MK5 Golf GTI

All Things Mk5 => Members Rides => Topic started by: shannon-ob on February 10, 2020, 01:50:24 pm

Title: GTI Track Car - Manual, Wavetrack Diff, Caged, Polycarbs, KO4, DB9 Brakes, METH
Post by: shannon-ob on February 10, 2020, 01:50:24 pm
Hi all,

Been a member for some time now and thought it's about time i did a build progress of my GTI track toy  :driver: I've had it over a year now!

This is actually my second MK5 GTI, I had another black 3 door manual AXX a few months before but couldn't warrant having 3 cars so one had to go which was the Golf.

I ended up buying the current Golf as my new track car after my 106 GTI had a big rust issue. From my experience of the last GTI I owned I thought they'd make a great track car!

I didn't want to spend too much on buying a MK5 as it was just going to be a track car. The only things i was worried about was it being a 3 door and manual.

After looking around a bit I manged to find this on Gumtree, It was in London so I got a mate to take up at the weekend.

57 Plate
BWA Engine
Manual
3 Door
Heated Tartan Cloth
Xenons
Edition 30 alloys
R8 Coils
112k miles

(https://uploads.tapatalk-cdn.com/20200210/8db3cda30518eebc11701aeae95692a8.jpg)

(https://uploads.tapatalk-cdn.com/20200210/7781171f866dcb61f209bd92486b379d.jpg)

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Wasn't the cleanest and someone has tried to break into it in the past which had bent the door and dented the pillar. However, it drove well and was a good base for the track build. I walked away paying only £1700 for it!

On the way back from buying the car I picked up a drivers OMP seat mount base, custom harness bar and X brace and a RAMAIR induction kit.

(https://uploads.tapatalk-cdn.com/20200210/9377253dec46302227e09ac60af57483.jpg)

First thing to do when i got it home was put it on a diet! All interior removed, carpets, radio, rear seats, rear doorcards, trims etc. Borrowed friends Cobra seats whilst i was waiting for mine to be delivered. I changed the cam follower also.

(https://uploads.tapatalk-cdn.com/20200210/33172821ba1aa53bbd1b901eaf602bfe.jpg)

(https://uploads.tapatalk-cdn.com/20200210/638b19b6f9fbb789600a4cd9b427aec6.jpg)

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Next was to get the handling sorted so I bought a set of BC coilovers with S3 alloy hubs.

(https://uploads.tapatalk-cdn.com/20200210/1ec4e7fcf211d1058deffdeac40dd046.jpg)

(https://uploads.tapatalk-cdn.com/20200210/de18c6a8116434a088f0cec198ec02df.jpg)

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Replaced a broken PCV hose.

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Ordered a 300mm satin black sunstrip due to removing visors I couldn't see!  :laugh:

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A random picture of the old daily E91 and GTI on a cold morning.

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Bought a GFB DV+ and the latest revision DV. Helped the boost out ALOT!

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Was daily driving it for a couple of days after cracking a wheel on the E91 and this was just not my week...

(https://uploads.tapatalk-cdn.com/20200210/c330797e34993fd7008d5ee680e3d087.jpg)

Gave the cars a clean...

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Found some bargain Team Dynamic Pro Race 1.2 18x8 come up on FaceBook so I got them bought and sold the ED30 wheels.

(https://uploads.tapatalk-cdn.com/20200210/54c032997b59392b79e36ee5857809ea.jpg)

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(https://uploads.tapatalk-cdn.com/20200210/b2762026a1a816f47d5d6adb3f7c5ff0.png)

Fitted a red coilpack wiring cover, not sure about it still!

(https://uploads.tapatalk-cdn.com/20200210/65e5873c84726ad9dba8a3685c3e1dd2.jpg)

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Bought some Nankang NS2R semi slick tyres to replace the bald ones that came with the TD wheels.

(https://uploads.tapatalk-cdn.com/20200210/12560d76a082aefd609202c921b1caee.jpg)

Some Random picture when out with friends...

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Bumper off to remove headlight washing system, fog lights and repair broken tabs on the xenons.

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Track session at Castle Combe, my wheel luck strikes again after hitting the kurbs a bit hard...

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A random driveway picture with old daily E91...

(https://uploads.tapatalk-cdn.com/20200210/bf87534d7a70ba7fee89945b64b503a6.jpg)

Made a radio blank

(https://uploads.tapatalk-cdn.com/20200210/24dff0f1e7d6978fc0bf14357c087aee.jpg)

Mounted my mocal 13row oil cooler ready to be plumbed in and fitted aerocatchs

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(https://uploads.tapatalk-cdn.com/20200210/e24249b8dcac021500d5e84041e86c95.jpg)

Replaced front ball joints after killing them on the track session.

(https://uploads.tapatalk-cdn.com/20200210/edce10ac8fc430147813623a95d285ff.jpg)

Random picture on a multi story car park in Bath.

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Cleaned the car day before attending Castle Combe for a show and booked a track session  :wink:

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Bought some alloy lower arms ready to fit power flex bushes

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Sold the E91 daily driver so used the golf for a couple of days whilst waiting to collect new daily driver.

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Went for a drive down to Cheddar Gorge with a mate who kindly got the Golf very dirty.

(https://uploads.tapatalk-cdn.com/20200210/24076f38bb66ced87d4d29e267ba1c9d.jpg)

Bought a fibreglass bonnet.

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Love how it cocks a wheel going on the drive  :P

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Now coming up to date, I treated the golf to some christmas Pressies...

Alloy foot plate
Porsche 996TT Calipers, DS2500 Pads, J Hook Discs, HEL lines, Motul RBF500
Powerflex black series bushes for alloy lower arms
OMP WRC wheel and boss
HEL rear lines
S3 Alloy intercooler

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Got the bushes fitted to the new arms and fitted. Old bushes had definitely seen better days...

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Got the Porsche Calipers fitted  :love:

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Went to get the tracking done after doing the front arms to be told the rear toe bolts were seized. £38 later  :surprised:

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I also bought some more bits...
New Rear wheel bearings
Forge PCV Delete
VWR quick shift
Garage Midnight Stud and Nut conversion
Power Flex Black series rear bushes for hub and control arm

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Sold another daily driver so was using the golf daily again...

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Bought scirrco rear alloy hubs and new arms to fit the new bushes too.

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Bought a Varley Red top from a friend breaking a race car

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Fitted the new rear hubs (which are a 12mm wider track) and arms (which were a pain as I had to cut the old bolts out!) no pictures fitted I'm afraid. However,  whilst fitting I noticed that all the other bushes on the rear were a bit past it so bought more bushes and arms to have cleaned up and fitted to..

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That's it for now!

I'll try to keep this updated as that took a while  :signLOL: :signLOL:

Thanks for reading.
Title: Re: MK5 GTI Track Car
Post by: shannon-ob on February 10, 2020, 03:50:35 pm
forgot to mention. I have booked and paid deposit for a full weld in roll cage  :love:
Title: Re: MK5 GTI Track Car
Post by: bobby_fodge on February 10, 2020, 08:12:47 pm
Looks serious.

How much weight did you save removing the front fogs and headlight washers?

Have you got ducting connected up to the fog light holes now?
Title: Re: MK5 GTI Track Car
Post by: shannon-ob on February 11, 2020, 07:48:56 am
Looks serious.

How much weight did you save removing the front fogs and headlight washers?

Have you got ducting connected up to the fog light holes now?

Stupidly enough, I didn’t weigh it  :ashamed:

I haven’t yet put any ducting in yet, is on the list to do. May get the open fog grills though.
Title: Re: MK5 GTI Track Car
Post by: shannon-ob on February 14, 2020, 10:16:35 am
Got a delivery yesterday!

(https://uploads.tapatalk-cdn.com/20200214/d0b80f1a2638a4da40c76ae3dc340970.jpg)

I also had the second hand arms turn up too. However, no pictures of these. Got the old bushes pressed out and painted the arms ready for the powerflex bushes to go in


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Title: Re: MK5 GTI Track Car
Post by: shannon-ob on February 14, 2020, 08:22:29 pm
Did an edit with the radio blank to mount the boost gauge and bolt gauge. Works well in the car 
(https://uploads.tapatalk-cdn.com/20200214/1aeb361cdb31edaf59e5feda069ddc4d.jpg)


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Title: Re: MK5 GTI Track Car
Post by: Shoy1980 on February 15, 2020, 12:25:16 am
Great build mate, keep up the good work.

Sent from my SM-G950F using Tapatalk

Title: Re: MK5 GTI Track Car
Post by: shannon-ob on February 15, 2020, 07:31:15 am
Great build mate, keep up the good work.

Sent from my SM-G950F using Tapatalk


Thanks buddy.


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Title: Re: MK5 GTI Track Car
Post by: Robburgazzi on March 02, 2020, 12:10:06 pm
Looks like a good build mate - Where'd you pick up the S3 cooler from? Looks new!?
Title: Re: MK5 GTI Track Car
Post by: shannon-ob on March 02, 2020, 12:43:50 pm
Looks like a good build mate - Where'd you pick up the S3 cooler from? Looks new!?

Thanks mate!

Yes is brand new. I’m a Nissens dealer so got it at a great price also.


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Title: Re: MK5 GTI Track Car
Post by: shannon-ob on March 10, 2020, 04:33:12 pm
Not too much to update.

Got all the rear bushes mounted up and got the car geo set up done.

I can confirm it’s extremely tight/stiff.

In other news...

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(https://uploads.tapatalk-cdn.com/20200310/d882b30805986c87c5353b07c332ca71.jpg)

The golf’s new home! Finally got myself a unit :)

Which meant I could finally work in the dry, warm (ish) with power and a ramp (although working on the floor..)

(https://uploads.tapatalk-cdn.com/20200310/9a221a945526a4cbf20f751c4e37069c.jpg)

Test fit of the fibreglass bonnet..

(https://uploads.tapatalk-cdn.com/20200310/1520304dc7c78caee26f75509863b218.jpg)

Front end off to replace the broken slam panel and lots of maintenance jobs.

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(https://uploads.tapatalk-cdn.com/20200310/5e4a8bc6ec2c830af784af6d02a1f07c.jpg)

So the car goes off for cage this weekend coming! So I’ve got the dash out, seats out, glass out (to be replaced with poly carbs!) and got to drill out any spot welds.

I’ve also done so maintenance and upgrades;
Pick up pipe
Re seal sump
Ordered the missing gasket from turbo oil return to sump
Removed standard oil cooler to make way for the mocal 13 row cooler and oil stat.
Inlet been off to fit the RFD
Had an oil leak from the cam chain cover the gasket had seen better days and the o ring from the vacuum pump was missing
Whilst I have the cover off I’ll do the cam chain and tensioner
Rocker cover gasket was also very brittle so glad I’m doing it.
Cambelt and water pump will be getting done too.
I’ve also bought the latest revision of dipstick and tube.

Lots to do

Some parts supplied by AKS.

(https://uploads.tapatalk-cdn.com/20200310/5d5b58626a0d413336c35a65146e1f4f.jpg)

RFD installed

(https://uploads.tapatalk-cdn.com/20200310/ffdc7170140d349352c05d12b3bc646f.jpg)

The intake temp sensor that someone bodged and super glued

(https://uploads.tapatalk-cdn.com/20200310/606c516943239a59168d0a5dbca0c502.jpg)

That’s all for now. Will try to keep updated!


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Title: Re: MK5 GTI Track Car
Post by: shannon-ob on March 17, 2020, 10:13:10 am
Golf got stripped and sent off to James at Garage24 for the cage and a few other bits. Looks very mad max like this!

Cannot wait to get it back. For anyone interested in his work or seeing progress of the cage built his intsagram is @_garage_24

(https://uploads.tapatalk-cdn.com/20200317/b5b0fe4bb08d56af4eb56aecb6d1fb74.jpg)

(https://uploads.tapatalk-cdn.com/20200317/b107cc15499e25e5cd433fcca7a74d58.jpg)

(https://uploads.tapatalk-cdn.com/20200317/3bff640b8535cfd18278d0babfaebcfb.jpg)


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Title: Re: MK5 GTI Track Car
Post by: shannon-ob on March 25, 2020, 09:04:08 am
The cage is complete

(https://uploads.tapatalk-cdn.com/20200325/3c37eb434e50ccf906a4be7010087322.jpg)

(https://uploads.tapatalk-cdn.com/20200325/b555ba57947ff0c3c082436cc7d91661.jpg)

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(https://uploads.tapatalk-cdn.com/20200325/26a83c952120838d6f56e01428233489.jpg)

 
 
(https://uploads.tapatalk-cdn.com/20200325/8a18caaa7fcbf3c7792ba10d88a6fd70.jpg)

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(https://uploads.tapatalk-cdn.com/20200325/ddfe6def54123684b80b47e736e4fa01.jpg)


Bit of a tidy up/paint to do when I take collection of it. But wow. Looks incredible!


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Title: Re: MK5 GTI Track Car
Post by: shannon-ob on April 07, 2020, 12:13:45 am
 
 

(https://uploads.tapatalk-cdn.com/20200406/5524accfc5b0e21adb69bbef015accad.jpg)

(https://uploads.tapatalk-cdn.com/20200406/2dd93d05e95ccd8e38f0ff859aac3d47.jpg)

(https://uploads.tapatalk-cdn.com/20200406/c12b9d81bb3124bf53273a7c777a1d28.jpg)

Had the spare wheel well cut out and a new panel welded in to get ready for centre exit exhaust!

It’s slowly getting there


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Title: Re: MK5 GTI Track Car
Post by: LC5F on April 07, 2020, 08:51:19 pm
Nice gussets!
Title: Re: MK5 GTI Track Car
Post by: shannon-ob on April 10, 2020, 11:05:02 am
Nice gussets!
Thanks man :)


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Title: Re: MK5 GTI Track Car
Post by: shannon-ob on April 11, 2020, 03:17:30 pm
Got the cage/inside into primer

(https://uploads.tapatalk-cdn.com/20200411/4e98a5cd6e6fd2cc1f841de1165185de.jpg)

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(https://uploads.tapatalk-cdn.com/20200411/a9fe5596e0ef45ab79695e4952d85d27.jpg)

(https://uploads.tapatalk-cdn.com/20200411/06ea6bfadffacce464b4f24112a5d2b5.jpg)

(https://uploads.tapatalk-cdn.com/20200411/0f125494fcaf3a899cd0e9b791af8761.jpg)

(https://uploads.tapatalk-cdn.com/20200411/d87d807db70682278ea50c26c6713bbf.jpg)

(https://uploads.tapatalk-cdn.com/20200411/b6e588cf7f6cd72069829459519b30bf.jpg)

(https://uploads.tapatalk-cdn.com/20200411/af385de4517c1542e8f202e90a8d686f.jpg)


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Title: Re: MK5 GTI Track Car
Post by: shannon-ob on April 11, 2020, 03:32:46 pm
All painted up! Started to refit some parts. Waiting for some ring terminals to come then I can wrap the loom up.

(https://uploads.tapatalk-cdn.com/20200411/758c0d4976f2b173bdcf28a7d5b75ed4.jpg)

(https://uploads.tapatalk-cdn.com/20200411/b20f61fa8709ffa8f63e7fc25e558128.jpg)

(https://uploads.tapatalk-cdn.com/20200411/e19d5b3322caef4521a89264a125190e.jpg)

(https://uploads.tapatalk-cdn.com/20200411/a1e34bd7c94b88da5c75396df3092435.jpg)

(https://uploads.tapatalk-cdn.com/20200411/7253fa7b94e5bd00bc3cb60244847bfd.jpg)

(https://uploads.tapatalk-cdn.com/20200411/3456e99592b4050305d4a90136325efc.jpg)

(https://uploads.tapatalk-cdn.com/20200411/2e4b95aa4dff5d3b9d5f85a687d83f53.jpg)


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Title: Re: MK5 GTI Track Car
Post by: shannon-ob on April 11, 2020, 03:35:02 pm
Got the dash cut and test fitted before painting the cage. Heater blanks as I’ve decided to remove the heating system. Due to weight and size. Going to fit an electric fan instead.

(https://uploads.tapatalk-cdn.com/20200411/1c90f1989981c319a86ccf3d94613f9b.jpg)

(https://uploads.tapatalk-cdn.com/20200411/01affa4ec1b3eb9713bee011067e9f8c.jpg)

(https://uploads.tapatalk-cdn.com/20200411/d277fab70d018d17c76453178d759bac.jpg)


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Title: Re: MK5 GTI Track Car
Post by: El1M1N8OR on April 11, 2020, 09:34:10 pm
The gold inlet for the air filter is looking tidy
Title: Re: MK5 GTI Track Car
Post by: shannon-ob on April 11, 2020, 10:36:35 pm
The gold inlet for the air filter is looking tidy
Thanks mate. Will be going custom intake soon no doubt!


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Title: Re: MK5 GTI Track Car
Post by: shannon-ob on April 16, 2020, 10:20:42 am
Bought a new down pipe!

Ignore how close the cables sit. I’ve installed the shifter inside the car rather than under. So need to make a bracket for the cables.

(https://uploads.tapatalk-cdn.com/20200416/3f3f47adcbd55975abf82c46759958e9.jpg)

(https://uploads.tapatalk-cdn.com/20200416/5b1acca165cd0d8b3e527ac244cd5d10.jpg)

(https://uploads.tapatalk-cdn.com/20200416/7810ee3207a40210e62c9c6ea4d06f97.jpg)


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Title: Re: MK5 GTI Track Car
Post by: Marok on April 16, 2020, 11:11:43 am
Thats looking like a proper job, nice work dude!

How do you find the new brake set up?
Title: Re: MK5 GTI Track Car
Post by: shannon-ob on April 16, 2020, 11:19:09 am
Thats looking like a proper job, nice work dude!

How do you find the new brake set up?
It’s getting there man!

I’ve yet to use it under any force or hard driving. But did use it daily for a short while and defo stop well. Great pedal feel etc. Great upgrade for the money!


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Title: Re: MK5 GTI Track Car
Post by: Jo53uac on April 18, 2020, 10:05:54 am
Mega build  :happy2: how do u find the NS2R on track?
Title: Re: MK5 GTI Track Car
Post by: shannon-ob on April 20, 2020, 11:44:06 pm
Mega build  :happy2: how do u find the NS2R on track?
Thanks my dude.

Uhh they wasn’t too bad to be honest. For the price they’re good tyres! I think with more power I’ll be looking at the AR1 next tho.


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Title: Re: MK5 GTI Track Car
Post by: shannon-ob on May 12, 2020, 09:53:28 am
Bought a creation motorsports coolant and carbon canister silicone hose kit. Mainly to replace a couple of coolant hoses that were worn and perished.

(https://uploads.tapatalk-cdn.com/20200512/f77616b297fcb34eb8051241d4fe1309.jpg)

Sadly, one of the hoses I needed to replace didn’t come in the kit. Nor can I find any company that makes it in silicone. It’s the long hose that comes from top hose down past the oil cooler to the auxiliary water pump at the bottom of the engine. Hoping someone else has the answer?

This is the hose in question:

(https://uploads.tapatalk-cdn.com/20200512/a29451e41ba0d955c2286d16f9fdedd2.png)

Collected the poly carbonate windows from ACW motor sport plastics. For now I’ve just ordered the rear 3. Will get the fronts when funds aren’t so low.

Just waiting for the adhesive to come so I can get them bonded in.
 
(https://uploads.tapatalk-cdn.com/20200512/8194898fa4a8e820b70628bfcddf0620.jpg)

Few pictures of the car looking complete again.

Fibreglass bonnet all fitted.

(https://uploads.tapatalk-cdn.com/20200512/76014ee35f24b9ddc15f2c1314359419.jpg)

(https://uploads.tapatalk-cdn.com/20200512/e2f81d3b1e959bb1316d4b7d687b16e2.jpg)

(https://uploads.tapatalk-cdn.com/20200512/78498d9d5070dad8e3b8be2c8dc1a00b.jpg)

Loom has been wrapped and clipped into place. Had to relocate the fuse box as it sat too close to the cage.

You may notice there’s no heater box and a blank where matrix pipes would run - I’ve decided not to run heaters. Instead will get a 12v heater fan.

(https://uploads.tapatalk-cdn.com/20200512/1ad5483bb04a57bc023ace398bd09c19.jpg)

Chopped the boot...

(https://uploads.tapatalk-cdn.com/20200512/39d3553e96ac0abf0d2d864380e747a2.jpg)

Not much to do before the hopeful track day in June.


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Title: Re: MK5 GTI Track Car
Post by: shannon-ob on May 13, 2020, 09:20:58 am
So, I think I have found this issue regarding the aux water pump feed hose.

My set up is like the one below, where the aux pump (15) is fed from top hose (46) via a T piece (10).

The Lower rad hose (1) is one hose as is the turbo hose (20).

(https://uploads.tapatalk-cdn.com/20200513/cc443b993762c45b99239dcc28eb9c5c.png)

Below is the setup I think I’ll change to as most silicone hose suppliers make the lower coolant hose set for this type of set up.

The aux pump is fed from the lower road hose (1 & 7) via a T piece (10).

This then means that the top hose (46) is one hose with no T piece. For me this is best as my red silicone hoses I bought would require a cut in the middle.

Lastly, the turbo hose (20) is 2 separate hoses joined by a connector (21).

One question for anyone who has fitted the silicone lower hose kit - hose number 7 where that is a fitting on the end for a sensor, does this come apart from the OE hose?

(https://uploads.tapatalk-cdn.com/20200513/3ad7e654e2d9da02529fc0cc29f46ba4.png)

So going by what I’ve seen above. I think the only parts I’ll need is a lower coolant hose kit like below, and a couple of connectors 21 & 10. I believe things like the aux pump (15) and the turbo hardline pipe (22) should be the same.


(https://uploads.tapatalk-cdn.com/20200513/f7a8b7ba78e51a5fbfd5a047d4f3d37d.png)

I thought I’d add this to my thread for a reference to myself and for anyone else that may need these answers.

I will be buying the hose kit and checking it all works ok and will update with results.


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Title: Re: MK5 GTI Track Car
Post by: LC5F on May 13, 2020, 11:51:09 am
Item 21 looks like the in-line thermostat, some cars have 2 (like in the last image) - but the majority seem to only have the one (first image). You could just use a hose joiner here.
I would be happy with OEM rubber as long as there is no damage, its a lot more likely for the plastic in the connectors to degrade and fail before rubber.
Oh, if Creations heating hoses are anything like their boost hoses... you will have a lot of trimming to do
Title: Re: MK5 GTI Track Car
Post by: shannon-ob on May 13, 2020, 02:42:22 pm
Item 21 looks like the in-line thermostat, some cars have 2 (like in the last image) - but the majority seem to only have the one (first image). You could just use a hose joiner here.
I would be happy with OEM rubber as long as there is no damage, its a lot more likely for the plastic in the connectors to degrade and fail before rubber.
Oh, if Creations heating hoses are anything like their boost hoses... you will have a lot of trimming to do
Ahh ok thanks. I’ll check what the part number says it is.

My OEM are worn sadly. So if replacing. Would like to replace with silicone.

CMS hose kit I’ve used so far is slightly longer but nothing too bad! Good price too.


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Title: Re: MK5 GTI Track Car
Post by: shannon-ob on May 15, 2020, 12:03:19 pm
Thought I’d get a quick picture of the custom crash bar and the oil cooler location whilst I had the bumper off.

(https://uploads.tapatalk-cdn.com/20200515/e3737494e7f89bba4ff0b71543f24389.jpg)

How the engine bay is looking so far.

(https://uploads.tapatalk-cdn.com/20200515/9e1952097f9e0ceb517ffb6974078cfa.jpg)

Made a clip to hold the shifter cables away from the down pipe.

(https://uploads.tapatalk-cdn.com/20200515/152618c0ee36c1e1ffb5866dd3aa7f9d.jpg)

Rear poly carbs bonded in.

(https://uploads.tapatalk-cdn.com/20200515/7efde82a9b3b3a67a21821bc440be20f.jpg)

(https://uploads.tapatalk-cdn.com/20200515/123bf8c534900f01e6d614a444f12390.jpg)

(https://uploads.tapatalk-cdn.com/20200515/a4ea1052ea3b404e3d1f2b103aa5a202.jpg)


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Title: Re: MK5 GTI Track Car
Post by: shannon-ob on May 22, 2020, 11:10:07 am
Dash has been flocked and now fitted.

Probably going to wrap the bits in the vents satin black.

Screen booked in for next week!

(https://uploads.tapatalk-cdn.com/20200522/c378329417a37ccfabd3309b589ac69d.jpg)


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Title: Re: MK5 GTI Track Car
Post by: bobby_fodge on May 22, 2020, 12:00:05 pm
could just spray the vents satin black instead?
Title: Re: MK5 GTI Track Car
Post by: shannon-ob on May 22, 2020, 12:01:01 pm
could just spray the vents satin black instead?
Got a lot of vinyl left over anyway dude so I’ll try that


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Title: Re: MK5 GTI Track Car
Post by: shannon-ob on May 28, 2020, 07:16:55 pm
Screen was fitted yesterday.

Roughly did the exhaust to gauge sound and style. Have since ordered in 3”. Won’t be Turner down as much as this though.

Felt good to be back in it. Sadly it needs another alignment as it’s pulling a bit. Also steering the traction control off if I’ve not turned it off.

Also, I have the big cooling fan on all the time. I’m guessing this is due to me pulling the heaters? Could anyone shed some light on this?

It needs a good clean but can get the screen wet for 24 hours so this can wait till next down there.

(https://uploads.tapatalk-cdn.com/20200528/d27eeed38312df46a7f4142608d62b01.jpg)

(https://uploads.tapatalk-cdn.com/20200528/19fc25851afd0d5c9478f9cbf59d106c.jpg)

(https://uploads.tapatalk-cdn.com/20200528/49b101fce38f2728368d4a912e60a9ca.jpg)

(https://uploads.tapatalk-cdn.com/20200528/5ceb0f5232a4cc3bbccfca3dde770096.jpg)

(https://uploads.tapatalk-cdn.com/20200528/aba89aab4efa2eb454503b7aeebb90dc.jpg)


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Title: Re: MK5 GTI Track Car
Post by: bobby_fodge on May 29, 2020, 03:35:38 pm
Did you take any coolant pipework out?

Does the fan come on as soon as you start the car from cold?
Title: Re: MK5 GTI Track Car
Post by: shannon-ob on May 30, 2020, 07:13:21 pm
Did you take any coolant pipework out?

Does the fan come on as soon as you start the car from cold?
I’ve ran the aux water pump from the lower rad hose as apposed to the top hose.

Yeah fan comes straight on.

Perhaps it could be something to do with removing the heaters?


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Title: Re: MK5 GTI Track Car
Post by: rex on May 30, 2020, 07:23:19 pm
(https://uploads.tapatalk-cdn.com/20200528/19fc25851afd0d5c9478f9cbf59d106c.jpg)

Love the way you left room for the diffuser!
I also thought about that in the eventuality I need a rear diffuser...
Title: Re: MK5 GTI Track Car
Post by: shannon-ob on May 30, 2020, 07:24:31 pm
(https://uploads.tapatalk-cdn.com/20200528/19fc25851afd0d5c9478f9cbf59d106c.jpg)

Love the way you left room for the diffuser!
I also thought about that in the eventuality I need a rear diffuser...
I may just leave it open to be honest


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Title: Re: MK5 GTI Track Car
Post by: Andy on June 14, 2020, 12:37:29 pm
brilliant built thread and keep the updates coming.i have moved the other posts that were on here  :happy2:
Title: Re: MK5 GTI Track Car
Post by: shannon-ob on June 14, 2020, 03:20:31 pm
brilliant built thread and keep the updates coming.i have moved the other posts that were on here  :happy2:
Many thanks Andy :)


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Title: Re: MK5 GTI Track Car
Post by: John_Arthur on October 10, 2020, 06:49:23 pm
Wow man, I hope one day I will finish my Volkswagen golf tuning as well as it takes a lot of time and money. I have always been inspired by authors that are publishing a different kind of cars news (https://carbuzz.com/) and so one day I bought a Volkswagen golf gti in a decent condition and I want to make a good tuning to it. I see you did a pretty good job on the pictures and always was curious is it ok to drive such a low ground car and does it touch the ground when you ride it up the hills. Sorry if my questions sound a bit weird I am just new to tuning and after I bought my car for tuning I have a lot of questions before doing something and just want to learn from someone's mistakes.
Title: Re: MK5 GTI Track Car
Post by: shannon-ob on October 12, 2020, 02:58:43 pm
Wow man, I hope one day I will finish my Volkswagen golf tuning as well as it takes a lot of time and money. I have always been inspired by authors that are publishing a different kind of cars news (https://carbuzz.com/) and so one day I bought a Volkswagen golf gti in a decent condition and I want to make a good tuning to it. I see you did a pretty good job on the pictures and always was curious is it ok to drive such a low ground car and does it touch the ground when you ride it up the hills. Sorry if my questions sound a bit weird I am just new to tuning and after I bought my car for tuning I have a lot of questions before doing something and just want to learn from someone's mistakes.

I don't have any ground clearance issues.
Title: Re: MK5 GTI Track Car
Post by: shannon-ob on October 12, 2020, 02:59:40 pm
Need to do another update on this.

Some things have since updated/changed...  :grin:
Title: MK5 GTI Track Car
Post by: shannon-ob on October 15, 2020, 04:57:27 pm
So, as promised an update!

Not an awful lot has changed on the Golf.

I've taken it for some drives...

(https://uploads.tapatalk-cdn.com/20201015/ac9ef75309cfc3c44230f733bfab04ca.jpg)

(https://uploads.tapatalk-cdn.com/20201015/1236e30f50511bf41553a930e35e4cca.jpg)

(https://uploads.tapatalk-cdn.com/20201015/f0d5f4036dff98c84a3ba45f30320ccf.jpg)

(https://uploads.tapatalk-cdn.com/20201015/47c102534939fde510c5ab4ee516a58e.jpg)

(https://uploads.tapatalk-cdn.com/20201015/faa1c3178531bef2c3bbccb4adba4f80.jpg)

(https://uploads.tapatalk-cdn.com/20201015/2466aa53f27d4d05d0bf5ae53d76f13a.jpg)

(https://uploads.tapatalk-cdn.com/20201015/269a504b0801f82746df141cf9881355.jpg)

I also ended up getting the front poly carb windows in from ACW and chopped the door up  :scared:

(https://uploads.tapatalk-cdn.com/20201015/b23205eb93d06b504d36a23cd4773784.jpg)

(https://uploads.tapatalk-cdn.com/20201015/fff0117b9195084f5af4690056461cad.jpg)

(https://uploads.tapatalk-cdn.com/20201015/4b497990d1c965672a4f57a8d3cd02d9.jpg)

Also have added a catch can and blanked the PCV completely. Removed the Charcoal canister too! (Probably end up mounting the catch can where that was)

Cut the alternator bracket for all that weight saving  :grin:

(https://uploads.tapatalk-cdn.com/20201015/1766d0b89aaea4d0315efb71e1e1b97c.jpg)

(https://uploads.tapatalk-cdn.com/20201015/59c6aa9dc51761edfad742f2eef7eb93.jpg)

(https://uploads.tapatalk-cdn.com/20201015/0a296fdd4c3293fdcd0953c9b14ac359.jpg)

(https://uploads.tapatalk-cdn.com/20201015/fbf08f58129113ff663bb024e402c7c0.jpg)

Had a friend of mine come down and finish the rear section of the exhaust, now a full 3" system, no cats, 1 silencer. It sounds perfect! those welds too  :drool:

(https://uploads.tapatalk-cdn.com/20201015/3c4e49cb960c47880a7302280432f415.jpg)

(https://uploads.tapatalk-cdn.com/20201015/3975d5d87d462de96eec29cd03459ab6.jpg)

(https://uploads.tapatalk-cdn.com/20201015/faa00ecd64e3167ea52ad1f08c39cd7d.jpg)

(https://uploads.tapatalk-cdn.com/20201015/24696e539d6e4ce000f356e4ecfe7071.jpg)

I've got rid of the Pro Race 1.2 8J set up and gone for a 18X9 Pro Race 1.2 set. I was told they're ET35 but I think they're lower than this, I'm yet to measure properly. It's safe to say, they're wide  :jumping: I'm definitely going to have to look at getting the ABS Motorsport Golf S2000 arch kit.

(https://uploads.tapatalk-cdn.com/20201015/fd875ba00892775a4d7ff3b3e88070e4.jpg)

(https://uploads.tapatalk-cdn.com/20201015/d80ee62adfebf26be76ccb90a7d83791.jpg)

(https://uploads.tapatalk-cdn.com/20201015/1e0dd4e4722e47d4a9bac9dcd82a617a.jpg)

(https://uploads.tapatalk-cdn.com/20201015/e86a9c2c18de633efedb13a6bbcf3023.jpg)

(https://uploads.tapatalk-cdn.com/20201015/ce6430aa46acd24da9699ec7d74dd7b9.jpg)

(https://uploads.tapatalk-cdn.com/20201015/2fced273d92e29df17fc1b60ee5f764d.jpg)

The car is now going to sit at the back of the unit, again  :sad1: I have a serve oil leak from the rocker cover I believe, I've tried 3 gaskets now and if anything it's just getting worse. I think that my cover has warped, so I'm going to bite the bullet and buy a Billet rocker cover from Bartek.

Engine will be coming out shortly to have the K04 fitted  :evilgrin: clean the oil leak mess and generally have a tidy up in the engine bay. I may also bin off the DMF whilst I have the engine on the stand and fit a SMF, possibly buy a LSD too  :ashamed:

Until next time  :happy2:
Title: Re: MK5 GTI Track Car
Post by: rex on October 18, 2020, 09:42:10 am
Regarding the wheels, I am not sure what wheel arches you will find to fit 9 inch wide, ET20 wheels.
My Kerscher wheel arches are an extra 2.5 cm wider, but, with my camber setting (a bit over 2 degrees) 8 inch wide wheels and ET 40 look just right. I am 99% if you were to go with Kerscher or something similar, the wheels will not fit, nor look good.
Title: Re: MK5 GTI Track Car
Post by: shannon-ob on October 18, 2020, 11:47:12 am
Regarding the wheels, I am not sure what wheel arches you will find to fit 9 inch wide, ET20 wheels.
My Kerscher wheel arches are an extra 2.5 cm wider, but, with my camber setting (a bit over 2 degrees) 8 inch wide wheels and ET 40 look just right. I am 99% if you were to go with Kerscher or something similar, the wheels will not fit, nor look good.
I’m think I may get the ABS motorsport S2000 arch kit man. Emailed them, said 30-40mm wider.

https://absmotorsport.co.uk/product/vw-golf-mk5-s2000-arch-set-4/


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Title: Re: MK5 GTI Track Car
Post by: rex on October 18, 2020, 12:18:46 pm
What wheels (diameter, width, offset) are they using in BTCC?
Title: Re: MK5 GTI Track Car
Post by: shannon-ob on October 18, 2020, 12:46:28 pm
What wheels (diameter, width, offset) are they using in BTCC?
I should probably try find an old blog for that!


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Title: Re: MK5 GTI Track Car
Post by: shannon-ob on October 22, 2020, 03:20:59 pm
So last night I decided to get the engine out in order to give it a much needed clean (as you’ll see in pics below)

(https://uploads.tapatalk-cdn.com/20201022/061ed08580348883adb6858cabd572e3.jpg)

(https://uploads.tapatalk-cdn.com/20201022/b0814106f16946dea15da65d1302949d.jpg)

Disgusting oil everywhere!

(https://uploads.tapatalk-cdn.com/20201022/55abe123a52a244bbca0c2a89a1665b4.jpg)

(https://uploads.tapatalk-cdn.com/20201022/4c79ef4ea8bee28469b7ffb7ce0dfee5.jpg)

(https://uploads.tapatalk-cdn.com/20201022/4684c96106ba687e2f23844ba8915a4c.jpg)

(https://uploads.tapatalk-cdn.com/20201022/733165e419c7cdc796e14265be1815f2.jpg)

(https://uploads.tapatalk-cdn.com/20201022/ec48357c3269878face37aa1a53d2ab6.jpg)

(https://uploads.tapatalk-cdn.com/20201022/ebeec2c021a0432dcf955f05fc901858.jpg)

Replacement turbo?

(https://uploads.tapatalk-cdn.com/20201022/a6ca8a25e8d41f42777bbe36a8a6520e.jpg)

(https://uploads.tapatalk-cdn.com/20201022/5ee5861d1836aba02d27c556f15bc094.jpg)

(https://uploads.tapatalk-cdn.com/20201022/bf72424ef5dd3f9f1b947933666ae5e3.jpg)

(https://uploads.tapatalk-cdn.com/20201022/4016321b9cd1dab328ac69acea5228ed.jpg)

So plans are to pull the box off the engine, along with clutch and flywheel. Put the engine on a stand a strip it down, give the block a good clean and paint.

Get some bits powder coated (we have caged laser next door and very friendly with them )

Get the KO4 set up on it.

Order and fit a billet rocker cover - hoping to then put my catch can over where the charcoal canister was.

Whilst I have the box off the engine I’m thinking about having a diff fitted and 4th gear mod done. May as well chuck a SMF and Helix paddle clutch in.

Wanting some slimline fans also.

Probably more plans I’ve missed but will update once I get the engine on the stand and make a start.

Can’t see this being a quick bit of work. Many ££££ needed with those plans

Cheers all


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Title: Re: MK5 GTI Track Car
Post by: shannon-ob on October 28, 2020, 09:16:12 am
(https://uploads.tapatalk-cdn.com/20201028/3990384de33a8e18f2d32c39ee61dc5f.jpg)

(https://uploads.tapatalk-cdn.com/20201028/336bbf028d6cf020726f8f94754f94d3.jpg)

Made a start on stripping the engine last night. What an absolute state.

Measured the offset on the new wheels - ET25.


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Title: Re: MK5 GTI Track Car
Post by: shannon-ob on November 05, 2020, 03:17:05 pm
Bought a thing yesterday.

Some of you may have seen this for sale.

(https://uploads.tapatalk-cdn.com/20201105/7878584cc1e7ee002c98f7a5c86e1e7e.png)

(https://uploads.tapatalk-cdn.com/20201105/966df9327a7b160743111e193346c076.png)

(https://uploads.tapatalk-cdn.com/20201105/2ff73e4602ce04adfd6cce6b2f9158ad.png)

(https://uploads.tapatalk-cdn.com/20201105/53fbd74a1bee4fcd7e2261b13c6a8f65.png)

(https://uploads.tapatalk-cdn.com/20201105/40a0aa5f199547d5fcebb15a8a6e04f5.png)

(https://uploads.tapatalk-cdn.com/20201105/6794e2564112d67096844475c2ac7ee4.png)

(https://uploads.tapatalk-cdn.com/20201105/8b9dcbf4149a976935501f087d90d837.png)

(https://uploads.tapatalk-cdn.com/20201105/30c16a870011d3ef74b09123512a902e.png)

(https://uploads.tapatalk-cdn.com/20201105/b6b590504d067435b81a554fcb4d64a8.png)

Gearbox from an edition 30. Full rebuild including the fitting of the wavetrack diff / arp hardware. As you can see from AKS it’s a expensive bit of kit, plus the fitting!

I paid quite a bit less than this.

Also included was a brand new HEL braided clutch line £55 when new.

Can’t wait to get this built back up again!

Cheers,


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Title: Re: MK5 GTI Track Car
Post by: shannon-ob on January 28, 2021, 01:18:19 pm
Happy New Year all.

A few new parts have been bought:

BarTek Billet rocker cover
KO4 injectors
Subframe deadset kit front and rear
VIS HPFP internals
TTRS LPFP
310mm Rear brake set up
I have sold my 996T front brake set up and purchased a 370mm floating disc, DB9 set up
Silicone DV relocation hose
Alloy radiator
ARP flywheel bolts
RS4 FPRV


I have also cut the balance shaft cog off my oil pump.

I've also painted the block and ordered a lot of new hardware to refit everything.

All my Powerflex bushes have been removed in order to clean them and have all suspension components powder coated.

I will update once everything gets delivered with pictures  :smiley:

Cheers for now.
Title: Re: MK5 GTI Track Car - Manual, Wavetrack Diff, Caged, Polycarbs, KO4
Post by: shannon-ob on March 13, 2021, 10:06:20 am
Not a huge update, but I’m off later to collect the DB9 front brakes, 310mm rear brakes, TTRS LPFP and the AEM meth kit.

I’ve had a lot of the powder coating done now. Will update with pictures soon. I’ve also fitted the billet rocker cover, KO4 turbo to the engine.

I also decided to buy a private plate...

(https://uploads.tapatalk-cdn.com/20210313/d9aa384e320ab82d31e5f8ef8c36c662.jpg)
 

Thanks it for now. Hopefully the next update will be lots of pictures of new parts


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Title: Re: MK5 GTI Track Car - Manual, Wavetrack Diff, Caged, Polycarbs, KO4
Post by: shannon-ob on March 15, 2021, 09:26:48 am
So, I went up to Bury St. Edmunds Saturday and got the following.

Aston Martin DB9 calipers
370mm reyland bells and rotors
310mm rear brake set up
TTRS LPFP
AEM water meth kit

(https://uploads.tapatalk-cdn.com/20210315/4afa3349e6902a40f3a4fa8b2c9c7956.jpg)

(https://uploads.tapatalk-cdn.com/20210315/cb50d700af61d2d6ec7e4bab5fd6ebe1.jpg)

(https://uploads.tapatalk-cdn.com/20210315/e2e9caf734a454c1deb324080f395009.jpg)

(https://uploads.tapatalk-cdn.com/20210315/63bd2a183ef24b53f70399ddf8007842.jpg)
 
(https://uploads.tapatalk-cdn.com/20210315/cd4d3833943f12e061bca8d6e80dcb1d.jpg)

Couldn’t resist test fitting the front brakes behind a wheel

(https://uploads.tapatalk-cdn.com/20210315/7b82bf2059f1b79f8f71caeee101dff8.jpg)

I think it was well worth the 6 hour round trip


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Title: Re: MK5 GTI Track Car - Manual, Wavetrack Diff, Caged, Polycarbs, KO4
Post by: colesey on March 15, 2021, 11:56:39 am
From Nat Foley perchance? He breaks a lot of high spec cars and has interesting gear for sale
Title: Re: MK5 GTI Track Car - Manual, Wavetrack Diff, Caged, Polycarbs, KO4
Post by: shannon-ob on March 15, 2021, 12:46:38 pm
From Nat Foley perchance? He breaks a lot of high spec cars and has interesting gear for sale
It was indeed mate.

He gave me a heads up about it so I put a deposit on it all.


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Title: Re: MK5 GTI Track Car - Manual, Wavetrack Diff, Caged, Polycarbs, KO4
Post by: colesey on March 15, 2021, 02:59:33 pm
I had a braided clutch line from him last month.  He's a good lad and comes highly recommended.
Title: Re: MK5 GTI Track Car - Manual, Wavetrack Diff, Caged, Polycarbs, KO4
Post by: shannon-ob on March 16, 2021, 01:54:18 pm
Got all the aluminium stuff back from powder coaters yesterday so started on putting the engine back together.

Sadly, I feel the head and the HPFP are letting down the rest of the engine. I did try and clean as best as possible. Perhaps, I'll have it properly cleaned later down the line?

(https://uploads.tapatalk-cdn.com/20210316/2cfdd9375d9a3e1f8b7b5b7c99223817.jpg)

(https://uploads.tapatalk-cdn.com/20210316/bd21a5c4293e9f64e012311f4187c489.jpg)

I love this billet rocker cover. I'm not sure what to do about the timing belt cover. Should I try and fabricate some brackets so I can put it back on?

(https://uploads.tapatalk-cdn.com/20210316/15bcae5f09d587b7c685cff956467794.jpg)

(https://uploads.tapatalk-cdn.com/20210316/6bde122c4e9fe3d8e215a8a4c5fd2be4.jpg)

Here's the oil filter housing I have used. 1/2" BSP fittings TIG welded for my Mocal oil cooler. AN fitting in the top from BarTek for the catch can. I think this is a much better option than the horrid plastic oil filter housings.

(https://uploads.tapatalk-cdn.com/20210316/e98d5260ae1feee8dc75f8cb558de5f3.png)

One of my Christmas pressies:

(https://uploads.tapatalk-cdn.com/20210316/96995e7aa508a13e9da6c79bb03ebf87.jpg)


I'll try and get some pictures tonight of the front and rear subframes etc. now it's all powdercoated.

Cheers for now!

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Title: Re: GTI Track Car - Manual, Wavetrack Diff, Caged, Polycarbs, KO4, DB9 Brakes, METH
Post by: shannon-ob on March 17, 2021, 10:45:46 am
Wasn’t at the unit very long last night. Managed to get the flywheel, clutch and gearbox on.

(https://uploads.tapatalk-cdn.com/20210317/318abacafa6f191aaaa532d959ccd586.jpg)

Gearbox letting it all down now

(https://uploads.tapatalk-cdn.com/20210317/a3a258c1532db3e538e5d3a4313d8911.jpg)

Had a MK4 golf cable brakes holder laying around. Decided to get it powdercoated and fitted. Being metal I’m hoping there will be less flex than the MK5 plastic one. Same for the side shifter part, usually metal but I’ve switched for metal version.

Hopefully all this together will make shifting feel a lot better!

(https://uploads.tapatalk-cdn.com/20210317/94a84414b63cff4f88502251e98bf6f2.jpg)


As I wasn’t there very long I didn’t get any pictures of the suspension parts.


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Title: Re: GTI Track Car - Manual, Wavetrack Diff, Caged, Polycarbs, KO4, DB9 Brakes, METH
Post by: Mekaniko on March 17, 2021, 05:21:21 pm
Very nice build with very good components.

I'm curious for the pedal feel with this calipers, will you keep the original master cilinder?
Title: Re: GTI Track Car - Manual, Wavetrack Diff, Caged, Polycarbs, KO4, DB9 Brakes, METH
Post by: shannon-ob on March 17, 2021, 05:36:27 pm
Very nice build with very good components.

I'm curious for the pedal feel with this calipers, will you keep the original master cilinder?
Thank you mate.

Yes will keep same MC. Pedal feel was great with old brakes. Should be ok with these too.


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Title: Re: GTI Track Car - Manual, Wavetrack Diff, Caged, Polycarbs, KO4, DB9 Brakes, METH
Post by: Hypertuned on March 18, 2021, 05:19:02 am
Very nice build with very good components.

I'm curious for the pedal feel with this calipers, will you keep the original master cilinder?
I've been told the sweet spot is 4 pot calipers on the stock brake master cylinder. If you go beyond that the MC doesn't move enough fluid to move all the pistons, leading to a longer than normal brake pedal. It's at this point when many upgrade to the Audi TTRS MC.

https://www.akstuning.co.uk/shop/home/497-genunine-ttrs-master-cylinder-upgrade-for-ea113.html (https://www.akstuning.co.uk/shop/home/497-genunine-ttrs-master-cylinder-upgrade-for-ea113.html)

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Title: Re: GTI Track Car - Manual, Wavetrack Diff, Caged, Polycarbs, KO4, DB9 Brakes, METH
Post by: shannon-ob on March 18, 2021, 04:00:12 pm
Very nice build with very good components.

I'm curious for the pedal feel with this calipers, will you keep the original master cilinder?
I've been told the sweet spot is 4 pot calipers on the stock brake master cylinder. If you go beyond that the MC doesn't move enough fluid to move all the pistons, leading to a longer than normal brake pedal. It's at this point when many upgrade to the Audi TTRS MC.

https://www.akstuning.co.uk/shop/home/497-genunine-ttrs-master-cylinder-upgrade-for-ea113.html (https://www.akstuning.co.uk/shop/home/497-genunine-ttrs-master-cylinder-upgrade-for-ea113.html)

Sent from my SM-N9750 using Tapatalk

Exactly that mate. Was trying to explain this to someone on Facebook yesterday. I gave up!
Title: Re: GTI Track Car - Manual, Wavetrack Diff, Caged, Polycarbs, KO4, DB9 Brakes, METH
Post by: Hypertuned on March 18, 2021, 05:08:39 pm
Very nice build with very good components.

I'm curious for the pedal feel with this calipers, will you keep the original master cilinder?
I've been told the sweet spot is 4 pot calipers on the stock brake master cylinder. If you go beyond that the MC doesn't move enough fluid to move all the pistons, leading to a longer than normal brake pedal. It's at this point when many upgrade to the Audi TTRS MC.

https://www.akstuning.co.uk/shop/home/497-genunine-ttrs-master-cylinder-upgrade-for-ea113.html (https://www.akstuning.co.uk/shop/home/497-genunine-ttrs-master-cylinder-upgrade-for-ea113.html)

Sent from my SM-N9750 using Tapatalk

Exactly that mate. Was trying to explain this to someone on Facebook yesterday. I gave up!
Sometimes you just gotta learn from experience. I went 8 pot and the pedal fell almost 2 inches before the brakes made contact with the discs then almost sent me through the windscreen. Lol
Upgraded my MC and all is good!

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Title: Re: GTI Track Car - Manual, Wavetrack Diff, Caged, Polycarbs, KO4, DB9 Brakes, METH
Post by: Bulldugg on March 21, 2021, 02:09:23 am
Don’t know if you posted it, but where did you get the red harness bar for the seat belts.
Title: Re: GTI Track Car - Manual, Wavetrack Diff, Caged, Polycarbs, KO4, DB9 Brakes, METH
Post by: shannon-ob on March 21, 2021, 08:52:00 am
Don’t know if you posted it, but where did you get the red harness bar for the seat belts.
Hi mate,

It was custom made.


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Title: Re: GTI Track Car - Manual, Wavetrack Diff, Caged, Polycarbs, KO4, DB9 Brakes, METH
Post by: Bulldugg on March 21, 2021, 03:17:50 pm
Looks like a nice solid mount. Like the saying goes, “ Built, not bought”.
Title: Re: GTI Track Car - Manual, Wavetrack Diff, Caged, Polycarbs, KO4, DB9 Brakes, METH
Post by: shannon-ob on March 24, 2021, 10:17:18 pm
Here’s some pictures as promised of the powder coating!

Bought fresh FAG bearings front and rear.

(https://uploads.tapatalk-cdn.com/20210324/fe7cb76c133ade0d5312cafda9c56331.jpg)

Gotta take the Garage Midnight studs out the old hubs to fit to the new ones.

(https://uploads.tapatalk-cdn.com/20210324/fbc4088a128ab5ee628e8cd79509f101.jpg)

Most of the front parts.

(https://uploads.tapatalk-cdn.com/20210324/eb6e0857a1418afb5a662c5c533771b4.jpg)

All the powerflex bushes cleaned and re-greased.

(https://uploads.tapatalk-cdn.com/20210324/cf11854f5539dc9a87f3f2845dce6faf.jpg)

All built up I do need to get the BC coilovers cleaned up next.

(https://uploads.tapatalk-cdn.com/20210324/29a2e914395ef641a0073666be6a1382.jpg)

Some pictures of the rear set up:

(https://uploads.tapatalk-cdn.com/20210324/2e6c88ba2d32cb331c8c3a30a189df79.jpg)

(https://uploads.tapatalk-cdn.com/20210324/9205174de1af1800fbab0bc8e398b4fc.jpg)

(https://uploads.tapatalk-cdn.com/20210324/79b87d2f31b0894ea9c0c095c907dcf1.jpg)

(https://uploads.tapatalk-cdn.com/20210324/69fbfc9ad913e4162f16e63c4bb6b475.jpg)

Next the engine is getting dropped off to badger 5 to have the inlet valves cleaned and injectors flow tested and re-sealed.


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Title: Re: GTI Track Car - Manual, Wavetrack Diff, Caged, Polycarbs, KO4, DB9 Brakes, METH
Post by: GTI DAZ on March 25, 2021, 07:43:26 pm
fantastic work, im planning a refresh this month for my rear subframe, swap out my old one for a rebuilt one, is it alot of work? and do you have a parts list?
Title: Re: GTI Track Car - Manual, Wavetrack Diff, Caged, Polycarbs, KO4, DB9 Brakes, METH
Post by: shannon-ob on March 25, 2021, 08:35:07 pm
fantastic work, im planning a refresh this month for my rear subframe, swap out my old one for a rebuilt one, is it alot of work? and do you have a parts list?
Thank you!

Umm not really a lot of work no, having the unit and a ramp really did help.

Parts list for what man?


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Title: Re: GTI Track Car - Manual, Wavetrack Diff, Caged, Polycarbs, KO4, DB9 Brakes, METH
Post by: GTI DAZ on March 25, 2021, 08:55:15 pm
lucky bugger, I got a friend with a unit to help, was after a parts list for the build. arms, bolts bushes ect
Title: Re: GTI Track Car - Manual, Wavetrack Diff, Caged, Polycarbs, KO4, DB9 Brakes, METH
Post by: shannon-ob on March 25, 2021, 10:14:22 pm
lucky bugger, I got a friend with a unit to help, was after a parts list for the build. arms, bolts bushes ect
It’s very helpful

Arms are the same but we’re just powder coated. Bushes were from powerflex (I’m a dealer) bolts were through Coverdale Car Parts.


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Title: Re: GTI Track Car - Manual, Wavetrack Diff, Caged, Polycarbs, KO4, DB9 Brakes, METH
Post by: LC5F on March 26, 2021, 04:27:42 pm
Great progress - what rear hubs are you running - still need to fit my Passat front with new Fags too!

fantastic work, im planning a refresh this month for my rear subframe, swap out my old one for a rebuilt one, is it alot of work? and do you have a parts list?
Not too bad:
Drop the exhaust back box
Detach brake lines, handbrake cables level sensor & ABS cables
2 bolts on each side holding shock top bolts - or  - the 1 bottom bolt on each side
4 bolts on each side holding the trailing arms
4 bolts holding the subframe and down it comes
Title: Re: GTI Track Car - Manual, Wavetrack Diff, Caged, Polycarbs, KO4, DB9 Brakes, METH
Post by: shannon-ob on March 26, 2021, 09:24:19 pm
Great progress - what rear hubs are you running - still need to fit my Passat front with new Fags too!

Thanks man.

They’re Passat rear hubs buddy.


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Title: Re: GTI Track Car - Manual, Wavetrack Diff, Caged, Polycarbs, KO4, DB9 Brakes, METH
Post by: shannon-ob on April 01, 2021, 10:22:32 am
Just had chance to weigh the new bell/rotor set up. 9kg, the old 350mm ML disc from the Porsche set up were 12kg each. So a nice saving of 3kg per side.
Title: Re: GTI Track Car - Manual, Wavetrack Diff, Caged, Polycarbs, KO4, DB9 Brakes, METH
Post by: colesey on April 01, 2021, 04:10:59 pm
Very nice clean work there and you’ll have another 3kg of unsprung weight savings each side from the alloy hubs and arms.
Title: Re: GTI Track Car - Manual, Wavetrack Diff, Caged, Polycarbs, KO4, DB9 Brakes, METH
Post by: shannon-ob on April 01, 2021, 04:15:22 pm
Very nice clean work there and you’ll have another 3kg of unsprung weight savings each side from the alloy hubs and arms.

Exactly that man. I had fitted all that then the Porsche brakes so technically no weight saving at all. But as you say, probably about 6-7kg a side!

Title: Re: GTI Track Car - Manual, Wavetrack Diff, Caged, Polycarbs, KO4, DB9 Brakes, METH
Post by: colesey on April 02, 2021, 07:33:38 am
Add another 3kg from a lighter wheel like TD1.2 to hit almost 10kg per front corner. Huge reduction in unsprung mass.
Title: Re: GTI Track Car - Manual, Wavetrack Diff, Caged, Polycarbs, KO4, DB9 Brakes, METH
Post by: shannon-ob on April 02, 2021, 08:52:27 am
Add another 3kg from a lighter wheel like TD1.2 to hit almost 10kg per front corner. Huge reduction in unsprung mass.
I’d completely forgot about them I’ll have to get it on a weigh bridge when it’s complete


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Title: Re: GTI Track Car - Manual, Wavetrack Diff, Caged, Polycarbs, KO4, DB9 Brakes, METH
Post by: shannon-ob on April 03, 2021, 01:05:50 pm
Well, this was far from ideal.

I’ve been prepping the underside ready to underseal.

I always knew that was a little scabby in this area but I did not expect this.

The wheel arch has a lot of like residue rust behind the seam sealer. Which now I’m thinking of removing as much seam sealer as possible and either applying new. Or stitch welding it

Side skirts were holding so much dirt and moisture it’s ended up doing this to the sill. Luckily it’s an easy fix. But sadly has pushed things back 1/2 week(s)

I did feel like throwing the towel in. But I’m way to far into this build to do that.

(https://uploads.tapatalk-cdn.com/20210403/a6d4df798000f69809d9e9b59f679069.jpg)

(https://uploads.tapatalk-cdn.com/20210403/074b2a967b4d3b51b833766fafe3b536.jpg)

(https://uploads.tapatalk-cdn.com/20210403/503a299ef3eba8c7105202a22e4c801e.jpg)


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Title: Re: GTI Track Car - Manual, Wavetrack Diff, Caged, Polycarbs, KO4, DB9 Brakes, METH
Post by: Clarkj93 on April 03, 2021, 01:50:18 pm
Ouch... I've noticed some residue under some peeling seam sealer as well lately, sill i think is okay but will probs have a good look now after seeing this. I have been toying with the idea of removing the side skirts all together and the fitting screws as I've seen a few people with same issue as you here. Assuming they don't serve any functional purpose like deflecting crap from getting into places?
Title: Re: GTI Track Car - Manual, Wavetrack Diff, Caged, Polycarbs, KO4, DB9 Brakes, METH
Post by: shannon-ob on April 03, 2021, 01:58:02 pm
Ouch... I've noticed some residue under some peeling seam sealer as well lately, sill i think is okay but will probs have a good look now after seeing this. I have been toying with the idea of removing the side skirts all together and the fitting screws as I've seen a few people with same issue as you here. Assuming they don't serve any functional purpose like deflecting crap from getting into places?

Seems to be very common with the skirts just catching all the road grim between the skirt itself and the arch liner. Skirts are only there for cosmetics. I will be running them again once this is repaired and the car is painted. But will most likely not run the arch liner nor will the car be out on sh*tty days.

I'd defo look into it sooner rather than later. At least get the arch liners out and clear the crap out.
Title: Re: GTI Track Car - Manual, Wavetrack Diff, Caged, Polycarbs, KO4, DB9 Brakes, METH
Post by: Hypertuned on April 03, 2021, 02:01:36 pm
In the old days cars didn't have arch liners, only sealant. Somethings were better back then than they are now, IMO.

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Title: Re: GTI Track Car - Manual, Wavetrack Diff, Caged, Polycarbs, KO4, DB9 Brakes, METH
Post by: shannon-ob on April 03, 2021, 02:04:59 pm
In the old days cars didn't have arch liners, only sealant. Somethings were better back then than they are now, IMO.

Sent from my SM-N9750 using Tapatalk

Not wrong mate. The worst ones are the fabric arch liners. Stupid idea.
Title: Re: GTI Track Car - Manual, Wavetrack Diff, Caged, Polycarbs, KO4, DB9 Brakes, METH
Post by: Hypertuned on April 03, 2021, 03:06:02 pm
In the old days cars didn't have arch liners, only sealant. Somethings were better back then than they are now, IMO.

Sent from my SM-N9750 using Tapatalk

Not wrong mate. The worst ones are the fabric arch liners. Stupid idea.
You're not wrong there! They soak up water when it rains & help your arches rust quicker.

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Title: Re: GTI Track Car - Manual, Wavetrack Diff, Caged, Polycarbs, KO4, DB9 Brakes, METH
Post by: shannon-ob on April 15, 2021, 10:57:26 am
The arches finally came!

(https://uploads.tapatalk-cdn.com/20210415/3b6c28ceab7a15566a02d0a529069e29.jpg)

(https://uploads.tapatalk-cdn.com/20210415/e5ae2283f429a2b563cfc5fdf291a764.jpg)

(https://uploads.tapatalk-cdn.com/20210415/3cfd6ccdcb726eae3706bd1b450e3fab.jpg)

(https://uploads.tapatalk-cdn.com/20210415/9cde3dcf6c1e645560483e298e889979.jpg)

(https://uploads.tapatalk-cdn.com/20210415/a7ec1679f1fa68462367fd33502d8c2f.jpg)

(https://uploads.tapatalk-cdn.com/20210415/ddb2408180c574a83906cad765a26f65.jpg)


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Title: Re: GTI Track Car - Manual, Wavetrack Diff, Caged, Polycarbs, KO4, DB9 Brakes, METH
Post by: rich83 on April 30, 2021, 11:27:31 pm
The alloy rear hubs… can you reuse all the MK5 bolts? Or are they different?
Title: Re: GTI Track Car - Manual, Wavetrack Diff, Caged, Polycarbs, KO4, DB9 Brakes, METH
Post by: Pudding on May 01, 2021, 02:03:40 am
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.
Title: Re: GTI Track Car - Manual, Wavetrack Diff, Caged, Polycarbs, KO4, DB9 Brakes, METH
Post by: LC5F on May 01, 2021, 11:47:26 am
The arches finally came!

(https://uploads.tapatalk-cdn.com/20210415/3b6c28ceab7a15566a02d0a529069e29.jpg)

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. No - made an arse of that one - bought everything new so must have got lost in there.
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.


Title: Re: GTI Track Car - Manual, Wavetrack Diff, Caged, Polycarbs, KO4, DB9 Brakes, METH
Post by: shannon-ob on May 01, 2021, 01:18:46 pm
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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Title: Re: GTI Track Car - Manual, Wavetrack Diff, Caged, Polycarbs, KO4, DB9 Brakes, METH
Post by: rich83 on May 01, 2021, 01:19:44 pm
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
Title: Re: GTI Track Car - Manual, Wavetrack Diff, Caged, Polycarbs, KO4, DB9 Brakes, METH
Post by: shannon-ob on May 01, 2021, 01:20:23 pm
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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Title: Re: GTI Track Car - Manual, Wavetrack Diff, Caged, Polycarbs, KO4, DB9 Brakes, METH
Post by: shannon-ob on May 01, 2021, 01:21:19 pm
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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Title: Re: GTI Track Car - Manual, Wavetrack Diff, Caged, Polycarbs, KO4, DB9 Brakes, METH
Post by: shannon-ob on May 01, 2021, 01:22:36 pm
The arches finally came!

(https://uploads.tapatalk-cdn.com/20210415/3b6c28ceab7a15566a02d0a529069e29.jpg)

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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Title: Re: GTI Track Car - Manual, Wavetrack Diff, Caged, Polycarbs, KO4, DB9 Brakes, METH
Post by: LC5F on May 01, 2021, 01:29:56 pm
The arches finally came!

(https://uploads.tapatalk-cdn.com/20210415/3b6c28ceab7a15566a02d0a529069e29.jpg)

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.