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Golf Rallye 2.0 TFSI + Haldex 2gen

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2fast4you:
Ok here is how everything went :

I own a Golf Rallye and I'm  starting a engine swap. I have my eyes on an 2.5 tfsi engine from an  Audi TT RS witch I haven't found yet but I will.


















This are the parts that I already bought. Because my Rallye had a bit of rust on the front wing I had to find a new one








and I bought spare front and back fender


Haldex gen.2



ABS and the pump from a Golf 5 R32



Another spare pair of headlights



Dashboard from an Audi A3(leftover from the previous project)



Prop shafts:



one from Audi TT and another from a Golf 5 R32

And some more parts have just arrived

Recaro Speed seat



tail lights:



and the steering wheel




Going on with the dis assembly



I am removing the paint because I'm looking for rust and I was thinking to be repainting the body in tornado red or maybe...

2fast4you:
I bought these wheels





But I figured that those wheels are too big so I bought the OZ ultralegera 17x8 5x100







I thought these are the wheels for my project

What do you think?



I  have stopped removing the paint because when I'm done with everything I  will take the body shell to sanding and let the professionals do their  job.This is what I am doing right now.

And started fitting the MK5 dash





and modifying the rear axle to except the Haldex 2nd generation

first taking measures



then cutting and starting the fitting







the first holder















and bought a pair of front and rear Brembo brakes from a Touareg



here is to see how much space is the gen.2 haldex is going to take





and the work that has been done around the fitting of the dash

first of all I bought a new subframe



and the original Golf 5 holders that the sub frame is tighten to and cut them to fit





then more cutting



and then started making some pieces to weld on the chassis that would except the holders for the sub frame







after I welded the holders I cut the rest of the sub frame to fit between the pieces







took the sub frame to be welded and here are the results:





and...







after the sub frame was fitted next was the intake for the air conditioning



first I took a part of the air conditioning to be a little modified





and then everything could be welded



After all of these I had to redo the shifter because it had to move 2 sm back ( it was too close to the dash)










Then bought these Brembo 4 pot calipers because I've mounted the other ones that I had on the Audi S2 project that I've been working on so the Rallye gets them brand NEW.

2fast4you:







finished painting the Brembo's and this is how they look now.








opened the hole for the MK5 Heating



and done the engine mount








and  something very important to me is that finaly I finished my garage.  When I started mu project I got some comments saying "that's a creepy  garage"
Well lets see how you like it now










Then some parts (of the many that I ordered) arrived so here they are:

The front disc 323x28 punched from Seat leon Cupra



and here they are with the BREMBO's



OMP Competition Belt 3", 4 fastening points x2



and more to come

the powerflex for the front axle



I  also ordered adapters for the brembo and been waiting for them for a  month. They newer came, so I email ed the firm that I bought the  adapters from and they told me that they haven't sent them yet :mad:  because they are inserting some new features on them :confused:
In the mean time I will be painting the complete front Axle with the control arms


And some more parts






The front axle was sandblasted covered with primer, painted and finally assembled













bought a steering rack from VW Polo 9N and the servo motor

2fast4you:
and the Brembo Adapters came finally after 2 months of waiting



and after I had all the parts in one place everything started to come together as it should











and I must say that I've had help from Mario. You must ask you're self "who the f..k is Mario"
Well  Mario is the guy who's car was the inspiration for me to begin with  this project, you can find his project a MK2 golf with a 2 liter TFSI  engine and doing a very good job here is a link of his site where you can find some info and pictures of Mario's Golf.

http://www.golf2tfsi.de/html/home.html

I think he is watching this thread so I will use this chance to thank him for his help "THANK YOU MARIO"
Although I'm not finished with you I will need some advices in the future


I'm  getting ready to finish up some minor things around the dash and start  building a Roll cage. In the mean time the only part that was ordered,  and arrived were the H&R triple C chamber bolts




I'm just about to finish up the rear axle
This is how the rear axle looks:











one of the things I need to finish are these for Camber/toe adjustments



I bought these from my local VW dealer they are from Audi RS6 rear axle, you can find them on the ETKA as part number:WHT001682   that is if anybody needs them. All i need to do now is to make  camber/toe plates. If you want these all done you can find them on this  site:
http://www.dutchbuild.com/index.php?page=shop.product_details&flypage=flypage.tpl&product_id=87&category_id=15&option=com_virtuemart&Itemid=104&lang=en&vmcchk=1&Itemid=104


gathered all the screws and nuts including the ones needed for the chamber adjustment and took them to be chromed.



and how they turned out









not perfect but OK

OK finally came the last parts that I needed to finish the rear axle.

Powerflex





And  these are the rings and the bonded aluminum bush that I need to finish  the mounting points on the axle. There are going to be 4 mounting points  something similar to the factory rear axle from golf Mk5 4 motion



and  the piece between the rings is an adapter that I need to combine the  Golf Mk5 brake master cylinder and the 94 Passat VR6 brake and clutch  pedals. And when these piece is welded it should look like this:
















I also took the rear axle holder to be chromed



the Roll Cage from OMP arrived :

2fast4you:
... so the work continues

I finally found a Lancia delta Integrale hood
Here are some pictures







I was looking foe these hood for a ling time and finally found one :peace:


finished installing the roll cage . The roll cage needed some modifications to accept the Golf 5 dash but finally it's done Here are some pictures:















And here is the support to the suspension housing from the roll cage that I planed on doing :confused:
What do you think?























finished the rear reinforcement







also finished the front reinforcement from the suspension housing to the roll cage









so moving forward with the project


Today I finished modifying the tunnel to receive the Golf MK5 selector mechanism .
Started by cutting a bigger hole for the selector mechanism and drilling holes to get it fixed:



the small holes were made to remove the MK2 selector mechanism mounts



did some modifications on the tunnel to fit the MK5 selector mechanism



and here is how it came out:








in the mean time I mange to find time to build this :









so I can move the shell in mu garage :laugh:
and some shopping was done:
Rear 4 piston calipers from Shevrolet Camaro SS 2010+ for the rear axle



brake disc for the rear :



also bought H&R FRONT SWAY BAR VW GOLF 3 VR6 25MM
and the emblems:


Finally finished the roll cage

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