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Post by howardb66 on Aug 9, 2022 10:25:25 GMT
TSIs really help on the MK1 with intake temperatures. Something else to think about is a fan over ride switch? When you come to stop when the turbo is hot, it stays hot for some time & can lead to a hot core. I run mine off the front fog light switch but did yours have aircon? There maybe a convenient way of using that?
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Post by scottydugg on Aug 9, 2022 12:05:37 GMT
TSIs really help on the MK1 with intake temperatures. Something else to think about is a fan over ride switch? When you come to stop when the turbo is hot, it stays hot for some time & can lead to a hot core. I run mine off the front fog light switch but did yours have aircon? There maybe a convenient way of using that? I'll make sure I get them on then if that's the case, I'd tried to connect the 2 wires under the dash for the A/C fan to come on, but it didn't work out. So I need to revisit that, I've got a SPAL fan to fit in place. |
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Post by scottydugg on Aug 23, 2022 16:04:44 GMT
Can't seem to find any of the perforated double layer aluminium sheet, for the intake heat shield I was going to make up, so I've decided on some 1mm aluminium sheet for now. Anyone know where to buy the rubber edge trim? Everything I see has the wrong profile. It'll be getting tarted up with some gold tape eventually, still got some things to do before the tuner, but plan is to get it to him this weekend. Still to do: - Coilover Socks (can already tell these are annoying to fit) - Undertray (can already tell this will consume a few hours at least!) - Wire in EBC (but don't activate) - Try refitting the fuel pump assembly, as my fuel gauge has seemingly stopped working? - Cable tie the heater matrix heat shield (don't forget!) - Bolt check - Fit Hard Top - Test Drive - Wash I did pick up another underbody brace but that can wait. I've always looked at th metal under trays you can get in the US, but thought getting one sent over would cost a fortune, hadn't realised Jass do there own: HERE be easier to cut up for the intercooler piping. Here's hoping it doesn't fight me too much! |
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Post by lowender on Aug 23, 2022 20:21:21 GMT
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Post by scottydugg on Aug 24, 2022 9:25:38 GMT
Thank you, should have checked this before I bought some sheet, I think I'll get some eventually and add some shielding, rather than make it all out of this material. Spent some time cutting up the undertray, it's not the best but it'll do for the short term. the FM guide on where to cut doesn't work at all with the BOFI intercooler kit, but that's to be expected. |
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Post by scottydugg on Aug 30, 2022 9:19:56 GMT
I've missed the tuner this time he's home, it wasn't even close in the end, so plan is to get it to him start of September when he's back onshore. He is going to adjust my current tune so I can take it a "safe" test drive to make sure everything is as it should be. Started mocking up an intake shield, couple issues with this being that: my turbo actuator is probably not clocked enough so clearance will be a bit of a chew, the strut brace makes things even tighter. I think I'll need to recut the intake 90 degree elbow to give me a little more clearance if possible.  IMG_20220830_192924 by Scott Reid, on Flickr Plan is to attach the EBC onto this and the catch can if possible, or perhaps put it near where the washer bottle was originally located. I'll get a second catch can for the intake side in due course. Undertray is now in position, I managed to keep the majority of fixtures, but there are gaps above both intercooler pipes, I'm going to have to fill in - I'm thinking some of the 1mm Aluminium sheet, with some rivnuts in the plastic to hold everything together.  IMG_20220831_184311 by Scott Reid, on Flickr Have now fitted the coilover socks, which were a total pain, but at least that'll hopefully keep the threads clear should I need to adjust them again. Also picked up one of THESE as it was going cheap, no idea if it'll do much. I think I've just discovered, after a sales post on Facebook, that I've actually got a BEGI manifold and DP and not an FM kit like I originally thought! |
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Post by scottydugg on Sept 12, 2022 9:40:05 GMT
Spent some time "fabricating" up some plates to block off the under-tray holes left by the intercooler pipework. It's just 1mm THK aluminium, easy enough to cut and bend, I've used split vac hose on the aperture for the intercooler pipework. Mocked up with some cardboard then transferred to the sheet metal, still needed a bit of trimming to fit afterwards.  IMG_20220910_112714 by Scott Reid, on Flickr One of the rivnuts kept pulling out so I got fed up and used a cable tie, back of the plate has self adhesive foam to try promote a decent seal. Passenger Side:  IMG_20220910_195056 by Scott Reid, on Flickr Drivers Side:  IMG_20220911_171859 by Scott Reid, on Flickr Also mocked up a second intake shield out of cardboard, need some tooth picks to figure out the top edge with the bonnet.  IMG_20220910_112651 by Scott Reid, on Flickr Cut out the aluminium for now with plenty meat left on top for the edge to be cut:  IMG_20220910_112707 by Scott Reid, on Flickr Contemplating bonnet vents instead of the shield but not quite decided yet, I've got the tuner back a week today so I might run it as it sits now, add the rest of these bits when it's running and tuned. It could still blow up so I don't want to waste anymore time on it if it's going to be a garage ornament. Under bonnet temps can get a bit high for a few hundred miles, I mean the TSI's are ready to go on, I've the hole from the Randall intake, see how it goes. 4 wheels are on anyway. |
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Post by howardb66 on Sept 12, 2022 16:49:48 GMT
Good progress, keep going! TSIs & the vented headlight cover will really help your temperatures.
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Post by scottydugg on Sept 13, 2022 9:01:12 GMT
Good progress, keep going! TSIs & the vented headlight cover will really help your temperatures. Thank you, all encouragement welcome! It does seem a little never ending at times, but it seems to be coming together a bit, as per I've decided to do way to much at the same time. I don't know how long I've spent getting these TSI's painted and wired in! Got some wiring harness sleeve to try protect them a bit more. Fitted up and tested:  IMG_20220912_191804 by Scott Reid, on Flickr  IMG_20220912_191742 by Scott Reid, on Flickr  IMG_20220912_191647 by Scott Reid, on Flickr Spiked Performance bonnet vents ordered, contemplating changing the oil filter/oil again since drilling the oil pan, just for piece of mind a bit. I' going to delay the intake heat shield till after it's tuned. Fuel pump is the most annoying job left, will start that tonight/tomorrow. |
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Post by scottydugg on Sept 16, 2022 14:31:10 GMT
Decided to change the oil in the car before it goes off to tuning, checked the oil that came out and there was 1 or 2 bits from drilling and flushing the pan, but nothing of great concern, it's only really idled for a short spell. I'll get it off the jack stands Monday and take it a quick test drive with a temporary boost tune from the tuner. So a wee before and after:  IMG_20220626_164245 by Scott Reid, on Flickr  2022-09-16_11-24-46 by Scott Reid, on Flickr I was expecting it to be quieter with the turbo fitted, but I think it's going to sound rowdy on boost, I think my left tailpipe is effectively almost straight piped, I've kept the silenced de-cat which I hadn't intended to do. Click on image below to watch video: VID_20220915_204123 by Scott Reid, on Flickr I'll update post test drive, it'll get the catch can and bonnet vents fitted at some stage after tuning. |
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Post by boggissimo on Sept 20, 2022 8:22:18 GMT
Looking really good, exciting to get it off to be tuned soon!
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Post by scottydugg on Sept 21, 2022 9:04:11 GMT
Still awaiting an updated boost tune and I want to replace one of the exhaust clamps before I drop it (should arrive today), so hopefully test drive it tonight, as all that's left is the bonnet vents. Fitted up the EBC, everyone says strut braces serve no purpose, but I counter...great place to fit an EBC.  IMG_20220920_204026 by Scott Reid, on Flickr  IMG_20220920_204032 by Scott Reid, on Flickr With some added heat sleeve on the boost reference line, my wiring isn't the greatest, but I'm going to get my Dad to run through it all once it's all up and running, the joys ohavign a retired sparky to hand. If I don't get the map till later in the week I'll throw the bonnet vents at it and take it to the tuner at the weekend, original plans gone a bit to prarrie canoe, but we'll get there! |
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Post by scottydugg on Sept 22, 2022 8:25:44 GMT
Car is now down off jack stands, took it to the top of the road and back to turn it round in the garage, gave it a little juice to see if any boost built or not, it looks like it does but I can't 100% confirm. I was seeing atmospheric pressure not at wide open throttle so I can only imagine I am. I do however have an exhaust leak and/or oil leak, so I need to check the oil feed line at the block and all the exhaust fittings today now that it'll have cooled down. Fingers crossed it's nothing drastic, but who knows at this stage. Looks like it's back up on jack stands tonight to have a poke about. Edit: Boost tune now received!  |
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Post by atlex on Sept 22, 2022 9:17:43 GMT
Still awaiting an updated boost tune and I want to replace one of the exhaust clamps before I drop it (should arrive today), so hopefully test drive it tonight, as all that's left is the bonnet vents. Fitted up the EBC, everyone says strut braces serve no purpose, but I counter...great place to fit an EBC. Neat Install! :-) |
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Post by scottydugg on Sept 23, 2022 9:35:12 GMT
So...that was eventful. How my evening started:  IMG_20220922_190725 by Scott Reid, on Flickr Warmed the car up for a good 15 minutes, then took it a couple loops round the local street, before parking up in the garage again. The Good: We didn't blow up, from what little I did give it it'd going to fly, coolant temps were within a manageable window, intake temps didn't get as high as I'd worried about, The BOV is stupid loud (I may need to go recirc valve). The Bad: Front brakes need re-bled, I can't find my exhaust leak (I think it's the Down pipe flange, so will remove and refit), some light revving produced quite a lot of smoke in the garage. The Ugly:  IMG_20220922_201409 by Scott Reid, on Flickr Filter was only on the cam cover temporarily for the test drive, I know people do see some oil from here (fire Hazard), but I was not expecting this level to have escaped. I'm still running a relatively new stock PCV, so have bought a 323 metal unit and I've got the catch can pretty much fitted in position to stop oil hitting the manifold. I was going to soak the rings with the atlex method after the tuning but might need to before, if I can't get this reduced/resolved beforehand. Primary issue with that being it'll be well into October if not November before I can get it to him. I was seeing some oil in the intake and small puffs of smoke on high rpm overrun whilst running N/A, the heads basically serviced so it only can be the rings I'm guessing (hoping). Anyway, this is how the night ended (back in it's natural state):  2022-09-23_09-57-26 by Scott Reid, on Flickr From reading the thread HERE, I think I'm going to catch can the intake side, try an enclosed system that links into the intake, but I'm open to suggestions as I need this fixed ASAP if I've any hope of getting it to the tuner. Anyway, it's always eventful with this thing! |
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le sigh