedal!

I'll worry about the fusebox at a later date

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This is looking well, Definetly gonna keep you in once get to the fitting and the mounts and engine stage hope your on here often :)

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I just got a piece of stainless steel, chopped it about, bent it and then riveted it to the wheel arch/bulkhead and put some riv nuts in prior to fitting so I can remove pedal!

I'll worry about the fusebox at a later date

ok am with you mate cos i have been chasing a polo/luopo gti pedal to fit my peadal box but that means messinmg around with the loom and plug,

just a quick one tho mate you did not need to chop into nthe chassis like you did they can be mounted with out any welding

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Use your donar car pedal and loom saves playing with even more wires!

There is noway that engine would of fitted without chopping chassis rails and using both original mk4 mounts, I want to make it look like a factory fit.

I wish I'd started cambelt side and chopped gearbox side chassis leg as wouldnt of needed so much but the way I've chopped the chassis and plated it means I can do cambelts and water pumps in place

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Use your donar car pedal and loom saves playing with even more wires!

There is noway that engine would of fitted without chopping chassis rails and using both original mk4 mounts, I want to make it look like a factory fit.

I wish I'd started cambelt side and chopped gearbox side chassis leg as wouldnt of needed so much but the way I've chopped the chassis and plated it means I can do cambelts and water pumps in place

ok mate I am with you,, not judging your build skills btw

but ive mounted mine with different mounts so I don't have to weld or chop anything,as for the acc pedal I might as well copy you and keep it simple cheers

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No that's cool!

I think it's because I'm using the stock mounts because the bracket that bolts to the engine cambelt side is really thick and curved and I wanted to make it possible to do cambelts and water pumps in place!

I've got to cut a bit more out of gearbox side so I can slide engine over little as alternator belt will foul!

I'm still in garage now trying to sort out looms!

4 late evenings now but just got it all labelled up now just need to join it all up!

I'm a long way off yet

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Lool I know the feeling mate am at the look stage now and have been there for about a year lool I don't want to pay out like £300+ for what is not worth that sort of money in my eyes.

But yh am with you about how you have built your bay I don't mind taking the engine oh to do my belt and so on as I do it on my drive way in a hour so not fussed lool, but this weekend am going to work on that pedal as it's been pissing me off and I don't want to chop into my pearl box as its from a tdi lupo

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Just an little update!

IT FINALLY CAME ALIVE TODAY ????????

Got a few issues if any one can help?

Oil pressure light flashing wonder if I need lupo oil pressure sensor?

And more importantly no comms? Wired in correct but no joy?

Pics of my custom 3" homemade down pipe

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Not a big fan of this but needs must

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Need to find a way to modify bumper but keep reasonably standard looking as I want it a sleeper

Edited by baker1983

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Not a bad welder from what I can see! and spray it black? more subtle?

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No because I've put the mounts on at an angle it gives me better clearance for diff,driveshaft angles and sump clearence

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Just a reminder to all doing 1.8t looms don't forget to run the Kline wire from ecu. Most later ecus are me7.5 and pin 43 big terminal is Kline,grey/white

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Oil pressure wise I checked it today,4.5bar cold cranking with a battery booster to up rpm so no oil pressure issues only thing I've found is mk4 golf switch is 1.2-1.6bar and lupo is 0.3-0.6bar.havnt run it since as still building exhaust system

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