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Author Topic: GTI Track Car - Manual, Wavetrack Diff, Caged, Polycarbs, KO4, DB9 Brakes, METH  (Read 9461 times)

Offline shannon-ob

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The alloy rear hubs… can you reuse all the MK5 bolts? Or are they different?
No mate. Need longer bolts, get them off a Passat or scirocco being broken mate.


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MY 3 DOOR MANUAL GTI TRACK BUILD - WAVETRACK DIFF, CAGED, POLYCARBS, KO4, DB9 BRAKES, METH, BARTEK, VIS, HELIX PADDLE CLUTCH/SMF, FLOCKED DASH, 18X9 PRO RACE

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Offline rich83

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The alloy rear hubs… can you reuse all the MK5 bolts? Or are they different?
No mate. Need longer bolts, get them off a Passat or scirocco being broken mate.


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OK.. thanks mate... I think ill just stick with OEM hubs I think, its turning into more hassle than its worth

Offline shannon-ob

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I've got Scirocco alloy hubs waiting to go on to mine.  As far as I can tell the bolts are the same.  They add 15mm per side extra track though, so if you do go ally rear knuckles, jack the wheel up into the arch as far as it'll go to check for clearance.

You might want to balance the track with ally front knuckles, which add 10mm per side, so evens it out...ish.  Check the tie rod heights before committing to different knuckles though as no one likes a chunky portion of bump steer on their chips.

As for the rust  :grin:  A lot of people are too scared to pull their side skirts and have a dig, but it's only cosmetic.  The core structure is made of burly war bunker grade stuff Hitler would be proud of.
Bolts are different mate. As the casting is thicker.
Adds 12mm per side mate.

Yeah the side skirt is a sh*t trap for mud and crust.


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MY 3 DOOR MANUAL GTI TRACK BUILD - WAVETRACK DIFF, CAGED, POLYCARBS, KO4, DB9 BRAKES, METH, BARTEK, VIS, HELIX PADDLE CLUTCH/SMF, FLOCKED DASH, 18X9 PRO RACE

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Offline shannon-ob

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The alloy rear hubs… can you reuse all the MK5 bolts? Or are they different?
No mate. Need longer bolts, get them off a Passat or scirocco being broken mate.


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OK.. thanks mate... I think ill just stick with OEM hubs I think, its turning into more hassle than its worth
Yeah I got mine cheap and the whole lot was being powder coated anyway. Also, they have a 32mm stub axle rather than 30mm on the steel ones. So need new bearings too...


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MY 3 DOOR MANUAL GTI TRACK BUILD - WAVETRACK DIFF, CAGED, POLYCARBS, KO4, DB9 BRAKES, METH, BARTEK, VIS, HELIX PADDLE CLUTCH/SMF, FLOCKED DASH, 18X9 PRO RACE

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Offline shannon-ob

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The arches finally came!



Wow, you will need wide load signs on the road!
Can't remember if you are keeping this road legal(ish)?
The rear arches go a lot higher than the OEM arch, how much metal do you think you will be chopping out?

I've got Scirocco alloy hubs waiting to go on to mine.  As far as I can tell the bolts are the same.

Yes - bolts the same.
Just note that the rocco ABS sensors plug in and work with the Mk5, but physically they are different length - you wont be able to use your old sensors as spares. Hopefully the ones in your hubs are good.
Yeah will be kept road legal buddy. Mainly for nice weather drives and driving to local tracks.

I’ve cut out about 50mm. I have pictures so will update


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MY 3 DOOR MANUAL GTI TRACK BUILD - WAVETRACK DIFF, CAGED, POLYCARBS, KO4, DB9 BRAKES, METH, BARTEK, VIS, HELIX PADDLE CLUTCH/SMF, FLOCKED DASH, 18X9 PRO RACE

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Offline LC5F

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The arches finally came!



Wow, you will need wide load signs on the road!
Can't remember if you are keeping this road legal(ish)?
The rear arches go a lot higher than the OEM arch, how much metal do you think you will be chopping out?

I've got Scirocco alloy hubs waiting to go on to mine.  As far as I can tell the bolts are the same.

Yes - bolts the same.
Just note that the rocco ABS sensors plug in and work with the Mk5, but physically they are different length - you wont be able to use your old sensors as spares. Hopefully the ones in your hubs are good.
Yeah will be kept road legal buddy. Mainly for nice weather drives and driving to local tracks.

I’ve cut out about 50mm. I have pictures so will update


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That a lot to take out, inner wing chopped too -  this will be mad on the road.

Thanks for correcting me my bolts error - I recall cross referencing the bolt sizes between Mk5 & Scirocco - all came up the same PN on 7zap - can only assume the Mk5 must have been superseded by the longer scirocco bolts.
Bearings I just ordered rocco ones.
« Last Edit: May 01, 2021, 01:41:57 pm by LC5F »

Offline shannon-ob

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Sadly no pictures of before to show the state of under the car.

You can seem all the seem sealer on the floor that I’ve removed! Never again will I do that

So all under the car and arches have had the seam sealer removed, rust removed and treated, zinc primed and then stone chipped.

Below is primed.



Stone chipped (is actually black, but wasn’t dry so looks grey)







Fitted both front and rear subframes so it could be rolled outside.



Very dusty! Can see the new sills here. Think I’ve done well getting the wheels to fit the arch.





I LOVE these brakes



Finally got it outside to rinse it off. Please ignore the rear steel wheels! Only have 2 tyres on the TDs for mock up purposes.







Surprisingly the windows aren't too bad, I was expecting them to be very scratched with all the dust!



The front wheels sit out VERY wide with not wing/arch on  :ashamed:






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« Last Edit: May 10, 2021, 03:31:41 pm by shannon-ob »
MY 3 DOOR MANUAL GTI TRACK BUILD - WAVETRACK DIFF, CAGED, POLYCARBS, KO4, DB9 BRAKES, METH, BARTEK, VIS, HELIX PADDLE CLUTCH/SMF, FLOCKED DASH, 18X9 PRO RACE

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Offline shannon-ob

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Someone had asked how much of the originally arch had been cut, the inner skin has since been folded up and welded.



Had put the rear subframe in with no shocks or springs and with as much neutral camber as possible just to make sure the rear arches were going to cover the wheel! Very close but I’ll be running about -1° camber so should have plenty of room.








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MY 3 DOOR MANUAL GTI TRACK BUILD - WAVETRACK DIFF, CAGED, POLYCARBS, KO4, DB9 BRAKES, METH, BARTEK, VIS, HELIX PADDLE CLUTCH/SMF, FLOCKED DASH, 18X9 PRO RACE

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Offline rich83

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What discs are those? AP or reyland?

Offline shannon-ob

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What discs are those? AP or reyland?
Reyland 370mm bud.


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MY 3 DOOR MANUAL GTI TRACK BUILD - WAVETRACK DIFF, CAGED, POLYCARBS, KO4, DB9 BRAKES, METH, BARTEK, VIS, HELIX PADDLE CLUTCH/SMF, FLOCKED DASH, 18X9 PRO RACE

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Offline rich83

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Nice... what pads did you go for? I have got some Mintex M1155 coming for mine, I hope they are the correct fit (slightly dodgy ebay listing)

Offline shannon-ob

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I believe these are 1166 if i remember corectly I’ll have to look back into it.


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MY 3 DOOR MANUAL GTI TRACK BUILD - WAVETRACK DIFF, CAGED, POLYCARBS, KO4, DB9 BRAKES, METH, BARTEK, VIS, HELIX PADDLE CLUTCH/SMF, FLOCKED DASH, 18X9 PRO RACE

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Offline rich83

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I believe these are 1166 if i remember corectly I’ll have to look back into it.


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Cool. I might message you tomorrow to cross reference part numbers just to check

Offline bobby_fodge

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Do you use any chemicals or just wire wheel on a grinder to get all the underseal off?

Offline shannon-ob

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Do you use any chemicals or just wire wheel on a grinder to get all the underseal off?

Just a wire wheel on the grinder. Wish there was some kind of chemical I could have left on there to soak. It was hard work.
MY 3 DOOR MANUAL GTI TRACK BUILD - WAVETRACK DIFF, CAGED, POLYCARBS, KO4, DB9 BRAKES, METH, BARTEK, VIS, HELIX PADDLE CLUTCH/SMF, FLOCKED DASH, 18X9 PRO RACE

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