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Carlan450 Mk5 GTI 4wd big turbo project

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Carlan450:
Again just after joining this site today. This is my project mk5 to go with my ed30. Here is the history up until now please excuse anything that seems out of place as I am copying from another forum.

So since work has physically begun i guess i should start this build thread.

Back in 2009 I inherited my golf from my dad, a standard gt tfsi 1.4 turbo.



I initially made a few light modifications:
Cat back milltek exhaust
Custom remap by Joe Power
K&N intake
Gti side skirts and rear bumper
R32 spoiler
Votex front splitter
Alpine head unit.

Last year I finally decided to turn the car into the gti that my dad had always wanted. However I wanted to put my own twist to it and as i'm powerhungry it wasn't gona just be a standard gti. So to start I went and bought myself a crashed 06 gti with manual AXX engine.

To get the power I wanted i needed to start ordering parts:



CTS GTX3071R turbo kit
CTS 600bhp Intercooler
Clutchmasters fx400 6 puck clutch and steel fly wheel
S3 injectors
high pressure fuel pump upgrade kit
Integrated engineering rifel drilled conrods
JE Forged pistons 9.5:1 compression
Ferrera valves and valve springs
BSH engine and gearbox mounts
ARP head bolts and studs
Layered steel compression dropping head gasket
Wavetrak LSD
Calico coated shell bearings
Newsouth performance, boost, oil temp, oil pressure gauges
S3 rail sensor
S3 MAP sensor

The first task of removing the engine was completed. To begin the chassis leg had been bent around the front of the engine so this needed to be straightened. (japs gotta have some use)

once this was done brought it in and stripped out the engine:







The turbo is just slightly smaller than the Garrett haha.Image

Next stage is to strip the engine and figure out the remaining parts needed

Got the engine stripped cleaned and sent off the head and block for a very light skim.

Checking big-n clearances with plastigauge great stuff.




Pistons ready to go in after adjusting ring clearances


In and torqued:




Head building


Went to put in exhaust cam and rockers but all badly corroded and pitted so order in for new ones.



So got the sump on and manifold. So decided to see how the turbo would look.





So with a delay due to the variable valve timing unit not wanting to be removed and collecting a few parts I have now made some progress.
Waste gate fitted.
Oil return pipe made up.
Valve timing unit on.

Just need to spend some time figuring out the rest of the Cts turbo kit



Update time: so I've got the engine together and timed up. Got a nice little rs4 part in the post, fuel return valve.
Awaiting new oil cooler before I complete plumbing and wiring. Also awaiting alternator belt.



Next steps:
Oil cooler on
Alternator on
Finish connecting loom.
Cut pipes for diverter valve to size.
Mount the gearbox

At the minute the engine is assembled with gearbox and clutch now attached. Need to get some bodywork done on the car over the next few weeks then r32 subframes on and test fit engine.

This is where my project is still lying currently. I am hoping to get a chance to get near it over the next couple weeks and get the subframes in and wired for haldex but unfortunately it is hard to predict the progress of this project.

th3_f15t:
Excellent work so far. Think someone has all the gear for converting a FWD mk5 to 4motion on here at a good price... I'll be watching this closely.

Andy:
Welcome to the forum and sharing you're project on here

Dublin Dub:
Great read might be slow now. But won't be in the further...

dansmith180:
Love reading builds like this, although it does make me very jealous. Can't wait to see the progress  :happy2:

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