MK5 Golf GTI

All Things Mk5 => Members Rides => Topic started by: tommygti on September 20, 2013, 08:21:25 pm

Title: Tom's MK5 GTI OEM+ Build - Forged engine and BBT Hybrid
Post by: tommygti on September 20, 2013, 08:21:25 pm
Hi all. Ive been a member on here for while now, mainly for advice and technical help which has always been answered so much appreciated to those who helped. Ive never posted any pics of my car so thought its about time I did. I want to start this thread to show people my ideas and keep track of the progress. I have tried to carry out most of the work myself with a little help along the way, as I want to learn the skills and mechanical knowledge for future projects. Im no mechanic but with a bit of research and help from you guys its possible. Anyway heres the spec:

05 plate gti
85,000miles
diamond black

- forge twintake
- forge dv kit
- 3" milltek non res cat-back
- 3" exhaust uk 200cell hi-flow sports cat and downpipe
- AP coilovers
- whiteline rear adjustable arb

- Genuine ed30 front bumper smoothed
- Genuine gti grill smoothed and wrapped matt black (+ lipstick to be sprayed custom colour and fitted next week)
- Tinted foglights
- Votex side skirts
- US Spec rear bumper with colour coded rear valance
- De badged rear

(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Fnn193%2Ffiestacossie%2FIMG_2952_zpse7fd9256.jpg&hash=380a0f3afe416098cee694eab72891b14bcdd347)
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Fnn193%2Ffiestacossie%2FIMG_2957_zpsfb44bcbf.jpg&hash=26825ad85412d258c6c137b7b50543aad870dd03)
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Fnn193%2Ffiestacossie%2FIMG_2971_zps0472e318.jpg&hash=d9485f45a10ab884c58adbae2e64dc9af5166b7b)
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Fnn193%2Ffiestacossie%2FIMG_2975_zps0d53e595.jpg&hash=300164d47a538b86d98571b5081254d8c357ecea)
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Fnn193%2Ffiestacossie%2FIMG_2977_zpsa27213a2.jpg&hash=e103a00d78b7cf879d8c50a601f587ad2a3521cc)

TO DO....

As the previous owner did not take very good care of the car and after a closer inspection at work found that the ps of the car has been repaired but not logged on the V5. Nothing major but they did a poor job so Im having to sort it.

Respray ed30 lip as it has been scuffed and rear bumper upper section
Repair dents in the DS rear arch
Repair dents and re-aline the ps side door

- Custom true CAI
- Custom dv relocate
- Custom Boost pipe (IC-TB)
- Custom catch can
- Revo stage 2 remap
- S3 front brake setup
- TTS engine cover
- clean+shave engine bay (relocate battery/fuse box/coolant tank)

Not much then
Title: Re: Tom's Project DIY
Post by: prp74 on September 20, 2013, 09:44:07 pm
Really like what I am seeing... Can't wait to see the wheels and this post updated.
Title: Re: Tom's Project DIY
Post by: tommygti on September 20, 2013, 10:28:09 pm
Cheers. The crappy quality of the iphone and my lack of photography skills dont really do it justice. The bodywork needs some tlc. Once the wheels are on and stance is sorted then I'l be happy. Wish I could afford to fit air ride as the roads around me are a nightmare.
 
Title: Re: Tom's Project DIY
Post by: james on September 21, 2013, 04:19:59 am
looks good but that number plate it taking a lot of air away from the ic/rad.
Title: Re: Tom's Project DIY
Post by: tommygti on September 27, 2013, 09:55:55 pm
Little update. The keskin kt1's arrived after a months waiting. In very good condition, looks like they have just been resprayed, but could do with the lips been sanded better.They came without any centre caps even though I payed for them so need to chase the seller up again. Need to buy some spigot rings, new bolts, and then get tyres fitted.

(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Fnn193%2Ffiestacossie%2FIMG_3030_zpsd8ccfb5f.jpg&hash=2f3200a5483ae049c55e3f55bf6ac22f1aaa4230)
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Fnn193%2Ffiestacossie%2FIMG_3032_zps82b91ccb.jpg&hash=7f79ba6840c5318f595e105e8adc19641bbba75e)
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Fnn193%2Ffiestacossie%2FIMG_3036_zps19991418.jpg&hash=96d35c01ebb6eae5f897e0d1c954a03756366361)
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Fnn193%2Ffiestacossie%2FIMG_3034_zpsa1c9f022.jpg&hash=7d9bd47fbd1e84fb33dc1d35fa2d821ac0abe273)

I test fitted the rears. They are 10j et30. Poke slightly more than I thought they would so looks like Im going to have to get the arches rolled? Anyone know of a good bodyshop that can do it near liverpool?

(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Fnn193%2Ffiestacossie%2FIMG_3044_zps41d2eb56.jpg&hash=27bd1fd03f615c11ea4ac99be6d93d397ba22a9a)
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Fnn193%2Ffiestacossie%2FIMG_3048_zpsfdc9e195.jpg&hash=ca9e6f50e5dba923ea5afc99f4fa40780e280658)

Thought i'd start stripping, sanding, and polishing the lips.

(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Fnn193%2Ffiestacossie%2FIMG_3050_zps9d08c3e8.jpg&hash=8835123221e61d5abdac603c46054fc6d7177f1b)
 
Title: Re: Tom's MK5 GTI OEM+ build
Post by: tommygti on April 08, 2016, 12:17:44 pm
So..... this thread has been dead for the past 2/3 years as I have been back at Uni doing my Masters so the car basically sat there doing nothing. This gave me alot of time to collect parts and decide which direction I wanted to take the project in. Now that I have more freedom/time to get things done and I'm finally earning money I can revive the thread and show you some updates. Anyway since my last post things have changed a little. The bodywork has got worse and could do with a respray so that will be on the cards somewhere down the line once ive saved enough cash and got the more important jobs out the way. Ive fitted a new cam belt kit + water pump and over the next couple of weeks I will be doing a complete engine oil flush, replace the pick up pipe, and a inlet valve clean.

The spec as of now:

Engine
BCS turbo back
Forge Twintake
Forge DV
Autotech internals
RS4 FPRV
Aircon delete
RS4 coilpack
NGK iridium sprak plugs

Suspension
AP coilovers
Superpro ALK
Superpro full f+r polybush kit
S3 alloy wishbones
Whiteline f+r ARB's
subframe spacer kit
replaced ball joints and front subframe bolts

Drivetrain
42dd shifter bushings

My intention was to go no further than stage 2+ with a good suspension setup so I could do a couple of track days. Since then things have spiraled slightly. If your going to do it, do it properly so...

TTS K04
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Fnn193%2Ffiestacossie%2FIMG_7032_zpsslzkdv8o.jpg&hash=7ccb9c08c561726620b19ec03901a61c580ed729)

Mishimoto J-line fmic intercooler
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Fnn193%2Ffiestacossie%2FIMG_7029_zpsj6buugs0.jpg&hash=fc703afd567ae8d95b558edc6d5c02407e9edce8)
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Fnn193%2Ffiestacossie%2FIMG_7031_zpswadgrsxj.jpg&hash=709ee48779f6def1a699caa8a052f1c260815877)

Sachs organic clutch and plate
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Fnn193%2Ffiestacossie%2F_57_zpswhxutu2k.jpg&hash=fb87d12e891d22158efd09a4235233e8f20ca5dd)
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Fnn193%2Ffiestacossie%2F_57_1_zpsv0d1wrlh.jpg&hash=3c630cba35179c780784b0543f57c4d748ad1b13)

Alcon 6 pot brakes
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Fnn193%2Ffiestacossie%2FIMG_7024_zpszj9zmbu6.jpg&hash=f18d0bd773a45d049b1c3e01bcbeddd94b6361ff)
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Fnn193%2Ffiestacossie%2FIMG_7025_zpsmzulsaee.jpg&hash=aa9e668041e0dfeb10cd6ccb936255ab7509a840)

and some bits that will be arriving from the US soon:

BFI Stage 1 mounts, USP runner flap delete, AWE dv relocate, 42dd shifter bracket bushings, Osir vent gauge pod (not pictured)
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Fnn193%2Ffiestacossie%2Fimage001_zpsdllh8yfy.jpg&hash=677107ff7ce3d4e4c115458d9f28647fd9328e50)

(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fwww.osirusa.com%2Fimages%2F640%2FVGT6-OPOD-MONR-01.JPG&hash=aafc39e1aacfda44e2563af9ecbfce3e1ed43e1a)
Title: Re: Tom's MK5 GTI OEM+ build
Post by: jayha11 on April 08, 2016, 02:03:51 pm
Nice thread revival there  :happy2: Looking forward to seeing this take shape!
Title: Re: Tom's MK5 GTI OEM+ build
Post by: AJP on April 08, 2016, 05:05:14 pm
Very nice. Love the brakes.

Are you still going to try and squeeze those Keskins on? They're a lovely wheel.

Should make good power with the k04 and the rest of the hardware. Careful of the Autotech pump internals... a few respected tuners much prefer Loba/APR.
Title: Re: Tom's MK5 GTI OEM+ build
Post by: tommygti on April 09, 2016, 10:42:17 pm
Very nice. Love the brakes.

Are you still going to try and squeeze those Keskins on? They're a lovely wheel.

Cheers. They need powder coating though and some of the pistons may need replacing. Ive been in contact with Reyland Motorsport about some custom 2 piece discs and brackets but they will have to wait till ive done the engine 1st as money as tight at the minute.

I sold the Keskins along time ago. Ive moved onto some 18" Rial Daytona splits wheels now but im considering selling them as the they don't work well with big brake kits at all.
Title: Re: Tom's MK5 GTI OEM+ build
Post by: tommygti on April 09, 2016, 11:28:13 pm
A few more parts to be fitted

High flow boost pipes (ebay)
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Fnn193%2Ffiestacossie%2FIMG_7056_zpsdrxe67re.jpg&hash=2a026e1ef22a735862a8924971a54a4d7ef81562)
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Fnn193%2Ffiestacossie%2FIMG_7057_zpsu4qd0rlo.jpg&hash=c033626e7f0e818292e3bf5aea44b1f9dd52a71e)

with K04 Muffler delete
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Fnn193%2Ffiestacossie%2FIMG_7038_-_Copy_zpsqhivgdsl.jpg&hash=d0e642269108d2f28ce1b861a6ad063c70f54c54)
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Fnn193%2Ffiestacossie%2FIMG_7039_zps3owyhhap.jpg&hash=2444041bb6e770a9a860eba344f1b14791af9179)
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Fnn193%2Ffiestacossie%2FIMG_7040_zpsva1ofw2r.jpg&hash=fce2020b12c78f92fa30c2ef7103ac33b6831d54)

Alloy pipes and silicone hoses for custom fmic+hard pipe setup
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Fnn193%2Ffiestacossie%2FIMG_7058_-_Copy_zpskznpw1wx.jpg&hash=d645b5ef988c502b0725309487b20edb59d6bd4e)

Custom catch can setup (Tegiwa baffled catch can, 034motorsport pcv plate, AN10 fittings+hoses, 42dd block off plug)
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Fnn193%2Ffiestacossie%2FIMG_7051_zpsv4ka94xd.jpg&hash=bda5133c80accac514a57eb08818b62c02150bcd)
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Fnn193%2Ffiestacossie%2FIMG_7054_-_Copy_zpsg8cp1riy.jpg&hash=6a1437b5633732b76d6d04cea5b93db01c4a3fd2)
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Fnn193%2Ffiestacossie%2FIMG_7053_zpshflzuafi.jpg&hash=eeb87bc618ac3fa7733fca6630c46cddc41b0f8b)
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Fnn193%2Ffiestacossie%2FIMG_7055_zpsxvzeampu.jpg&hash=a78b686275bb830f1f5b487224a8fa86fc6b52df)

Cheap engine oil, engine flush fluid, new pickup pipe, sump gasket, and cam cover gasket
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Fnn193%2Ffiestacossie%2FIMG_7047_zpsn06gclmp.jpg&hash=684d575dd2fac2a5d953c02d39a206d281f0ead1)
Title: Re: Tom's MK5 GTI OEM+ build
Post by: tommygti on June 07, 2016, 12:25:42 pm
So a little update. Ive been busy most weekends so Ive not had chance to get much done. I did however find time to change to do an oil change, filter change, and new oil pickup pipe installation. The filter was fubar'd so I caught it just in time. The plan is to run the cheap oil whilst doing all the engine cleaning and maintenance jobs before a full engine flush and upgrade to Millers Nanodrive. Last weekend I got busy fitting the BFI engine and trans mount. The difference in both noise and handling is very noticeable. The car seems to pull more aswell under throttle.

(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Fnn193%2Ffiestacossie%2FIMG_7249_zpsxoehcrq0.jpg&hash=cd470646c39e96ee2e6a3c7c06b6d86eab300340)

(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Fnn193%2Ffiestacossie%2FIMG_7250_zps76ccaofb.jpg&hash=2bba182bdfb3131bcbafa859a1dd70b5ee9eebb0)

I also managed to get my custom catch can setup installed. I made temporary mounting bracket as it will be moved over to the right hand-side of the engine bay once the car goes off to SS Autowerks for some fabrication work. 

(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Fnn193%2Ffiestacossie%2Fbfd2b411-e5e7-4d13-8e63-0bb74ed2a3ed_zpsdgb8xbui.jpg&hash=1ed571a90e7e0288d7cc9c6e1e9fd7b0cb612d41)

(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Fnn193%2Ffiestacossie%2FIMG_7257_zpsmgc0q8j3.jpg&hash=371af55941fa89603d7d046b5dbc1b2fbbddc135)

(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Fnn193%2Ffiestacossie%2FIMG_7260_zps9vnt0k5k.jpg&hash=2442cabd7871145a3d6b53cfdeabc9532e804532)

Next big job is the cam chain and tensioner change which I will be attempting this weekend.
Title: Re: Tom's MK5 GTI OEM+ build
Post by: Paradox1 on June 07, 2016, 12:36:44 pm
Really like this thread. your doing it the right way id say.

Any reviews on the RARB as I'm looking to get one next
Title: Re: Tom's MK5 GTI OEM+ build
Post by: tommygti on June 09, 2016, 02:00:14 pm
Really like this thread. your doing it the right way id say.

Any reviews on the RARB as I'm looking to get one next

Cheers. I can't afford to make mistakes so Ive meticulous planned the upgrades in stages gathering all the correct tools and parts to get the job done properly. Ive learnt alot about mechanics along the way so that's a benefit. I also have an addiction to ebay so all the parts have just accumulated over the past year.

When I installed the rear arb I also did the coilovers so I couldn't say exactly but it did seriously stiffen up the rear end and improve handling. I would definitely recommend it. I then did the front arb, SALK, and full polybush at once and the difference was light and day. I just need a good set of tyres now. 
Title: Re: Tom's MK5 GTI OEM+ build - Soon to be TTE420 powered CDL
Post by: tommygti on August 13, 2016, 11:05:51 pm
So things are escalating quickly and my pockets are getting lighter even faster. Ive bought a CDL engine with 27K miles on it ,which I am planning on fitting along with a TTE420. I also have a few billet trick bits for the engine and transmission which will be arriving from the US over the next month. I'd like to believe ive done my fair share of research but I would like a little advice from fellow members who also run the TTE420. The setup I am looking it is as follows so if you can advise on additional parts I should look at I would appreciate it?

-CDL (Stock internals)
-TTE420
-APR HPFP
-DW65 LPFP
-R8 injectors (new revision similar to RS4 but without black smoke)
-155 FPRV
-06A oil filter housing conversion to run a Mocal external oil cooler
-I.E. valve cover
-Custom catch can and pcv system

I have all supporting stage 2+ parts such as fmic, TBE, intake, R8 coilpack, etc.. I also have a sachs organic clutch with DMF but I am not sure of the torque ratings. I have been in contact with Alex @AKS and her recommended looking into an LSD so thats on the cards. I will be getting R-tech to do the mapping. Any advice is appreciated as always.
Title: Re: Tom's MK5 GTI OEM+ build - soon to be TTE420 powered CDL
Post by: fab5freddy on August 13, 2016, 11:31:23 pm
You're pretty much bang on with that list Tommy, as Alex has already said, you'll need the diff.
I'd also suggest a GFB DV+. Mines just eaten two rev g DV's in two weeks  :scared:
Title: Re: Tom's MK5 GTI OEM+ build - soon to be TTE420 powered CDL
Post by: tommygti on August 14, 2016, 12:24:50 am
You're pretty much bang on with that list Tommy, as Alex has already said, you'll need the diff.
I'd also suggest a GFB DV+. Mines just eaten two rev g DV's in two weeks  :scared:

I already have a forge DV which I will overhaul when fitting the boost pipes.
Title: Re: Tom's MK5 GTI OEM+ build - soon to be TTE420 powered CDL
Post by: Martk19871 on August 14, 2016, 02:03:31 pm
Looking forward to when this all comes together man.
Title: Re: Tom's MK5 GTI OEM+ build - soon to be TTE420 powered CDL
Post by: r5gtt on August 14, 2016, 02:38:52 pm
Hi @tommygti (http://www.mk5golfgti.co.uk/forum/index.php?action=profile;u=5865) where did you get those lovely engine and trans mounts from  :grin: are there any customs and excise costs to pay?. what did they cost in total?.
Your motors looking really nice and I'm liking the rear bumper too.  :wink:
Thanks

R5
Title: Re: Tom's MK5 GTI OEM+ build - soon to be TTE420 powered CDL
Post by: tommygti on August 15, 2016, 01:31:05 pm
Hi @tommygti (http://www.mk5golfgti.co.uk/forum/index.php?action=profile;u=5865) where did you get those lovely engine and trans mounts from  :grin: are there any customs and excise costs to pay?. what did they cost in total?.
Your motors looking really nice and I'm liking the rear bumper too.  :wink:
Thanks

R5

Cheers. The bodwork needs sorting but thats next on the list.

The mounts are Black Forest Industries from the US. I know Garage Midnight are the UK distributor for them but I got these shipped from the US along with a few other bits to keep shipping costs and import duty down. Shipping + import duty was around £80-90 but bare in mind that was for other items aswell, therefore additional weight = higher shipping cost + import duty. I buy quite alot of the VWvortex forum as most of the best parts for tfsi's are made in the US. Its were i picked up the 2nd hand I.E. valve cover and other bits.
Title: Re: Tom's MK5 GTI OEM+ build - soon to be TTE420 powered CDL
Post by: mvb12 on August 15, 2016, 01:41:46 pm
Could you tell me how the mishimoto cooler performs?
Title: Re: Tom's MK5 GTI OEM+ build - soon to be TTE420 powered CDL
Post by: tommygti on August 15, 2016, 06:33:16 pm
Could you tell me how the mishimoto cooler performs?

I could if I had fitted it yet. Ive been waiting to find a good fabricator around the North West to fit it along with the boost pipes. I only found one last Saturday but I need to wait until all my parts come from the US so it can be measured up accurately. Check out this guys build thread as he has the exact same setup that I am going to be running: http://www.mk5golfgti.co.uk/forum/index.php/topic,102247.0.html (http://www.mk5golfgti.co.uk/forum/index.php/topic,102247.0.html). Hes not updated it for a while though so I am not sure how well it performs. Its basically a wellycooler but with a better quality intercooler core.
Title: Re: Tom's MK5 GTI OEM+ build - soon to be TTE420 powered CDL
Post by: r5gtt on August 15, 2016, 06:50:02 pm
Hi @tommygti (http://www.mk5golfgti.co.uk/forum/index.php?action=profile;u=5865) where did you get those lovely engine and trans mounts from  :grin: are there any customs and excise costs to pay?. what did they cost in total?.
Your motors looking really nice and I'm liking the rear bumper too.  :wink:
Thanks

R5

Cheers. The bodwork needs sorting but thats next on the list.

The mounts are Black Forest Industries from the US. I know Garage Midnight are the UK distributor for them but I got these shipped from the US along with a few other bits to keep shipping costs and import duty down. Shipping + import duty was around £80-90 but bare in mind that was for other items aswell, therefore additional weight = higher shipping cost + import duty. I buy quite alot of the VWvortex forum as most of the best parts for tfsi's are made in the US. Its were i picked up the 2nd hand I.E. valve cover and other bits.
it'll probably coat around £45 for customs as I recall buying a set of Deka 630 cc injectors for my tt and they stung me  :signLOL: swore I would never buy from the US again  :doh: They do do the best stuff n all  :sad1: barstuards  :fighting: :sick: I'm on vw vortex to and have noticed quality bits but sadly I'm not going to be buying from the US again. But thanks for the reply  :drinking:
Title: Re: Tom's MK5 GTI OEM+ build - soon to be TTE420 powered CDL
Post by: tommygti on August 15, 2016, 09:24:32 pm
Don't get me wrong, its a f*****g rip off but it depends on how much you buy the parts for in the first place. They cheaper the parts the more margin you have when been stung by charges. Also you can risk it and claim the parcel contents is worth less so you pay less import duty but sometimes that might come back to bite you in the ass.

Title: Re: Tom's MK5 GTI OEM+ build - soon to be TTE420 powered CDL
Post by: r5gtt on August 15, 2016, 09:49:48 pm
I was thinking that too but all depends on the seller and if they say the items cheaper than the actual price.
Also they can open the parcel at the customs depot so it is a gamble too.
Title: Re: Tom's MK5 GTI OEM+ build
Post by: tommygti on September 08, 2016, 09:30:06 pm
Small update, been collecting parts for a while now ready for the big build to start. My rooms starting to look more like a garage. This is minus the CDL engine, clutch, and parts been shipped from the US.

(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Fnn193%2Ffiestacossie%2FIMG_7745_zpsoaohsste.jpg&hash=8659137e89422988348322cf8ad3370c6de530fd)
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Fnn193%2Ffiestacossie%2FIMG_7749_zpsisdtr2ln.jpg&hash=afb0c9f08adcd5c5908f09607c65615d6ff87f86)
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Fnn193%2Ffiestacossie%2FIMG_7750_zpsunn2qcob.jpg&hash=b836b35baf0ebc239f1b295398e674248218fc0b)
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Fnn193%2Ffiestacossie%2FIMG_7753_zpskb32uslp.jpg&hash=5ed78a8a8a3293c5ec593c61f676645d0e7c8b41)
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Fnn193%2Ffiestacossie%2FIMG_7754_zpsduyld3at.jpg&hash=28ede093730415dfdf08585b9ebd4545a1caa671)
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Fnn193%2Ffiestacossie%2Fimg_1587_zpsmxszqb45.jpg&hash=a0669205b7d62c2e20d2a0124bcd0b9108d71328)

Ive sent my 19" BBS speedlines off for stripping before I can split them and get them refurbed as the previous owner had painted over the bolts so I can't remove them without damaging the threads. Also have a set of S3 front alloy hubs and passat rear alloy hubs that are getting sand blasted and powdercoated ready for new bearings.

Oh and this happened, I accidentally bought this. Ive decided to scrap the TTE420 and go big turbo. Looking at getting a gtx2871r first off and then upgrading to a gtx3071r when I can afford forged internals.  :driver:

(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Fnn193%2Ffiestacossie%2F14192585_10154613056315815_6490415663826390936_n_zpsmpwr6l0o.jpg&hash=e8ef0059d0c8a50a8cabcf4211b055a4aad84da9)
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Fnn193%2Ffiestacossie%2F14287629_10154614399145815_1585451107_n_zpsxqw5mlx9.jpg&hash=29577e7c269edbf6e5de333454fb23c90cc1d693)
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Fnn193%2Ffiestacossie%2F14287527_10154614399140815_461165460_n_zps1pusn79n.jpg&hash=e0f586e66f81e650ddcd8755c2da459cd97c99ab)
Title: Re: Tom's MK5 GTI OEM+ build - slow progress
Post by: Paradox1 on September 09, 2016, 10:10:25 am
Your a nutjob :laugh: :laugh: :laugh:

but I love it. Cant wait to see how this goes!
What LSD are you going with?
Title: Re: Tom's MK5 GTI OEM+ build - slow progress
Post by: tommygti on September 09, 2016, 12:49:22 pm
Your a nutjob :laugh: :laugh: :laugh:

but I love it. Cant wait to see how this goes!
What LSD are you going with?

I know. I'm a secret horde really. I'm looking at a Quaife LSD and arp bolts. Got a Sachs clutch kit with smf to go in along with steel shifter forks and upgraded bearings so putting the power done should be sorted.
Title: Re: Tom's MK5 GTI OEM+ build - slow progress
Post by: Little_Dave on September 09, 2016, 06:32:45 pm
Wow that got serious pretty quick  :laugh:

Look forward to seeing the build coming along

Dave
Title: Re: Tom's MK5 GTI OEM+ build - slow progress
Post by: r5gtt on September 10, 2016, 02:10:28 pm
Wow loads of bits to go on  :smiley:

Seen one of those manifolds on sale in FB. oops it's your one  :signLOL:
Title: Re: Tom's MK5 GTI OEM+ build - slow progress
Post by: SurreyED30 on September 10, 2016, 02:39:26 pm
I will definitely be keeping an eye on this thread :happy2:

Jake
Title: Re: Tom's MK5 GTI OEM+ build - slow progress
Post by: vRSAlex on September 10, 2016, 04:50:34 pm
Is that a 38mm wastegate?
Title: Re: Tom's MK5 GTI OEM+ build - slow progress
Post by: tommygti on September 10, 2016, 07:07:39 pm
Is that a 38mm wastegate?

Yeh 38mm
Title: Re: Tom's MK5 GTI OEM+ build
Post by: tommygti on September 24, 2016, 05:08:00 pm
Small update. I bought some VIS motorsport hpfp internals to swop out with my autotech pump. I had a spare pump off the CDL I bought so I cleaned it up and painted it ready for the rebuild. I also painted the throttle body and I'm painting the alternator, tensioner, and bracket just to tidy the engine up ready for the engine build. Whilst the manifold was off I fitted the USP RFD kit. My box of goodies was shipped from the US aswell so hopefully will be here by the end of next week.

(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Fnn193%2Ffiestacossie%2FIMG_7859_zpszu0cy72g.jpg&hash=b938c146ffdd18d25d2a1e1c8b6b5cf5154b6a59)
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Fnn193%2Ffiestacossie%2FIMG_7854_zpsd0wjwuuj.jpg&hash=d5af757262889dda2d3b763f5eeb9de3bffd3123)
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Fnn193%2Ffiestacossie%2FIMG_7853_zpsa0d07wuy.jpg&hash=0db118cc9779e2f55503d051ac948177a053f4aa)
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Fnn193%2Ffiestacossie%2FIMG_7858_zps2pgkc6ew.jpg&hash=37b02deb28a5aee827049c3e535ca26a575bc440)
(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Fnn193%2Ffiestacossie%2FIMG_7857_zps5miha4mm.jpg&hash=fdd5fcd589c20d6a95a4787a81a0c208d574eb38)

My next job is to decide what turbo to get. Ive been weighing up a Borg Warner EFR turbo vs Gtx3071r. Most of the feedback is mainly a mixed view; some say get the EFR as it spools better than the gtx and holds constant boost, whereas others say the gtx is alot easier to map and fit as the EFR requires an independent control/management system. What are peoples views on them? I'm only after around 450hp and both units comfortably reach those figures with around the same price bracket aswell.
Title: Re: Tom's MK5 GTI OEM+ build - slow progress
Post by: tommygti on October 11, 2016, 09:04:52 pm
My parts arrived from the US. I'm slowly but surely gathering all the parts so I can start the build itself. Ive decided to go with a gtx3071r .63 A/R turbo with tial housing. Collecting it next weekend and hopefully going for a ride in a 550hp mk5 with the the same setup to get an idea of the fun.  :driver:

(https://www.mk5golfgti.co.uk/forum/proxy.php?request=http%3A%2F%2Fdaz.co%2Fmedia%2Fnn193%2Ffiestacossie%2FIMG_7904_zpsvwsanzmn.jpg&hash=f8fc97080380f6e473b861dca3f3d34425297bff)
Title: Re: Tom's MK5 GTI OEM+ build - slow progress
Post by: r5gtt on October 11, 2016, 11:59:41 pm
I'm glad you bought the VIS hpfp internals as I did that about 6weeks ago  :grin:
Title: Re: Tom's MK5 GTI OEM+ build - slow progress
Post by: tommygti on November 08, 2017, 12:02:34 am
So it has been a very long time since I have updated the build thread but I just have not had the time. Since the last post the project has taken another direct. I have decided to Forge the bottom end and go BBT K450 hybrid K04. It is a prototype turbo so don't really have many details yet but I believe it is based on their already successful K430x unit which so north of 440hp on rtech rollers so plenty of fun to be had. I'l see where this takes me and if I decided to go BT later on then most of the hard work has already been done.

I sold the CDL block and bought a used AXX block for a steal. I dismantled the block and dropped all the parts off at Ee Lye Racing in Runcorn as they are doing the bottom end build for me. I would love to have ago myself but I have never build an engine before and even with the aid of youtube and tons of tutorials I just can't risk something going wrong.

The block is getting hot washed, honed, and then painted before assembly beings.

(https://farm5.staticflickr.com/4553/26476408619_1c5e4af0cd_k.jpg)

(https://farm5.staticflickr.com/4545/38252231801_8e2554bcfd_k.jpg)

(https://farm5.staticflickr.com/4540/26476401589_7f82345f42_k.jpg)

The crank gear was an absolute bitch to get off as I did'nt have the VAG locking tool so made my own with an old crank pulley. Worked a treat.  :drinking:

(https://farm5.staticflickr.com/4585/26476396449_5f327c468d_k.jpg)

(https://farm5.staticflickr.com/4534/38197539356_589f00609c_k.jpg)

(https://farm5.staticflickr.com/4540/38252219271_1def77c2d7_k.jpg)

And the end result

(https://farm5.staticflickr.com/4526/38252208901_7cddafc0ab_k.jpg)

I kept the CDL head I removed from the block as it is in very good condition (only done 28K miles) and obviously has the better cams fitted. It is getting inspected and pressure tested, cleaned, walnut blasted, and skimmed before it gets fitted. A few of the bottom end parts, brackets, sump, etc are getting cleaned and painted the same colour as the block.

(https://farm5.staticflickr.com/4567/37541546564_3d63876993_k.jpg)

I decided to go with wossner pistons and ZRP rods from TSR performance as they have been proven to be a good package.

(https://farm5.staticflickr.com/4533/38220602162_32e5efde0d_b.jpg)

(https://farm5.staticflickr.com/4569/38252199831_378aa7e699_k.jpg)

Here's a quick breakdown of the engine spec;
Wossner pistons 82.5mm
zrp rods (rifle drilled)
ACL Race bearings
1.8t oil pump conversion
ARP head bolt set
CDL cylinder head
I.E. valve cover
New block and head gasket/seal kits, water pump, timing belt, etc
Fluidampr crank pulley
1.8t oil filter housing with I.E. adapter plate to run a mocal oil cooler

Not a small list and that's not all of it. The block will hopefully be back by the end of the month and Ee Lye Racing are going to document and take pics for me so I will update you with the progress as it comes. Been waiting on the turbo for a good 6+ months now but I am aware it is a prototype and can understand they don't want to let it go out the door until it is 100%.

Title: Re: Tom's MK5 GTI OEM+ Build - Forged engine and BBT Hybrid
Post by: tommygti on November 18, 2017, 07:16:10 pm
Ive had a set of S3 alloy hubs and KW V1 coilovers laying around for a while now so had chance to get some work done this weekend. I already had S3 wishbones, whiteline ARB's, SALK, and fully polybushed so I'm pretty happy with the suspension set up now.

To save time I fully assembled each leg so I could just swop them over. KW V1's, S3 hubs, new bearings, TTRS top mounts, new track rod ends, and bolts throughout

(https://farm5.staticflickr.com/4544/37618302705_a3ca7e7536_c.jpg)
(https://farm5.staticflickr.com/4585/37618302095_7f21126923_c.jpg)

Test fitted my alcon 2 piece discs and brackets. The kit runs a huge 370mm disc. Might have to rethink my wheel choice to achieve a decent caliper clearance.

(https://farm5.staticflickr.com/4536/24632764608_ee5a63d310_c.jpg)

Got the fronts done rather easier than I thought I would. Fitted new R32/Golf R splash guards aswell as mine had basically rusted away and didn't see the point of buying standard ones as I would need to upgrade again once I fit the alcon brake setup.

(https://farm5.staticflickr.com/4547/37618298695_d24bd888e6_c.jpg)
(https://farm5.staticflickr.com/4529/24632763678_991550b8d2_c.jpg)

Whilst the drivers side leg was out it gave my chance to easily access the Forge DV fitted to the tiny K03 so I decided to remove and service it. After removing the seal/cap on the top of the valve I realised it was probably due a service as there was a large amount of gunk in the valve. The spring was also coated in crap so got that cleaned up aswell and put everything back together.

(https://farm5.staticflickr.com/4522/24632764878_7cdcb2d65e_c.jpg)
(https://farm5.staticflickr.com/4536/37618300735_16709c0800_c.jpg)

Decided to fit my chinese muffler delete and Fluidampr pulley aswell. Didn't really notice any difference in throttle response after fitting the muffler delete but I definitely noticed less engine vibration after fitting the fluidampr. I'l be running a SMF, 1.8t pump, and have upgraded engine mounts so this will be a much appreciated addition when that time comes.

(https://farm5.staticflickr.com/4480/26476753539_0b8e51b518_z.jpg)
(https://farm5.staticflickr.com/4542/37618299535_e36c83f94a_c.jpg)
Title: Re: Tom's MK5 GTI OEM+ Build - Forged engine and BBT Hybrid
Post by: harveym3 on November 19, 2017, 05:45:53 pm
When you fit the breather tank are you going to cap the rear breather that gose into the old turbo setup ?
Title: Re: Tom's MK5 GTI OEM+ Build - Forged engine and BBT Hybrid
Post by: tommygti on February 11, 2018, 09:53:54 pm
When you fit the breather tank are you going to cap the rear breather that gose into the old turbo setup ?

Sorry bud ive not updated the thread for a while so never replied. Ive got the I.E. rear pcv plate adapter so I can run an AN-10 line to by catch can setup.
Title: Re: Tom's MK5 GTI OEM+ Build - Forged engine and BBT Hybrid
Post by: tommygti on March 04, 2018, 12:29:53 pm
So made some good progress recently. Picked the freshly built engine up from my engine builders. New gaskets, seals, bearings, etc...

(https://farm5.staticflickr.com/4698/26688926148_63776e5a44_c.jpg)
(https://farm5.staticflickr.com/4663/26688925268_1df754d1ef_c.jpg)
(https://farm5.staticflickr.com/4652/26688922788_ab4bdc0609_c.jpg)
(https://farm5.staticflickr.com/4747/40517568792_8f9d34a27b_c.jpg)

Decided to go with the 1.8t oil pump assembly rather than deleting the balance shafts from the OE unit. I'm running the 1.8t oil filter housing aswell so there should be no oil pressure issues that some people have found when using the 1.8t pump.

(https://farm5.staticflickr.com/4678/39664958365_9423164b2f_c.jpg)
(https://farm5.staticflickr.com/4708/39664958515_069f7114cd_c.jpg)

I got the head pressure tested for good measure before putting the engine back together and its a good thing I did as it turned out that the timing chain had slipped and ended up bending the inlet valves. So unfortunately I had to cough up and get the head had to be stripped, cleaned, and rebuilt with new inlet valves. Whilst it was in pieces I upgraded to R8 valve springs aswell. Although its cost more than I wanted to spend I am really pleased with the outcome. The head looks brand new. Keeping it wrapped up and clean until I start the rebuild.

(https://farm5.staticflickr.com/4668/39664952645_0fe4f6de2a_c.jpg)
(https://farm5.staticflickr.com/4610/39664952125_936f2851ec_c.jpg)

And a big piece of the project arrived. After some rather long delay's, complications, and communication issues the one-off prototype BBT K450 hybrid. Custom billet compressor wheel, larger clipped turbine wheel, upgraded thrust bearings, CNC'd housings, upgraded actuator, and a few other goodies. Lets see what power it will make.

(https://farm5.staticflickr.com/4618/40517560902_e5ac8f567f_c.jpg)
(https://farm5.staticflickr.com/4654/26688926848_d962f1c8ca_c.jpg)
(https://farm5.staticflickr.com/4764/26688914228_88ba3e8faf_c.jpg)

I need to get a few parts sand blasted and prepped ready for paint, then we can begin the assembly. I'l try keep the thread updated more regularly now as I should be able to start making some progress.   
Title: Re: Tom's MK5 GTI OEM+ Build - Forged engine and BBT Hybrid
Post by: tommygti on April 04, 2018, 10:26:39 pm
The alcon's are getting rebuilt with new rotors and pads so should help freshen the brakes up and to help cope with the power increase. Tax isn't really affected but no its not cheap anyway.
Title: Re: Tom's MK5 GTI OEM+ Build - Forged engine and BBT Hybrid
Post by: tommygti on April 05, 2018, 10:45:04 pm
Sorry for the slow updates but things have been rather slow due to a few unforeseen issues. Anyway here are some pics for you.

Made a rather large list so I can keep an eye on where I'm at.
(https://farm1.staticflickr.com/897/41260986781_5ae0fe92ae_c.jpg)

Started to prep the block for painting by masking all the mounting surfaces that I wanted to keep clean.
(https://farm1.staticflickr.com/786/40365140635_bb7d8baa17_c.jpg)

All done.
(https://farm1.staticflickr.com/815/40365146255_cb2db22324_c.jpg)

The block was first degreased (has already been done twice already before been built), a coat of anti rust protection, then etch primer, and finally two coats of VHT hi temp cast iron grey. And the final result.
(https://farm1.staticflickr.com/886/41260995211_79ee2d689c_c.jpg)

(https://farm1.staticflickr.com/893/41260994511_0807061782_c.jpg)

Got a few parts sand blasted to clean them up before painting.
(https://farm1.staticflickr.com/902/41260993751_9c6cca8055_c.jpg)

(https://farm1.staticflickr.com/798/40365143205_155f542b95_c.jpg)

Trimmed the alternator bracket as I'm not running aircon therefore don't need the pump. Got it painted along with the front main cranksaft seal.
(https://farm1.staticflickr.com/879/40365142615_03ae22fab5_c.jpg)

Then And finally I test fitted the cylinder head and beautiful I.E. cam cover
(https://farm1.staticflickr.com/804/40365142275_4aabbba670_c.jpg)

The plan was to get 99% the engine back together over the Easter bank holiday weekend but annoyingly things ground to a holt. It turns out when the engine was built a few things were not installed due to miscommunication. So I'm currently waiting on the engine builders to correct the mistakes before I can start making anymore progress.

In the mean time I ordered some new cam cover bolts. It's not going to be a show car in the slightest but I like attention to detail so I'm trying to go with a colour theme under the bonnet which I will hopefully use elsewhere.

Old
(https://farm1.staticflickr.com/811/40365141145_fbf6ee0506_c.jpg)

New
(https://farm1.staticflickr.com/787/41260988381_d49f7d7e9c_c.jpg)

Got the alternator dismantled so I can paint the casing along with a few other engine parts.
(https://farm1.staticflickr.com/809/41260991281_9c0654f065_c.jpg)
Title: Re: Tom's MK5 GTI OEM+ Build - Forged engine and BBT Hybrid
Post by: Molesy on April 06, 2018, 07:53:56 pm
 :drool: :drool:wow now that's an engine build, will be brilliant to see it installed and up and running!! Top work mate!

Molesy  :happy2:
Title: Re: Tom's MK5 GTI OEM+ Build - Forged engine and BBT Hybrid
Post by: Christiank on April 07, 2018, 08:08:17 pm
Great work mate, nice to see I'm not the only one crazy enough to rebuild an engine for these "old" cars :D  :driver:
Title: Re: Tom's MK5 GTI OEM+ Build - Forged engine and BBT Hybrid
Post by: Shoduchi on April 09, 2018, 12:06:29 pm
Wow! Really nice work! Love the detail of pictures too. :congrats:

Hope you can get it finished and running strong soon! :drinking:
Title: Re: Tom's MK5 GTI OEM+ Build - Forged engine and BBT Hybrid
Post by: tommygti on April 09, 2018, 08:34:44 pm
Cheers for the comments. Its my first ever serious build so its a bit of a learning curve but also gives me a chance to test some new skills. I'm in no rush to get it finished but will hopefully be done in time for summer so I can start to enjoy some road trips and track days.

I have a few more updates to come this week as the cylinder head has been installed with ARP studs and got the new timing belt kit on. Unfortunately couldn't get the head sealed up as I forgot to order a new timing chain tensioner and chain so that has been ordered. As this was most likely the cause of the damage to the original inlet valves I thought it might be wise to replace it. I have also ordered a custom upgraded aluminium radiator to go with the wellycooler as part of my front mount setup but it will take nearly 2 months till it arrives in the UK as it is been shipped from China (same company that make Mishimoto radiators). It has been designed to sit where the OE intercooler does which will mean it sits further forward so I can run mishimoto/Spal fans and larger boost pipes without worrying about clearance issues. It will also hopefully make maintenance a little easier.
Title: Re: Tom's MK5 GTI OEM+ Build - Forged engine and BBT Hybrid
Post by: teo_parvu on December 13, 2018, 12:29:17 pm
Hey man, any updates with this project?
Title: Re: Tom's MK5 GTI OEM+ Build - Forged engine and BBT Hybrid
Post by: csrigo on December 15, 2018, 12:53:38 pm
Great build mate just had aread through there very. Ery impressive :happy2:
Title: Re: Tom's MK5 GTI OEM+ Build - Forged engine and BBT Hybrid
Post by: tommygti on December 31, 2018, 01:26:05 am
Hey man, any updates with this project?

Sorry for the lack of updates. Had a busy year and many things have changed. Long story short, the edition 30 that I was going to build into a track car unfortunately is no longer happening and is now up for sale. On the other hand I have purchased a sprint blue 3dr S3 8P to take its place. The forged engine and all the goodies I planned on fitting to the ed30 are now going to be transplanted into that. Basically it will cut my work load down massively as I simply don't have the time. Not sure I will be able to post updates and pics from now on as it is not a golf but I will do my best to sort something out.
Title: Re: Tom's MK5 GTI OEM+ Build - Forged engine and BBT Hybrid
Post by: RBS on January 21, 2019, 10:40:04 pm
I like where thuis going :congrats: :congrats: