MK5 Golf GTI

All Things Mk5 => Members Rides => Topic started by: M4T VW on September 06, 2016, 08:24:32 PM

Title: MK5 Edition 30 #57 Track/Race Build
Post by: M4T VW on September 06, 2016, 08:24:32 PM
Something a bit different from your road & show car, a full on track based approach  :happy2:
(This is a copy/paste from Club GTI so some of the names might not make sense)

Moving on from the Mk2, still with the bug to get out on a track, I think it was inevitable I would end up with another VW. I looked at a few options but to be honest, I don't know anything else other than Volkswagen. An Elise or Exige may have crossed my auto trader search but not for long, I always ended up back at the MK5 Golf's or Scirocco's. The Scirocco was a hard one to choose as it's less supported in the market, Although the same chassis as the MK5 it just didn't feel right so it had to be a MK5.
I went to look at a "standard" GTI in Wales, A red 3 door manual with 68000 on the clock. The only modifications I could see in the pictures were 2 red VW badges but at 68000 it had to be looked at. It was in a ford dealer so I went up on a Saturday. The car was in very good condition but not standard on the engine front by any means. Lots of metal pipes and a massive halfords cone filter. It drove well though so I made a cheeky offer but we could not agree on price so I walked away. In hindsight I'm glad I did walk away.

I then went to look at one near Bath, A red 3 door manual with...err I cant remember how many miles on the clock but it was an edition 30 base car. It was already heavily modified into a track car, Running about 500 BHP! It was close to me so I had a look, Sadly it was not what I was after and decided I needed to build one myself lol

A few weeks passed keeping my eye on all the usual spots. I had decided on an Edition 30 due to the better TFSI engine and it's potential so this narrowed the search as only about 2500 were produced.
One cropped up in wales again, Not a million miles so it was worth a look. It was a...Yes you guess it, Red 3 door manual with 94k on the clock. The price was not bad so I went over on a Saturday. The car was dirty as there was a building site next to the dealer but other than that it looked quite clean. I took it for a test and it went really well. The interior is in excellent condition for 94000 miles. We haggled on price and I managed to get a good price with me taking the car away there and then. A few phone calls to Admiral and I took it away! The drive home was good, No problems and it went well but I didn't push it much as I wanted to give the engine a once over first.

(http://daz.co/media/M4TVW/Edition_30/DSC_2512_zpsvucoxhxi.jpg)

(http://daz.co/media/M4TVW/Edition_30/DSC_2513_zpsjg9gs65e.jpg)

(http://daz.co/media/M4TVW/Edition_30/DSC_2502_zpszqifpkpw.jpg)

As you can see the engine bay is a little dirty but it seems in order. There is red over-spray on the front a little as I think it's had the wings done (MK5 problem) and the bonnet has no stone chips at all [:[]
It all looks straight though, no accident damage, Just a blow over. However whoever cleaned it must have used a brillo pad as I have never seen so many swirl marks on paintwork before! Not that it matters...lol

So, Here we go again. I will update tomorrow with the plan of action. Engine has already been serviced and upgraded and I'm half way through stripping and selling the interior parts :thumbup:

I must say a big thanks to Luke (Deako) with his help so far. He has answered all my questions and I'm sure it wont be the end of it lol
Title: Re: MK5 Edition 30 #57 Track/Race Build
Post by: M4T VW on September 06, 2016, 08:25:04 PM
Fast forward a couple of weeks and i needed to do a few jobs to the engine before i started on the rest of it. Mainly check the cam follower for wear to see what condition the engine was in. It's done 94k with a recorded cambelt and waterpump change at 90k but there was no mention of the cam.

I ordered a revo camcoat intake, Loba HPFP, a new Rev G diverter valve from TSR and also an R-Tech PCV delete kit. These are must change items it you are going to tune one of these engines so it made sense to change them all at the same time.
Thankfully the cam follower looked brand new so it must have been changed at some point. I put the new Loba one in anyway that comes with the HPFP so at least i know the engine is nice and healthy. I also gave it an oil and filter change while i was at it.

(http://daz.co/media/M4TVW/Edition_30/IMG_1446_zpsvhgjnvrt.jpg)

(http://daz.co/media/M4TVW/Edition_30/IMG_1448_zpshf7weefd.jpg)

(http://daz.co/media/M4TVW/Edition_30/IMG_1447_zpsvqsgb5zh.jpg)


Next up, Let the strip commence! (Also start gathering parts)
Title: Re: MK5 Edition 30 #57 Track/Race Build
Post by: M4T VW on September 06, 2016, 08:25:36 PM
Oh, I also managed to get hold of my build plaque for the car. It shows how genuine this car was because no one had applied for it and you only ever get one. VW customer services were amazing at dealing with my request, even calling me multiple times a day to let me know what the status of it was :clap:

(http://daz.co/media/M4TVW/Edition_30/IMG_1515_zpscwsg6qd4.jpg)
Title: Re: MK5 Edition 30 #57 Track/Race Build
Post by: martinEd30 on September 06, 2016, 09:00:13 PM
Loooking good ;) will be keeping an eye on what you get done
Title: Re: MK5 Edition 30 #57 Track/Race Build
Post by: M4T VW on September 07, 2016, 10:09:18 AM
Loooking good ;) will be keeping an eye on what you get done

Thanks Martin, Still lots to do. I have 2 pallets of parts to fit onto it!

Now that the car was nice and healthy and working great, I decided to rip the whole thing apart lol

I have been on a buying and selling spree for the last few months and have sold all the interior and parts to claw back some money on the build. I reckon i will be close to 3k back once the wheels are sold so that brings the total of the car to under 5k now which is what i needed to make this project work.
I started unbolting anything in place, took a picture of it and listed it on the relevant forum or well-known auction site. Thankfully the parts for these are sought after so i didn’t have trouble shifting some of the parts. I must have been asked 20 times for the steering wheel and gear knob. They are "eBay rare" with red stitching so plenty of people asked for them!

The car had an old MFD2 sat-nav unit that was worth some money and it was an easy item to remove so i started with that.

(http://daz.co/media/M4TVW/Edition_30/IMG_1476_zps3v50zs7b.jpg)

I wanted to sell the Sat-Nav with the GPS antenna and all the wiring but once i started looking at the wiring, it was all bound together and i was not in position to remove all that yet so had to sell it without. While i was looking at the wiring for the GPS the headlining had to be removed so that was the next job. However there was a problem. Airbags! These MK5's have a total of 6 airbags so it made sense to remove them all at the same time and try to sell them together.

(http://daz.co/media/M4TVW/Edition_30/IMG_1471_zps9gz8iy4e.jpg)

As you can see, the curtain airbag runs the whole length of the car right into the corner of the dash.

(http://daz.co/media/M4TVW/Edition_30/IMG_1472_zpssfwulvvi.jpg)

So with this lot removed, I now had a blank roof panel that i could actually see the wiring for the sat-nav. However it was still a no-go to remove this as it was wrapped with the rest of the loom and required a weekend to cut the tape on it and remove the wiring for it.
The roof insulation for these is a paper backed foam stuck to the roof with mastic. You can rip the foam off easy and then use one of those Stanley scrapers with a new blade to remove the mastic and it comes off lovely. Much better than the MK2 and i didn’t get any glue in my hair!

(http://daz.co/media/M4TVW/Edition_30/IMG_1473_zpsisvblhmv.jpg)

(http://daz.co/media/M4TVW/Edition_30/DSC_2638_zpsy3tvj8fn.jpg)

(http://daz.co/media/M4TVW/Edition_30/DSC_2639_zpsxczm05nd.jpg)

The next step is to remove all the wiring for the airbags, Sat-Nav etc. Taking it back to the essentials!
Title: Re: MK5 Edition 30 #57 Track/Race Build
Post by: M4T VW on September 07, 2016, 10:10:34 AM
On with the wiring then. After i removed all the dash insulation (who needs that right?) i managed to find the wiring loom from the fuse box, it was not hard to miss! :thumbd:

(http://daz.co/media/M4TVW/Edition_30/0FC0AD5A-913F-43A7-96CE-E5A8BDA3CCE8_zpsfp6pbulo.jpg)

I love how the MK5 clocks "plug" into the socket on the column. It's very handy to remove them.

(http://daz.co/media/M4TVW/Edition_30/DA43F2B6-C7F5-4B9A-B4AD-062B11BAFC53_zpsrktxdqgv.jpg)

Once i had cut back all the tape my hands were stuck together. What horrible stuff to work with. I had to take my time not to cut any wires and managed it all the way.

(http://daz.co/media/M4TVW/Edition_30/5F46BFCE-C4CF-4BEB-B12D-E875BA0D953F_zpsnmjtwbom.jpg)

This is the big plug to the airbag controller that was located in front of the gearstick, under the heater matrix.

(http://daz.co/media/M4TVW/Edition_30/4FC0FE6F-9237-4103-8709-8E840056961B_zpscqixvemz.jpg)

I have no idea why i took this picture! lol

(http://daz.co/media/M4TVW/Edition_30/ACDA1AE4-F98D-4105-8231-E8F9AD9CE3B8_zpsdejkcvxr.jpg)

All done, and here is all the wiring removed! The airbag loom is the bulk of it but there is the GPS and FM antenna cable, Rear wiper and heated screen, Front and rear speakers. Heated/electric seats. It all came out!

(http://daz.co/media/M4TVW/Edition_30/607F5E9A-F138-4D12-AD0F-E3C5DEE5CFD3_zpsxhspkgaw.jpg)

I plugged it all back in and connected the battery to test if it was all still working. When i turned the ignition on the brake lights came on which is strange but i thought it might have been because there was pressure in the system. I turned the key to start it anyway and.....nothing. A faint click from the fuse box but the engine didn’t even try to turn over. Not good.
Got the laptop out and connected it. A few issues but once i had removed all the airbags and errors there was nothing really stopping it from starting.

(http://daz.co/media/M4TVW/Edition_30/811182EF-1E23-4C44-9FA0-E2854FF79C30_zpsdc2ld2kl.jpg)

I pushed the car outside and connected up the Ed35 thinking it might be a dead battery. Still nothing, Very strange.

(http://daz.co/media/M4TVW/Edition_30/5C7C23F0-75BB-4348-B8A6-A5F26D05104C_zpsdsabk24l.jpg)

I messaged Rubjonny and Toyotec and they suggested to jump the starter to see if it was dead. I had trouble getting the black plug off the starter, what a bugger!
Managed to get it off and jumped it and the engine turned over fine so it must have been something i had done inside to stop it.

(http://daz.co/media/M4TVW/Edition_30/91F6E603-2CB1-4057-9FC7-966F1E91EB08_zpsgslwbuel.jpg)

Jonny also suggested to find the terminal 50 relay which is on the fuse board inside the cabin. I looked at this and noticed a cable was missing from the relay! It was a very thin earth cable that i had removed when i removed the headlining. I managed to find the cable and put the pin back into the relay and put a new ring terminal on the end so i could put it to one of the chassis earths. Turned the key and it fired straight up! Stupid mistake and it cost me a day really! [:x]

The brake lights were also still stuck on with the ignition. That turned out to be a similar problem. I traced back the earth for them and put a meter on it to find it was dead. This earth also supplied the rain sensor and rear view mirror dimming and that was coming up in VCDS as not found so i was on the right tracks. I made a new link cable from a chassis earth to this joint and it's all working again! :D

Next up, a nice early trip to Worcestershire to pick up some dinner plates ;)
Title: Re: MK5 Edition 30 #57 Track/Race Build
Post by: james_kav on September 07, 2016, 10:19:51 AM
Wow. Very interesting thread and great to see the golf down to it's barebones! Loving the pictures and details and have subscribed to this as I can't wait to see the finished project!  :happy2:

On anothe note, I don't suppose you'll be selling the Xeons will you at ay point?? (Probably shouldn't ask on this thread but thought I'd be cheeky)  :wink:
Title: Re: MK5 Edition 30 #57 Track/Race Build
Post by: Paradox1 on September 07, 2016, 11:41:42 AM
Finally!
A decent track car build thread. I like where this one is going
Title: Re: MK5 Edition 30 #57 Track/Race Build
Post by: lukemk5gti on September 07, 2016, 12:09:47 PM
 :notworthy: :notworthy: :notworthy: :notworthy: :notworthy: :notworthy:
Title: Re: MK5 Edition 30 #57 Track/Race Build
Post by: Shoduchi on September 07, 2016, 01:02:52 PM
A bit of a pain to see the Ed. 30 in lots of pieces but your threads are always awesome and great reads! Subscribed! :party: :notworthy:
Title: Re: MK5 Edition 30 #57 Track/Race Build
Post by: grey golfster on September 07, 2016, 01:15:04 PM
Fascinating stuff.
will be on this one
Title: Re: MK5 Edition 30 #57 Track/Race Build
Post by: M4T VW on September 07, 2016, 01:34:52 PM
Wow. Very interesting thread and great to see the golf down to it's barebones! Loving the pictures and details and have subscribed to this as I can't wait to see the finished project!  :happy2:

On anothe note, I don't suppose you'll be selling the Xeons will you at ay point?? (Probably shouldn't ask on this thread but thought I'd be cheeky)  :wink:

Thanks! Oh trust me, That is not barebones yet. I currently have a rolling shell with an engine  :grin:
When i was searching for information not much info came up on the MK5 and not many pictures so i hope this will help others.
I'm not looking at chaning the xenon lights yet. It's not really a weight saving but you never know at a later date. Lets get it running first!

Finally!
A decent track car build thread. I like where this one is going

Cheers! This is a no expense spared (within reason) build. I have many high end parts to use including VWR Brakes, KW clubsports etc.

A bit of a pain to see the Ed. 30 in lots of pieces but your threads are always awesome and great reads! Subscribed! :party: :notworthy:

I know, I really didnt want to do it to an ED30 as i loved the car while i had it on the road for a few days. My daily drive is an ED35 so i'm still keeping the heritage up  :happy2:

Next up, An epic gearbox rebuild.
Title: Re: MK5 Edition 30 #57 Track/Race Build
Post by: M4T VW on September 07, 2016, 01:37:04 PM
Dinner plates are in the next update, I promise! lol

I have a list of parts that i have been on the lookout for since i started this project. Some of them are quite hard to come by but i am prepared to wait for them. About 3 months in and i think i have 80% of them now, the main ones anyway. I will feed these into the thread as i bought them. I signed up to all the usual Facebook pages when i am on the lookout for parts.
Since the engine is good, I don't really want to spend another £1000-1500 on getting more power out of it. 230bhp is more than enough for the time being so i want to focus on the chassis first. However one part that does need looking at is the gearbox. I exchanged a few messages with our gearbox guru Martin Emment (aka Hotgolf) even before i found this car and he offered some great advice so a plan was hatched. I just needed to gather all the parts and ship them to him for the build-up.
Firstly, TSR had a great deal on Quaife LSD's so i ordered one in 02Q flavour along with the APR bolt kit.

(http://daz.co/media/M4TVW/Edition_30/A238C1AA-0EC7-4523-913F-945E6B13002F_zpsoy7htfwp.jpg)

I managed to find a very low mileage 02Q 'box from an edition 30 at a breakers for a great price so i bought that also. My plan is to build up a new 'box so i can just do a swap out and then sell on my old one. The new one is a different code but it's a slightly later code and mine is an early one. They are identical gearboxes though.

(http://daz.co/media/M4TVW/Edition_30/C9F7E878-112B-4B60-B97A-DD8CE90B4688_zpsnrqsykq6.jpg)

Luke Deakin mentioned that there were a few possible modifications to these 02M/Q 'boxes to strengthen them internally and externally. Some of them are VW parts from a later model and some custom made from the likes of Darkside Developments. After much more research i had an idea of the parts i needed, and it was adding up!

The VW parts are steel shift forks for the 1st-2nd & 3rd-4th gear. These are from a MK6 GTI gearbox whereas the MK5 GTI forks are made from bronze and are known to break. There is no steel shift fork for 5th-6th, only a pin/rivet to bolt mod.

(http://daz.co/media/M4TVW/Edition_30/0ff52670-fa84-431b-926c-880bff1612c5_zpsik6xrtvz.jpg)

These are the bronze sliders that go on the tips of the forks above.
(http://daz.co/media/M4TVW/Edition_30/Bronze_Sliders__57795.1457015840.400.300_zpsdh9vtqie.jpg)
This picture is actually from after Martin had built the box up and taken it apart again as it would not turn. You can see why as the bronze slider was too close to the input shaft and looking the box from turning. A small modification was needed and it's fine now :thumbup:

(http://daz.co/media/M4TVW/Edition_30/73ed7f53-1dc1-4a26-bde6-cccd40d8b326_zps7ibgvku4.jpg)

Then we have the 4th gear input shaft support mod.

(http://daz.co/media/M4TVW/Edition_30/4th_Gear_Input_Shaft_Upgrade_4__73039.1424779131.400.300_zpszuqu1wyp.jpg)

Then there were several pieces of machining needed for other mods. The input shafts on these are hollow and can be known to deform under higher power. As i will be getting more power from the engine eventually, i thought it made sense to do all these while it was open. Thankfully Martin is fully equipped and capable to manufacture all of these parts required. They include 2 input shafts.

(http://daz.co/media/M4TVW/Edition_30/d8ff27d3-8487-4a18-b665-8746f2ad04df_zpszvsfxenv.jpg)

(http://daz.co/media/M4TVW/Edition_30/58150b6d-7ff5-4b21-b099-18f138f1046f_zpsagovalfr.jpg)

(http://daz.co/media/M4TVW/Edition_30/aa13fab7-7d8d-4a90-ab4f-bd330e511046_zpslbu1kacc.jpg)

They have to be an exact fit to insert into the input shaft to strengthen it. Sadly they are both different as one has 2 steps and the other has 3 steps.

(http://daz.co/media/M4TVW/Edition_30/cbf34ac8-1b19-40ab-9985-c522050e81ed_zpstlx9npsl.jpg)

(http://daz.co/media/M4TVW/Edition_30/50831c31-154a-4a2b-9658-224f36fbc947_zps8p0byxh1.jpg)

These are then welded at the top to lock to two shaft together and stop it from moving around.

(http://daz.co/media/M4TVW/Edition_30/d7306c2e-d049-470e-acce-a1c295157274_zps7q1czkpd.jpg)

Then it was on to installing the Quaife. Martin machines the standard rivets to split the diff & crown wheel instead of drilling them out. This ensures that you do not elongate the hole and you can also reuse the standard diff after, as a paperweight maybe?

(http://daz.co/media/M4TVW/Edition_30/b26f04f6-2fc7-4834-bda9-af3187200cee_zpsa4ga8ccv.jpg)

However, another problem. The holes in the Quaife were a fraction too small so it meant the swarf from pressing the bolt in got stuck under the bolt head and it would not sit flat.
Apparently this was a problem a while back when Quaife first started making these. They designed them for use with the OE bolts but supply issues meant they had to switch to APR bolts which were slightly thicker. There was a cross-over period of some bolts not fitting the smaller hole but i gave TSR a call and this Quaife was from new stock so I’m not sure why we had this issue.

(http://daz.co/media/M4TVW/Edition_30/15d85d1b-81ff-4931-8dd5-cba336116fa3_zpsxizb3elv.jpg)

This is an APR bolt in the standard diff, No problem!

(http://daz.co/media/M4TVW/Edition_30/de118607-9461-406c-a2b3-0f34d742bba7_zpsc6pdijl9.jpg)

Sadly there was only one thing for it. Machine down all of the APR bolts to fit the Quaife Diff! Thankfully this is something Martin had done before for another customer so got straight on with it. Sadly there are 12 of them!!!

(http://daz.co/media/M4TVW/Edition_30/59b58ad1-57b7-4d76-a1a4-9eb2b517f020_zps2dg52zcz.jpg)

(http://daz.co/media/M4TVW/Edition_30/65d1ce0f-411d-4d4c-93fd-b37c004a9096_zpsctimkpt7.jpg)

(http://daz.co/media/M4TVW/Edition_30/53643099-e6cb-4e01-885e-cc9633e06773_zpsvninnb52.jpg)

This is the 6th gear mod. The old rivet has been drilled out. A bolt inserted and then ground flat. I think a bit of welding was involved also lol

(http://daz.co/media/M4TVW/Edition_30/2ca7a3b7-fc1c-425f-8f1d-ea111bc47bb8_zpsstsqa7sk.jpg)

A shim was required and instead of buying one he made one! Handy when you have the tools!

(http://daz.co/media/M4TVW/Edition_30/3075af02-a987-4926-a13e-db0c5b4424f4_zps2dhzpcws.jpg)

(http://daz.co/media/M4TVW/Edition_30/9795555f-3394-4e9c-9805-d5328b0ede51_zpsno2nldrh.jpg)

We have run into another problem. The 4th gear support block fouls the reverse switch. Martin managed to cut a little off the support block to allow a plug to go on. I might have to trim the plug down a little also but worst case is i have to use some spades instead of a plug system

(http://daz.co/media/M4TVW/Edition_30/fdeea5fd-0c32-4b6e-87c5-1049e9bcef80_zpsykqjedwi.jpg)

(http://daz.co/media/M4TVW/Edition_30/e28eddd6-cb0a-4dbb-9d6d-b360d6c9c3e3_zpstfplhuir.jpg)

And that’s it! One fresh 02Q/M 'box ready for the track. I can’t wait to get this installed. I will also use a few 034 motorsport bushes to tighten up the shift as the rubber ones have perished a bit and i have a sloppy stick lol

(http://daz.co/media/M4TVW/Edition_30/77c59e30-3071-4cfd-949c-9b330d84ac42_zpsxowpnyws.jpg)

I want to thank Martin for all his help and patience on building this gearbox. He really knows his gears so if anyone wants any work done, Give "Hotgolf" a PM or let me know and i can put him in contact with you.

While this was going on, A BCS Power valve exhaust which was on my list of parts came up for sale on Facebook. It was the R32 exit version instead of the Edition 30/GTI one sadly but i actually prefer the R32 style so i purchased this as well as the bumper freshly painted in Red. Luckily this was also in wales so planned to combine the 2 trips to collect it all at the same time...
Title: Re: MK5 Edition 30 #57 Track/Race Build
Post by: james_kav on September 07, 2016, 10:04:19 PM
Epic gearbox rebuild indeed!!! Brilliant and great photos/detail. I'm sure this will be referred to by a lot of people
Title: Re: MK5 Edition 30 #57 Track/Race Build
Post by: M4T VW on September 08, 2016, 08:50:20 PM
Epic gearbox rebuild indeed!!! Brilliant and great photos/detail. I'm sure this will be referred to by a lot of people

Thanks! It took me a while to write that one up and compile all the pictures. We are nearly up to date with the progress so far apart from the roll cage but i'm too busy getting it ready for paint that i'm struggling to find the time to write it up!

For the TSFI engines, there are really only two options that everyone swears by. The miltek or Powervalve BCS. The BCS is the more popular of the two as it’s cheaper so I kept an eye out for a second hand one. Luckily enough one came up in wales about the same time I was planning to go to Martin’s so I could collect both the exhaust and gearbox at the same time.
It was brand new and the non powervalve version which is what I was after (as apparently it’s quieter) but sadly it was the R32 exit. I do prefer the R32 look but this meant I had to purchase the R32 bumper with it which was more unnecessary expense but I had no option other than buying one new.  The guy was having his MK5 resprayed in red so got the bumper done at the same time (as it was R32 blue) so this is one less thing I have to worry about.

Here it is laid out on the floor, a lot of pipe work to bolt together!

(http://daz.co/media/M4TVW/Edition_30/18519EA1-AD1D-4C12-BE25-9E520B5A9981_zpsu03x9yio.jpg)

(http://daz.co/media/M4TVW/Edition_30/FD4F3348-282A-4366-937D-63369AA2718E_zpsl4s89ez1.jpg)

This is the bumper split in half. The bottom part is the half I require which I will attach to my current bumper as it has the parking sensors already in. I will attach the spare two together and sell them off.

(http://daz.co/media/M4TVW/Edition_30/97A06673-FEEF-4DC6-9541-C69E2782BA3F_zps8nptuxlh.jpg)
Title: Re: MK5 Edition 30 #57 Track/Race Build
Post by: tommygti on September 08, 2016, 09:38:47 PM
Sub'd. Looking forward to these updates. I'l be rebuilding a spare gearbox to fit a LSD in along with the steel shifter forks and upgraded bearings but I did'nt think about the other components you've covered. Great info and appreciate the detail.
Title: Re: MK5 Edition 30 #57 Track/Race Build
Post by: M4T VW on September 10, 2016, 09:52:32 PM
For a few months now I have been looking at different brake kits. There are loads of options out there but the problem is finding any for sale at a sensible price. The starting point is a kit called 'NQSBBK' (Not quite so big brake kit). This uses Boxster 987 rear calipers and Porsche 312mm discs but this is too small for what I wanted. It’s a good kit but people have reached the limit of them on track with little mods.

Next is the Porsche brake route using a 996 turbo caliper but finding any without scene tax is a hard job and then there are several other parts you need which push the price up quite considerably. This uses 350mm AMG discs but anything with AMG in the title is costly…

There are several other options including Volkswagen racing, Aston Martin DB9, Tarrox, Brembo, AP etc. I wanted to keep the standard master cylinder so this whittled it down to VW Racing (can’t find any second hand so new would mean a lot of money) and AP. (You can use the standard master cylinder with most of the other kits but for other reasons these were discounted)

I asked jtech for a price on a couple of AP kits and they were fantastic on service and offering advice where possible, even trying to get me to try the standard brakes on track before committing a heap of money on brakes.

While I was procrastinating about the brakes, I was in constant contact with Luke. He had been in a similar situation as me but managed to hunt down a set of VW Racing brakes that he had refurbished along with Audi S3 rear calipers. He offered lots of advice on different kits so it was just a waiting game for me to bite the bullet on an AP setup or wait for something on the second hand market to come up.
I kept checking MK5 & TFSI forums every day for about a month, nothing came up apart from a set of 8 pot Lamborghini calipers but these did not match my master cylinder lol

About a month passed and Luke had thoughts of selling his MK5 and even put it on the market. One thing was for sure though, he wanted to sell his brakes! :D
We had a quick chat and agreed a deal so I arranged a day for me to go up to Worcester for me to collect them. (Sadly I got hit with food poisoning that night so had to delay it by a week lol )
I left early one Saturday and it was a great drive up. Gave me chance to stretch the Edition 35’s legs as it’s not been on a long run for a while. (It went great and managed 35mpg most of the way). Met with Luke who took me out in his Ed30 running 375(?)bhp and it was mental. The power was effortless and endless. The type of power is really my end goal but it’s easy to chuck money at the engine and get results. I want to focus on the chassis for the time being. The factory 230bhp is more than enough on track (production GTI think 260bhp is enough) so I hope the chassis work will make up for it. The engine work will come later next year.

A couple of pictures. More in the next update as I test fit them [8D]

(http://daz.co/media/M4TVW/Edition_30/13090571_1637152449838771_850029745_n_zps9aauylbp.jpg)

(http://daz.co/media/M4TVW/Edition_30/13072143_1637152809838735_967999794_o_zpsimcllw9n.jpg)

(http://daz.co/media/M4TVW/Edition_30/13084043_1637157503171599_820738365_n_zpsn751k1yi.jpg)

(http://daz.co/media/M4TVW/Edition_30/E8E4D6F4-13FE-4184-A5CE-8F78A9DF6F45_zpszhkpsmwg.jpg)
Title: Re: MK5 Edition 30 #57 Track/Race Build
Post by: M4T VW on September 10, 2016, 11:03:55 PM
With the wiring out of the way. Prep work started for the cage install. This was going to be carried out by TSR who are not far from me. I have had a few chats with them and seen their work so confident that they can do the job.

I wanted to remove as much as possible from the inside including unwanted brackets, within reason. I was not up for hacking huge chunks out of it as some of them add strength and it was more effort that it's worth. It was mainly the ones that got in the way and i knew i would catch my knee on if i was crawling around the inside so the ISOFIX and rear seat brackets etc went.

I needed to remove the fuel tank for the welding but sadly this had half a tank of fuel in so spent a few ours bailing it out of the lift pump hole. I got as much as i could out and jacked it up to see what we could do.
Firstly the exhaust. The car had a supersprint backbox (ugly thing that stuck out under the bumper) however the whole thing has been welded all the way back to the turbo! Some bodge job that is and it meant i needed to cut it somewhere.

Access was an issue straight away. I couldn’t get the car high enough to get a swing on anything, or even the angle grinder under the car. I have two pretty big jacks but it just wasn’t enough and I have not even looked at removing the tank yet! There are loads of other jobs that need doing under it also like all the bushes, subframes, new exhaust etc. This job really needs a vehicle lift!

I jumped on the internet to see what was around. Working space is not so much of an issue for me but storage space is. Any fixed lift is out the window due to the layout of my unit. I needed something moveable. A single post lift, on wheels!
I managed to find a good company who I rang up and asked a few questions, number one being stability! Obviously it’s not going to be as good as a 4 post lift or even a two post lift but as long as you are sensible there should be no issue. So after justifying it to myself I purchased one and got it delivered next day!

However I didn’t expect it to arrive like this…

 (http://daz.co/media/M4TVW/Edition_30/BEB23D6D-DCD3-48B9-8774-B4106CCE0791_zpsr3kib9b1.jpg)

(http://daz.co/media/M4TVW/Edition_30/B6A683F9-A501-4E79-9492-07B3ADF0988C_zpsi8sfdh7j.jpg)

It took a lot of assembly. About 3 hours in total and thank god I have a forklift. The whole thing weighs 750kg and I think most of that weight is in the centre column. They don’t supply any way of lifting it, not even a hook at the top so we had to wrap a strap around it and hope for the best! Anyway, Finally I have access!

(http://daz.co/media/M4TVW/Edition_30/82122565-F4DD-44D7-AAED-A48B64F1F066_zpscwd6x44m.jpg)

It’s actually a lot more stable than I expected. We were hanging off it trying to get the exhaust and tank off and there was hardly any rock at all. Really impressed with it and it should make the rebuild sooo much easier! There is no limit to the jobs I can do now. Even just changing the brakes at a working height is amazing.
You cannot see from the picture but there is a handle and a set of wheels behind the centre post that you can lift the frame off the ground and drag it out of the way. It's much like a pallet truck in it's operation but a lot more heavy duty.
Title: Re: MK5 Edition 30 #57 Track/Race Build
Post by: SurreyED30 on September 11, 2016, 09:59:26 AM
Great build so far bud, gearbox overhaul is incredible and has been written up superb  :happy2:

Me and my father in law are talking about a lift type system like what you have got yourself, I will show him your pictures later and see if it twists his arm  :P

Let me know when you sell the day rear bumper please? Where are you based..

I will depo keep up with your progress updates  :happy2:

Jake
Title: Re: MK5 Edition 30 #57 Track/Race Build
Post by: gartht23 on September 11, 2016, 09:08:17 PM
Awesome work and write up sir. Keep the posts coming


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Title: Re: MK5 Edition 30 #57 Track/Race Build
Post by: james_kav on September 11, 2016, 09:22:46 PM
So, who is this company and what is the lift unit called or links to it please? Looks great and very useful to say the least!!!

Sent from my Lenovo YT3-850F using Tapatalk

Title: Re: MK5 Edition 30 #57 Track/Race Build
Post by: M4T VW on September 12, 2016, 11:25:13 AM
Great build so far bud, gearbox overhaul is incredible and has been written up superb  :happy2:

Me and my father in law are talking about a lift type system like what you have got yourself, I will show him your pictures later and see if it twists his arm  :P

Let me know when you sell the day rear bumper please? Where are you based..

I will depo keep up with your progress updates  :happy2:

Jake

Cheers!
I'm based in Bristol. Bumper will be coming off soon.

Awesome work and write up sir. Keep the posts coming


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Thanks!

So, who is this company and what is the lift unit called or links to it please? Looks great and very useful to say the least!!!

Sent from my Lenovo YT3-850F using Tapatalk



The company is Automotech. http://www.automotechservices.co.uk/
They do all sorts of garage equipment and were very helpful on the phone. There are lots of versions out there but i think they all get made in china and just painted a different colour!
Title: Re: MK5 Edition 30 #57 Track/Race Build
Post by: Bignod00 on September 12, 2016, 11:42:32 AM
Great build so far buddy, I'll be watching with interest!! :happy2:
Title: Re: MK5 Edition 30 #57 Track/Race Build
Post by: grey golfster on September 12, 2016, 10:26:53 PM

i think they all get made in china...

HOLY FECK!

And I'm fretting about my halfrauds Chinese axle stands!

Out of curiosity, did you consider  anything like these? Have been trying to justify for a while now...

http://www.frost.co.uk/strongman-28000-kg-tamar-mid-rise-mobile-scissor-car-lift-ramp-240v.html


Title: Re: MK5 Edition 30 #57 Track/Race Build
Post by: M4T VW on September 13, 2016, 12:41:51 PM

i think they all get made in china...

HOLY FECK!

And I'm fretting about my halfrauds Chinese axle stands!

Out of curiosity, did you consider  anything like these? Have been trying to justify for a while now...

http://www.frost.co.uk/strongman-28000-kg-tamar-mid-rise-mobile-scissor-car-lift-ramp-240v.html

Haha, its still made pretty well even if it was made for a bowl of rice  :grin:
There are saftey locks all up the center column so you can remove the hydraulic ram with the car in the air if you wanted. It's pretty stable in the air to be honest! You have to spend a few minutes getting the lift in the right position and test it each time.
I'm going to be removing the rear beam soon which is the only bit of weight left in the back end so it's going to be very front heavy. I think i will put the forklift under the front of it as a safety measure  :happy2:

I did look at those types but it didnt really help. All the frame work is in the way if you wanted to work under it and you care still on your hands and knees. Theres nothing better than working under a car stood up!
Title: Re: MK5 Edition 30 #57 Track/Race Build
Post by: M4T VW on September 14, 2016, 09:33:47 PM
I'm trying to get these updates in order as it's moving quite fast at the moment!

I had a delivery to do in Bridgewater so thought it would be good to pop in to TSR while i was there and speak to them about a roll cage. I had been in e-mail contact with Rob already but just wanted to show my face and have a quick chat. Once i was there they showed me a couple of the cars they were building and i booked mine in there and then. Sadly with both TSR's and my workload, this turned out to be nearly 2 months before i managed to take the car down.

While the car was away i still had plenty to be getting on with. When the car was on the lift I noticed that the rear axle was not in great condition and i needed to change all the bushes anyway so set about trying to find one that i could refurbish and build back up so all i would have to do is swap them over.

However getting hold of a MK5 GTI rear axle is actually quite difficult! I spoke to several breakers who never got back to me, A couple on eBay that had seen better days and others that were in Scotland or London with no way of getting them to me. I tried one of these "find a part" websites in the end and within half an hour i had a breaker on the phone with a low mileage complete axle and he could ship it to me! The price was actually better than what i was quoted from other people and that didn’t include shipping. It arrived a few days later and I expected it to be on a pallet wrapped up. However the driver said to me “6 parcels mate”. The breakers had taken the whole thing apart to ship it to me, saved me doing it I suppose! lol

Next, I needed some bushes. Funnily, at the same time as I was looking superpro released a new track/race kit for the MK5 Golf platform. You can see the press release for this at http://www.superpro.com.au/whats-new/media-a-press/item/309-superpro-upgrade-its-mk5-golf-kit (http://www.superpro.com.au/whats-new/media-a-press/item/309-superpro-upgrade-its-mk5-golf-kit)
Performance VW also did a feature on the kit which you can read here. http://www.superpro.com.au/images/whats-new/Mk5_Golf/SUPPVW0616_-_SuperPro_-_Golf_MK5-r.pdf
 (http://"http://www.superpro.com.au/images/whats-new/Mk5_Golf/SUPPVW0616_-_SuperPro_-_Golf_MK5-r.pdf")
I was already in contact with Henry Wright and Jamie Packham at Jtech performance parts as they are a Club GTI sponsor so I let them know what I wanted and they came back with a cracking price for it all. This included the alloy arms, front to rear bushes kit, front and rear ARB’s etc. The whole 9 yards. They also offered lots of advice which was great. It wasn’t just about the price, the service was excellent also. I ordered the kit from Henry and a few days later it turned up. It’s beautiful! [:|]

(http://daz.co/media/M4TVW/Edition_30/91C4F7E1-02FA-41A1-88F1-9C5478A8E44A_zpsykzrmsrq.jpg)

(http://daz.co/media/M4TVW/Edition_30/ALLOY0001K_-_Logo_small_zpstbdky8v4.jpg)

However, the replacement rear beam was not so beautiful. In fact it was a mess of flaky paint, surface rust, road grime. The usual problems any rear subframe faces to be honest. I couldn’t bolt on £1000’s worth of bushes, alloy arms and roll bars to a rusty subframe could i? ;)

Let’s get cracking on the paint removal then. I could have got this professionally done but I’m trying to save money at the moment as the spending is a bit out of control! I managed to pick up a sand blasting gun and some aluminium oxide shot for a good price from eBay. I have never done anything like this before so it was a bit of a learning curve to be honest but it came out pretty well I think.

First problem, we needed to remove the old bushes, I found the best way (as suggested by Justin) was to hole saw the middle out and insert a hacksaw blade to take a nip out the side. This releases the pressure and you can knock it out with a socket. I had them all done in an hour!

(http://daz.co/media/M4TVW/Edition_30/IMG_1819_zpswjnlvfn1.jpg)

(http://daz.co/media/M4TVW/Edition_30/IMG_1820_zps03m0asgh.jpg)

The second problem was where the hell do I sand blast these? I have a big workshop but it’s pretty full, I can’t just shoot metal filings everywhere and mixed with the rust it would have been a terrible mess. I also wanted to reuse the shot if possible as I know I was borderline if I had enough or not. So I needed a sealed container, big enough to take the subframe (arms removed). I know...

(http://daz.co/media/M4TVW/Edition_30/IMG_1821_zpsc6w518nh.jpg)

Yes, that is a pallet bin. We use it to tip waste into a large skip outside. We didn’t care about the paint on the bin and it’s sealed around the sides, bottom and back so it just needs a lid and it’s good to go! The pallet as a shelf worked well also, it allowed the media to fall through to the bottom and I could just hoover it out.

I spoke to one of my material suppliers to see if they had any scrap material. She had a scratched sheet of 3mm PETG that is perfect for what I needed so chucked it on my next delivery and it was like new to be honest. I managed to pick up a pair of blasting gloves from eBay also so I had the makings of a DIY blast cabinet for large items. A bit of hinge later and we have this contraption!

(http://daz.co/media/M4TVW/Edition_30/IMG_1830_zps20gnfp7q.jpg)

It worked really well, however I could have done with much more media for it. I put it through the 2nd time and it was less effective. It took twice as long to remove the paint but that’s all I could do really without spending more money.
Here are some comparisons of the parts.

(http://daz.co/media/M4TVW/Edition_30/IMG_1828_zpsis5gi8il.jpg)

 (http://daz.co/media/M4TVW/Edition_30/IMG_1831_zpskorsza3u.jpg)

Pretty good as you can see. The paint that is left on there is very strong so I left it on for added protection.
Then it’s just a case of hanging them up and giving them a few coats with the black hammerite. I did the arms and a few other bits one night as it was very hot that week. 30+ in the workshop so had to be done at night to stop it from drying out so quick.

(http://daz.co/media/M4TVW/Edition_30/IMG_1832_zpsqtiqdjhb.jpg)

(http://daz.co/media/M4TVW/Edition_30/IMG_1833_zps2jhvsb38.jpg)

(http://daz.co/media/M4TVW/Edition_30/5F5412BA-94CF-4D1A-BE47-3940E015CB05_zpsmbjkltx2.jpg)

I spent a morning outside painting the larger parts as I couldn’t fit it all on the forklift

(http://daz.co/media/M4TVW/Edition_30/3C762831-735A-4067-830E-D65F25AA1A19_zpsi8iyv7ax.jpg)

(http://daz.co/media/M4TVW/Edition_30/DAEBAD41-E7E8-48A9-A398-5F98E7DAC675_zpsdfb0dis8.jpg)

(http://daz.co/media/M4TVW/Edition_30/IMG_1841_zpshp3stdau.jpg)

They have been left for about 4 weeks now so I think that’s enough time to let it go hard. I will be putting it all back together with the superpro kit soon. :D
Title: Re: MK5 Edition 30 #57 Track/Race Build
Post by: SurreyED30 on September 14, 2016, 09:50:46 PM
Good work on the rear subframe mate, must of saved your self a few quid there!

 look forward to the fully assembled post soon :happy2:
Title: Re: MK5 Edition 30 #57 Track/Race Build
Post by: bad devotions on September 14, 2016, 10:08:25 PM
Epic work!

Sent from my Nexus 5 using Tapatalk

Title: Re: MK5 Edition 30 #57 Track/Race Build
Post by: tommygti on September 17, 2016, 11:42:24 AM
That DIY blast cabinet is brilliant. I would do most of the modification myself aswell if I simply had a garage/workshop.

If your building a track car I would recommend buying some S3/TTS/passat front alloy hubs to help save some weight and they are more robust than the oem steel versions. You can pick them up very cheap if your look properly.
Title: Re: MK5 Edition 30 #57 Track/Race Build
Post by: M4T VW on September 24, 2016, 04:36:38 PM
One of the many jobs that needed doing was a dash making up. This was to house the following items:
FIA cut-off switch

Ultra gauge, really handy device to have. I had it installed on the MK2 and it was great.

3 stack gauges, Oil Temp, Oil Pressure and boost!

I’m keeping the standard heater/blower setup (but removing aircon) so I needed to keep the factory controls. I could have moved them but it made sense to keep them in the same location as I can make a panel to fit into where the radio went.

First I needed to get the shape of the cut-out, easy when you have the tools!

 (http://daz.co/media/M4TVW/Edition_30/IMG_1785_zpsh2rec9tb.jpg)

Next, CNC the panel out from 3mm diabond.

(http://daz.co/media/M4TVW/Edition_30/IMG_1786_zpsaax8wvns.jpg)

Trial fit, like a glove!

(http://daz.co/media/M4TVW/Edition_30/IMG_1787_zpshsfhbokn.jpg)

The gauges turned up, They look good.

(http://daz.co/media/M4TVW/Edition_30/IMG_1794_zpso80ceuff.jpg)

I missed out sticking the panel in using fibreglass but it’s well stuck. Lastly, cover the whole in in carbon fibre wrap.

(http://daz.co/media/M4TVW/Edition_30/IMG_1804_zpsdiqrjxiw.jpg)

I went a little OTT

(http://daz.co/media/M4TVW/Edition_30/IMG_1803_zpshhkaeuo4.jpg)

That’s another job out of the way :thumbup:
Title: Re: MK5 Edition 30 #57 Track/Race Build
Post by: M4T VW on September 24, 2016, 04:39:03 PM
That DIY blast cabinet is brilliant. I would do most of the modification myself aswell if I simply had a garage/workshop.

If your building a track car I would recommend buying some S3/TTS/passat front alloy hubs to help save some weight and they are more robust than the oem steel versions. You can pick them up very cheap if your look properly.

Yes, I don't have a picture of them but i have a set of S3 alloy fronts. I put a wanted advert out for them and it was Luke who sold me the brakes messaged me to say he had a set also so i purchased them  :happy2:
Title: Re: MK5 Edition 30 #57 Track/Race Build
Post by: welshname on October 21, 2016, 03:35:55 PM
Some serious work going into this.

Loving the dash panel.
Title: Re: MK5 Edition 30 #57 Track/Race Build
Post by: M4T VW on October 25, 2016, 01:31:39 PM
Thanks!

Plenty of work has gone on since, Just need to find the time to write it all up.
Title: Re: MK5 Edition 30 #57 Track/Race Build
Post by: teo_parvu on November 08, 2016, 07:49:01 PM
Superb work here! Need to watch where this is going ...  :party:
Good idea with the carbon wrap, looks pretty cool.  :happy2:
Title: Re: MK5 Edition 30 #57 Track/Race Build
Post by: M4T VW on November 09, 2016, 10:13:52 PM
With the car still away getting the cage done i moved onto the brakes i bought from Luke. One new addition is alloy front hubs which i put a wanted advert out for. Who contacts me? Luke again lol
I wanted to mock them up (or one anyway) because reading around, i was going to have problems with the carrier as the mounting point on the alloy hubs are thicker for added strength so longer bolts are needed from the S3 to go with the hubs. Some bolts were supplied with the brakes so it was a case of put them together and see what happens.

(http://daz.co/media/M4TVW/Edition_30/IMG_1690_zpszamstxnd.jpg)

Here are the bolts supplied with the brakes. They have been replated so they look like new but sadly they are too short because of the alloy hub. This is even without a locking washer which they ideally need as the heads are quite small on them.

(http://daz.co/media/M4TVW/Edition_30/IMG_1693_zpsh3vwtxhz.jpg)


(http://daz.co/media/M4TVW/Edition_30/IMG_1691_zpspf2nlnyy.jpg)

This is a factory S3 bolt that would be correct with the hub and standard carrier. It's the perfect length and has a locking washer built in. However this is not a standard carrier so the thread is a fine thread, not a coarse thread like the VWR brakes so that's a waste of money.

(http://daz.co/media/M4TVW/Edition_30/IMG_1694_zpseybc8awh.jpg)

The two side by side.

(http://daz.co/media/M4TVW/Edition_30/IMG_1695_zps4gfdibil.jpg)

The other problem is wheels. I was having trouble shifting the edition 30 alloys as they are rare and no one wants to pay money for them. I saw a set go for £100 more than I'm asking on ebay and they were in worse condition than mine. I was thinking about using them as track wheels until i fitted one over the brakes, well i tried to! I couldn't even bolt them up as the offset is all wrong so i either run a 5-10mm spacer or sell them. I don't want to run spacers on this car really so the best option is to sell them and purchase some proper wheels.

(http://daz.co/media/M4TVW/Edition_30/IMG_1696_zpsks36q9mp.jpg)

It's a shame as they do really compliment the brakes.

(http://daz.co/media/M4TVW/Edition_30/IMG_1698_zpsvaoheh8j.jpg)


I look around on the internet and find a cracking deal on some pro race 1.2's. Doing research again these fit over the brakes fine with the correct offset and these are even the correct fitting from VWR. No spigot's, no spacers, nothing. Bolt straight on! They are also in the VWR anthracite grey which will look amazing once fitted. So i bought 10 of of them lol

(http://daz.co/media/M4TVW/Edition_30/IMG_1722_zpsfihfdh7b.jpg)

(http://daz.co/media/M4TVW/Edition_30/IMG_1721_zpsrwxn1gcq.jpg)

[l] They look amazing behind these wheels.

(http://daz.co/media/M4TVW/Edition_30/IMG_1729_zpsqylcfxi8.jpg)

Perfect amount of clearance, direct to hub fitment.

(http://daz.co/media/M4TVW/Edition_30/IMG_1731_zpsewwb8bc0.jpg)

Purchased longer bolts and nord-lock washers for the fixing. I bought two sizes so have an option when i come to fit them.

(http://daz.co/media/M4TVW/Edition_30/IMG_1732_zps9vlubuzr.jpg)

(http://daz.co/media/M4TVW/Edition_30/IMG_1733_zpswiyge9e1.jpg)

While all this was going on i received a call from a friend of mine that a suspension set that i have been looking for just popped up on facebook. I had to stop what i was doing and look straight away as these just done come up 2nd hand. This set was removed from garage midnight's track project that never made it to the road. They were fitted and it was pushed around the workshop only so they are like new. I saved a load of money on these. They are KW clubsports so should be perfect for this car.

(http://daz.co/media/M4TVW/Edition_30/IMG_1717_zpsv3ahwraw.jpg)

(http://daz.co/media/M4TVW/Edition_30/IMG_1716_zpsyetjz8qi.jpg)

Oh, It's back! :D

(http://daz.co/media/M4TVW/Edition_30/IMG_1842_zpszxzsjs3h.jpg)
Title: Re: MK5 Edition 30 #57 Track/Race Build
Post by: Shoduchi on November 09, 2016, 10:53:25 PM
Another awesome update! :congrats:
Title: Re: MK5 Edition 30 #57 Track/Race Build
Post by: Adamcrake1991 on November 10, 2016, 10:06:00 AM
How much you wanting for your pescaras? Could be intetested
Title: Re: MK5 Edition 30 #57 Track/Race Build
Post by: M4T VW on November 10, 2016, 02:00:34 PM
Another awesome update! :congrats:
Cheers. Looking forward to getting this done but i'm pretty busy all weekends up until christmas now so dont think it will be done by then. I have about 2 weeks off at christmas so plan to get a lot done then.

How much you wanting for your pescaras? Could be intetested

Sent you a PM.
Title: Re: MK5 Edition 30 #57 Track/Race Build
Post by: fab5freddy on November 10, 2016, 08:39:50 PM
10 wheels, love it.  :signLOL:

What offset did you go for to clear the brakes? 35? I'm looking for a set and interested to know what clears BBK, would you have a linky to where you got the wheels?

Those club sports look the business  :driver:

Such a great build  :happy2:
Title: Re: MK5 Edition 30 #57 Track/Race Build
Post by: M4T VW on November 10, 2016, 10:22:47 PM
Roll cage update.

I received a call from TSR that the car was ready but they wanted me to pop down to have a look so went down early one Saturday. All looked great, apart from half of the dash, steering column, shuttle, engine missing. I didn't think how much they needed to remove to fit the cage. I had removed as much as i could, or so i thought lol
Here are some pictures from the Saturday. We collected it on the following Monday but it was raining, hence the bubble wrap at the windows. Oh yeah, they were missing too! lol

(http://daz.co/media/M4TVW/Edition_30/P1000483_zpsmyxoctvp.jpg)

(http://daz.co/media/M4TVW/Edition_30/P1000484_zpscszcl8wc.jpg)

(http://daz.co/media/M4TVW/Edition_30/P1000486_zpsb2mb1zlk.jpg)

(http://daz.co/media/M4TVW/Edition_30/P1000487_zps3bmivzlk.jpg)

(http://daz.co/media/M4TVW/Edition_30/P1000489_zpsgo3vkgvk.jpg)

(http://daz.co/media/M4TVW/Edition_30/P1000491_zpsy4zi9v0i.jpg)

International spec cage with a few extra bits added. I didn't need it going through the bulkhead to the front struts so that saved a bit. Custom gear shift tower added also. I thought i might as well put a pretty good cage in seeing as i have come this far with the shell. It also adds to it's value but will limit it from some race series. I don't intend on selling it any time soon though [:s]
Back at my workshop it was time to mock a few things up before the inside was painted. Last thing i would want to do is ruin fresh paint on the inside.

Let's start with the hand brake.

(http://daz.co/media/M4TVW/Edition_30/28D4BA4D-A642-4A08-BC5A-9E4A9CBD4F19_zpsuusb1knu.jpg)

Oh dear, that doesn't work. Let's move on lol
I loosely assembled the dash bar and column back together so we could start fitting the dashboard. This needed lots of cutting to fit around the two uprights. It doesn't help that the dash falls right on the bend also. I wanted to keep the front of the dash intact so no cut's through the vents. I have seen some shocking jobs of these done so it took a good half a day to get this fitted.
I had to cut into the dash more than i wanted to get it into position so once it's in there is quite a gap. I can cover this with a plate at a later date but it's the lesser of the two evils. The front stand intact and i might be able to get the vents working still.

(http://daz.co/media/M4TVW/Edition_30/IMG_1848_zpsev4r7iaa.jpg)

(http://daz.co/media/M4TVW/Edition_30/IMG_1853_zpsrofouoj9.jpg)

(http://daz.co/media/M4TVW/Edition_30/IMG_1854_zps6pcx3b3u.jpg)

Fixed the hand brake. Had to make up some brackets to move it towards the driver. It's in the middle of the car now so i don't chop my fingers off. To be honest i could do away with the whole thing but it creates more problems than it's worth.

(http://daz.co/media/M4TVW/Edition_30/7B038EA0-9812-4C1B-B26C-43892FC84A96_zpswxvbvg0h.jpg)

(http://daz.co/media/M4TVW/Edition_30/DC900805-14D2-46B7-A2E7-5E32B1B42569_zpsvxujhfkc.jpg)

I thought i would leave this stuff in as i know what a ***** it was to remove on the MK2. However i spilt petrol on it removing the tank and it reacted a little so had to remove it or it would show in the paint and bug me. I wish i had done it before the cage was installed though [><]

(http://daz.co/media/M4TVW/Edition_30/IMG_1869_zpsl5mcrtfv.jpg)

It's actually a lot easier to remove than the MK2 stuff but i suppose it's only been there 10 years, not 20+

(http://daz.co/media/M4TVW/Edition_30/IMG_1870_zpskmwecnuc.jpg)

I originally purchased Cobra Suzuka's for this car. I had them in the MK2 in GT width and they were very comfortable but we did slop around in them. I knew at the time if i did another car that i would get the same seats in standard width, so that's what i did.
When they arrived i got one out to test it and i couldn't actually get my bum into the seat :thumbd:. I never knew how much difference 30mm could make as i have a standard width Evolution pro on another project and that is the perfect width. I had no option but to send them back and swap them for two Evolution pro's instead.

(http://daz.co/media/M4TVW/Edition_30/8FF0A5D1-C483-496A-A251-25C88922CACB_zpsuljz5kw2.jpg)

I had to test fit the harness as it seems a little short. I'm looping around the rear roll cage bar which is between the rear struts. It's further back than most that i see but they have much more webbing left on their straps so i think it's a combination of the bar being that far back and the harness being shorter than most. I think it will be fine but will check it again once everything is bolted in tight and i can pull the straps in nice and tight.

(http://daz.co/media/M4TVW/Edition_30/F669E3F8-9A12-4496-89D0-068F476D0D48_zpspvwbpxfr.jpg)

The door side lap belts fall right into the standard seat belt captive nuts, much like the MK2.

(http://daz.co/media/M4TVW/Edition_30/D4890664-BA49-4653-89AC-1198DB4C99B9_zpswcq7zhfp.jpg)

The inner ones require welding in so i let my old man do that while i worked on the gear shift tower.

(http://daz.co/media/M4TVW/Edition_30/IMG_1903_zps2rtdk0ep.jpg)

There was a little side to side movement in the tower so it needed changing. Now is the perfect time to do that so i set about beefing it up. I removed the two bars holding the actual shifter and welded in a flat plate to hold it properly. I can also mount the factory ABS and TC switches in front of the gear stick. I wont need them when it's mapped but have to switch them off manually currently. I will have to see if i can reach them once strapped in or might have to put them on a riser plate facing the driver.
I also changed the length of the side bars, making them shorter and bolted under the shifter means this is now very strong. There is no movement it in at all.

(http://daz.co/media/M4TVW/Edition_30/873B9F51-242A-4F22-A34C-EB6CCD94C012_zpsriz4nvtf.jpg)

A date was booked for the painting so worked a few late nights on it. The rear struts had some spot weld drill marks on from the removal of rear brackets so i wanted to so something about this. I welded them up and smoothed it over. I gave it a spray of primer to make sure it was OK.

(http://daz.co/media/M4TVW/Edition_30/9C2FF9D4-4E43-4CDF-8B08-FCCC9246E1E9_zpsipug7jvm.jpg)

Just had to mask up the rest of the parts i didn't want painting then. It was easier to paint with the gearstick in place than remove it again so i covered this over. Also i wrapped the cables up to the pedals and put a big bag over them.

(http://daz.co/media/M4TVW/Edition_30/IMG_1921_zpsbztq43pl.jpg)

Gave the cage a rubdown to remove the sharp edges and welding blobs. Pushed it outside and gave it a couple of coats of etch primer.

(http://daz.co/media/M4TVW/Edition_30/IMG_1922_zpsnjm19y4o.jpg)

All done ready for painting! :D
Title: Re: MK5 Edition 30 #57 Track/Race Build
Post by: M4T VW on November 10, 2016, 10:25:52 PM
10 wheels, love it.  :signLOL:

What offset did you go for to clear the brakes? 35? I'm looking for a set and interested to know what clears BBK, would you have a linky to where you got the wheels?

Those club sports look the business  :driver:

Such a great build  :happy2:

Thanks!

The offset is ET45 to clear the brakes. I have the older VWR BBK though, Not sure on the newer one with the mono-block type calipers but i expect it to be the same.
These are the wheels. http://www.ebay.co.uk/itm/4-x-Team-Dynamics-PRO-RACE-1-2-Gloss-Black-Alloy-Wheels-8x18-5x112-PCD-ET45-/302104116189?_trksid=p2141725.m3641.l6368

Title: Re: MK5 Edition 30 #57 Track/Race Build
Post by: Dan_ED30 on November 11, 2016, 06:48:04 PM
Theres some time, effort and money went into this!

Fair play to you mate it looks awesome!
Title: Re: MK5 Edition 30 #57 Track/Race Build
Post by: M4T VW on November 19, 2016, 05:49:51 PM
On to the paint then. We had a few choices for the inside and cage. White, which i did the MK2 in, was not very practical. It gets dirty & dusty quickly and these things aren't easy to climb in to hoover it out once the seats and cage is installed so that was out.
A couple of friends of mine just painted the inside of their MK1 in a dark grey. Although it looks great and very practical for a car like this, i wanted mine to give a professional look like it was factory built so there was only one choice, red! lol
I wanted a hard wearing colour as the white on my MK2 was just a colour, no clear coat or anything so you had to be careful. As we were trying to match the outside for colour it made sense to treat it like the exterior and follow the same products that were used. My friend managed to get me some LY3D hard coat base colour and also the other materials needed. He paints professionally for a living so i just left it up to him as i had no idea what i needed lol

A plan was hatched to use one of those paint booths that you can rent and they also have an oven. However, once the car came back from TSR and the state it was in currently, i think it would have been too much hassle getting it there and then getting it back without damaging the paint so we needed a plan B. We decided to do it in my unit as i had a good air supply, but a lot of planning was needed to stop the over-spray from covering everything. Firstly, I purchased a 3m x 6m one of these http://www.ebay.co.uk/itm/121465515324?_trksid=p2060353.m1438.l2649&var=420405119128&ssPageName=STRK%3AMEBIDX%3AIT (http://www.ebay.co.uk/itm/121465515324?_trksid=p2060353.m1438.l2649&var=420405119128&ssPageName=STRK%3AMEBIDX%3AIT) It was cheap enough and i can use it in the garden one day maybe, Apart from it looks like someone has now died it in lol
Me and a work colleague put it up one Friday afternoon with the plan to paint it early Saturday. I was busy as work during the week so the unit was a little tight for space sadly.

(http://daz.co/media/M4TVW/Edition_30/IMG_1927_zpsooby7goy.jpg)

Once we masked the car up outside of the "booth" to give us more space, we masked the inside also to try and protect the booth so it could have been used as a later date. I'm glad we actually gave it extra protection as it wasn't exactly sealed so every little helped on stopping the over-spray from getting out. The windows were so thin, I think a sandwich bag has thicker gauge material, but i suppose you get what you pay for [:s]

(http://daz.co/media/M4TVW/Edition_30/IMG_1930_zpsjdeosig9.jpg)

Although i had given the cage a coat with etch primer, guy wanted to go over it again with a light "mist" coat of normal grey primer.

(http://daz.co/media/M4TVW/Edition_30/IMG_1931_zpsv376hosv.jpg)

From this point on, it all seemed to get a little messy! lol The booth did have a door on it but we removed it at the end. This is after 2 coats of colour and also one coat of lacquer. The floor covering did get a little damaged as the paint stuck to Guy's shoes and ripped the material. He started sticking to the floor in the end!
I think it looks amazing :D

(http://daz.co/media/M4TVW/Edition_30/IMG_1932_zpswsbnffvf.jpg)

(http://daz.co/media/M4TVW/Edition_30/IMG_1933_zpsfxsah6jp.jpg)

(http://daz.co/media/M4TVW/Edition_30/IMG_1934_zpszaybctlv.jpg)

(http://daz.co/media/M4TVW/Edition_30/IMG_1935_zpspvafufe0.jpg)

(http://daz.co/media/M4TVW/Edition_30/IMG_1936_zpsrcsgf7tp.jpg)

This was the day after. I popped down to the workshop to peel off the covering and the colour just started to blend into the exterior colour. It looked a little dark in the previous pictures but it needed time to cure. As you can see from the next set of photos, the colour match is great.

(http://daz.co/media/M4TVW/Edition_30/IMG_1938_zpsjj49bfbh.jpg)

(http://daz.co/media/M4TVW/Edition_30/IMG_1939_zpsjtqhd52y.jpg)

(http://daz.co/media/M4TVW/Edition_30/IMG_1940_zpssocr0yyu.jpg)

(http://daz.co/media/M4TVW/Edition_30/IMG_1941_zps5bmt3q3d.jpg)

I slotted together the R32 rear bumper and just hung it on the car to see what it looked like. There was a slight colour difference. The bottom part was practically orange! More paint needed :cry:

(http://daz.co/media/M4TVW/Edition_30/IMG_1943_zpsev1wsmms.jpg)


I want to thank Guy for the painting and all the advice he has given to get to this stage. I'm very happy with the end result! I also want to thank his partner Charlotte for the support and biscuits while we watched Guy paint lol:clap:
Title: Re: MK5 Edition 30 #57 Track/Race Build
Post by: Orc on November 19, 2016, 06:29:53 PM
Great thread Matt, Lukes a good friend of mine and I've done a fair bit of work for him. This looks like a great build and your not far from me. I am doing the same currently in my garage getting ready for track.
Title: Re: MK5 Edition 30 #57 Track/Race Build
Post by: M4T VW on November 20, 2016, 10:01:30 AM
Great thread Matt, Lukes a good friend of mine and I've done a fair bit of work for him. This looks like a great build and your not far from me. I am doing the same currently in my garage getting ready for track.

Thanks! When do you think yours will be ready?
Title: Re: MK5 Edition 30 #57 Track/Race Build
Post by: Orc on November 20, 2016, 10:57:18 AM
Mines a little more in depth and has a few more issues, but hopefully reveal it after xmas.  :jumping:
Title: Re: MK5 Edition 30 #57 Track/Race Build
Post by: M4T VW on November 21, 2016, 10:37:07 AM
More in-depth than this? I'm intrigued!  :happy2:
Title: Re: MK5 Edition 30 #57 Track/Race Build
Post by: Pesky jones on November 21, 2016, 12:30:28 PM
Amazing work!
Title: Re: MK5 Edition 30 #57 Track/Race Build
Post by: Orc on November 22, 2016, 06:49:31 PM
More in-depth than this? I'm intrigued!  :happy2:

Yeah, talking complete chassis back strip etc and a special drive train system I'm designing. Its my 4th mk5 project now....if you need any advice just hola!
Title: Re: MK5 Edition 30 #57 Track/Race Build
Post by: M4T VW on November 23, 2016, 10:49:57 AM
More in-depth than this? I'm intrigued!  :happy2:

Yeah, talking complete chassis back strip etc and a special drive train system I'm designing. Its my 4th mk5 project now....if you need any advice just hola!

Nice! Look forward to seeing that then  :happy2:
Title: Re: MK5 Edition 30 #57 Track/Race Build
Post by: S800BRN on November 23, 2016, 04:47:29 PM
How nice are those brakes behind the TDs?
Title: Re: MK5 Edition 30 #57 Track/Race Build
Post by: M4T VW on December 22, 2016, 09:33:19 AM
Rebuilt the spare rear axe and used superpro bushes all round, i have pictures and will upload them over christmas. Not touched it for a month sadly as i have been too busy at work and had the flu. Hopefully get some stuff done over christmas as i have 2 weeks off!
Title: Re: MK5 Edition 30 #57 Track/Race Build
Post by: Orc on December 22, 2016, 12:31:17 PM
Go Matt!! i have a spare rear 2wd subframe if anyone wants it too do the same
Title: Re: MK5 Edition 30 #57 Track/Race Build
Post by: Orc on February 17, 2017, 11:24:12 AM
Matt......updates?
Title: Re: MK5 Edition 30 #57 Track/Race Build
Post by: M4T VW on March 30, 2017, 10:12:15 PM
I have been so busy with this car and work since Christmas that I have had no time to write any updates. We have lots of catching up to do for the past 3 months so I will try and type the updates up over the next few weeks. I have uploaded over 100 photos just for the past 3 months of work!

Firstly, I’m not one to sit around in the winter months so several weekends were spent in the unit building different components and mocking things up in prep for the final assembly. A nice easy one to do was assemble the refurbished rear axle and put in the new Superpro bushes. It’s a satisfying job to do, putting a new bush into the hole (no pun intended) but that silicone grease they supply gets everywhere! You can’t really wear gloves with it because it’s sort of sticky and if you don’t wear gloves you have to wash your hands 10 times before everything stops slipping out of your hands! Still, got there in the end and it looks great! Thanks to Henry and Jamie at Jtech Automotive for the superpro kit and also the advice on fitting.

Handy to have a workbench to do it on. I had to dust this off it had been sitting around for so long.

(http://daz.co/media/M4TVW/Edition_30/IMG_2050_zps4p92izct.jpg)

All the bushes ready to go. I used a laptop with the Superpro website on so i could see where each part number went.

(http://daz.co/media/M4TVW/Edition_30/IMG_2051_zpstqzvkrsq.jpg)

Some already done, Working out the others.

(http://daz.co/media/M4TVW/Edition_30/IMG_2052_zpsap7yimcr.jpg)

All done! New bolts, washers and nuts used everywhere apart from the one on the top trailing arm as i forgot to order that one. I have since changed it for a new bolt.

(http://daz.co/media/M4TVW/Edition_30/IMG_2056_zpspkrjfgrn.jpg)
Title: Re: MK5 Edition 30 #57 Track/Race Build
Post by: M4T VW on March 30, 2017, 10:22:20 PM
A couple more odd jobs that needed doing. Removing the AC system and wrapping the new down pipe. The AC system was pretty easy, wrapping the down pipe not so much but much easier than the 6-branch manifold on the MK2!. I hate working with this stuff. It turns out i wrapped way too much of the middle pipe, i only needed a few inches of it in the end lol

(http://daz.co/media/M4TVW/Edition_30/IMG_1945_zpsmfrqmmyj.jpg)

(http://daz.co/media/M4TVW/Edition_30/IMG_1947_zpseuwbgcmu.jpg)

(http://daz.co/media/M4TVW/Edition_30/IMG_1951_zpsrvrlbwjj.jpg)

(http://daz.co/media/M4TVW/Edition_30/IMG_1954_zps2zqlijul.jpg)

(http://daz.co/media/M4TVW/Edition_30/IMG_1955_zpshs4bbwdn.jpg)

(http://daz.co/media/M4TVW/Edition_30/IMG_1957_zpsvpqvglun.jpg)

(http://daz.co/media/M4TVW/Edition_30/IMG_1958_zpsgklpb6s7.jpg)
Title: Re: MK5 Edition 30 #57 Track/Race Build
Post by: Orc on March 31, 2017, 11:49:53 AM
Good work Matt.
Title: Re: MK5 Edition 30 #57 Track/Race Build
Post by: Pesky jones on March 31, 2017, 11:56:31 AM
Awesome... that axle :drool:
Title: Re: MK5 Edition 30 #57 Track/Race Build
Post by: ChrisGT on March 31, 2017, 12:44:11 PM
Love this project and the attention to detail.

Keep it up!

Chris
Title: Re: MK5 Edition 30 #57 Track/Race Build
Post by: M4T VW on March 31, 2017, 01:25:35 PM
Love this project and the attention to detail.

Keep it up!

Chris

Thanks guys. I have carried the attention to detail through to the inside so you will see that soon!
Title: Re: MK5 Edition 30 #57 Track/Race Build
Post by: damoegan on March 31, 2017, 06:02:22 PM
Great work mate, keep it going  :happy2:
Title: Re: MK5 Edition 30 #57 Track/Race Build
Post by: StuF on March 31, 2017, 06:58:31 PM
Just read the whole thread from start to finish - wow what awesome work!
Cant wait for the next installment

 :happy2:
Title: Re: MK5 Edition 30 #57 Track/Race Build
Post by: M4T VW on March 31, 2017, 08:12:35 PM
Cheers!  :happy2:

There were a few engine bay jobs that needed doing so planned as many as I could I one day/weekend. It was mainly the gearbox & clutch/flywheel install and new revo engine mounts but after some thinking about how to drop the gearbox out it was just as easy to whip the engine out and do what we needed to.
I had a couple of stripped studs on the turbo manifold that needed sorting and took advantage of the engine being out to install the new front ARB.

(http://daz.co/media/M4TVW/Edition_30/IMG_2014_zpsvtvbonq7.jpg)

Using the crane to lower the engine on the gearbox side didn't really work. I'm glad we gave up on that one now.

(http://daz.co/media/M4TVW/Edition_30/IMG_2015_zpsrvwa6ydc.jpg)

It's out! To be honest most of it was already disconnected. I think the only pipe we had to take off was the water and fuel but they were both empty anyway.

(http://daz.co/media/M4TVW/Edition_30/IMG_2016_zpsx1ztadzw.jpg)

I couldn't see a way to disconnect the cables running to the engine from the passenger side so left them connected. It was going back in on the same day anyway.

(http://daz.co/media/M4TVW/Edition_30/IMG_2017_zpszadqvlua.jpg)

(http://daz.co/media/M4TVW/Edition_30/IMG_2018_zpsdnq7jihz.jpg)

Gearbox off, quite a small engine to be honest!

(http://daz.co/media/M4TVW/Edition_30/IMG_2019_zpszu6y6zgo.jpg)

Install the new clutchmasters "stage 6" clutch and single mass flywheel. Good for 500bhp+ they say! ;)

(http://daz.co/media/M4TVW/Edition_30/IMG_2020_zpsmjo9gnah.jpg)

New hotgolf gearbox on. Also fitted is a forge quick shift on top

(http://daz.co/media/M4TVW/Edition_30/IMG_2025_zpsjjhk2wyx.jpg)

The new superpro ARB installed along with nearly new Revo engine mounts. These are meant to be harsh for a thousand miles or so, hopefully not too bad. Oh and also installed there is a braided AKS clutch line removing the VW hard line and plastic valve thing. I also modified the slave cylinder on the gearbox, removing the pin hole restrictor which they recommend on upgraded clutches.

(http://daz.co/media/M4TVW/Edition_30/IMG_2026_zpsrzifvfqn.jpg)

All back together! Took pretty much all weekend in the end but i don't like to rush these things.

 (http://daz.co/media/M4TVW/Edition_30/IMG_2027_zpstauojzly.jpg)

I had to drill a few holes in the tunnel to allow for the cables to run through. This has since been blocked up so no fumes can get through. I made that mistake on the MK2!

(http://daz.co/media/M4TVW/Edition_30/IMG_2212_zpstvdjqqhk.jpg)

With the car back on it's wheels i can start putting the interior back together.
Title: Re: MK5 Edition 30 #57 Track/Race Build
Post by: Shoduchi on April 01, 2017, 03:16:15 PM
Thanks for the update! This build is awesome. :happy2:
Title: Re: MK5 Edition 30 #57 Track/Race Build
Post by: M4T VW on April 13, 2017, 08:26:50 PM
Working late into the night, lots of wiring to sort out. Firstly the battery cables to the cut-off switch. I went for a small Braille battery so i can keep it in the front but this means i had to run two cables from the battery to the switch, a feed and return cable. I managed to poke these through the firewall where the rest of the cables go through on the passenger side. I also had to run the cables for the gauges which came through the drivers side.

(http://daz.co/media/M4TVW/Edition_30/IMG_2228_zpsukeqshjg.jpg)

(http://daz.co/media/M4TVW/Edition_30/IMG_2229_zpspfgdpyq9.jpg)

I bought myself a proper hydraulic crimp tool from eBay, it does the job well and looks factory after some heat shrink.

(http://daz.co/media/M4TVW/Edition_30/IMG_2230_zpseyxurtye.jpg)

Dashboard back in! I had to cut the plastics around the cage but it worked out well in the end. I would have left them off but some are key to the structure of the dash and some hold switches, for example the headlight switch so it just made sense to put it back in with a few bit's cut off. All in the name of saving weight, right?

(http://daz.co/media/M4TVW/Edition_30/IMG_2232_zpsgqmmpjub.jpg)

(http://daz.co/media/M4TVW/Edition_30/IMG_2233_zpstm4jn9uk.jpg)

(http://daz.co/media/M4TVW/Edition_30/IMG_2234_zpsnrfejgmm.jpg)

You can see the gap i have on the top of the dash for the bar, it's huge but was required to actually get the dash into that position. A small cover plate will be made to hide that later.

(http://daz.co/media/M4TVW/Edition_30/IMG_2235_zpsd4yibdpe.jpg)
Title: Re: MK5 Edition 30 #57 Track/Race Build
Post by: Tfsi_Mike on April 13, 2017, 08:54:58 PM
Excellent stuff.
Title: Re: MK5 Edition 30 #57 Track/Race Build
Post by: M4T VW on April 13, 2017, 09:07:09 PM
Thanks Mike!


This is an update I have not been looking forward to writing as I know it’s going to be a long one and I took a fair few pictures as I know a lot of people in this position. I’m very lucky to have a car lift and a forklift, I pretty sure we couldn’t have done this without either of them so good luck to those attempting this on your drive way on axle stands!
 
Replacing the rear end…

(https://www.askideas.com/media/48/Funny-Safety-Meme-Safety-First-Like-A-Genius-Picture.jpg)

Taking all the weight out of the rear end and putting the car up on a single post lift is a bit sketchy. Because of this we decided to tie the car down to a heavy pallet of scrap metal on the back end so it wouldn’t be so nose heavy. It wasn’t actually that bad in the end as the car is shifted back as much as we can get it so the nose weight is nearer the lift upright.

(http://daz.co/media/M4TVW/Edition_30/IMG_2240_zpsbjkfdvem.jpg)

Time to remove the suspension. Being a separate shock/spring on the MK5's makes this job easy.

(http://daz.co/media/M4TVW/Edition_30/IMG_2238_zps1cwhajll.jpg)

The only pain is limited room to compress the spring enough. In the end we took a bolt out of the lower arm and just let it hang down so the spring fell out.

(http://daz.co/media/M4TVW/Edition_30/IMG_2239_zpsu0m6iadk.jpg)

Lowering the old beam down

(http://daz.co/media/M4TVW/Edition_30/IMG_2241_zpsym0lokag.jpg)

(http://daz.co/media/M4TVW/Edition_30/IMG_2242_zpswipb7knr.jpg)

(http://daz.co/media/M4TVW/Edition_30/IMG_2243_zps6mppws4k.jpg)

(http://daz.co/media/M4TVW/Edition_30/IMG_2244_zps1vyby48h.jpg)

(http://daz.co/media/M4TVW/Edition_30/IMG_2245_zpsuac9fcbb.jpg)

One of the bushes on the old beam. Look past the flaking paint, that happens to most but the actual rubber part was really loose and floppy.

(http://daz.co/media/M4TVW/Edition_30/IMG_2246_zpsmkvzo2mh.jpg)

Old & new. It was good to put them next to each other to compare. We had to swap over a couple of small brackets for ABS sensors etc but it was 95% there.

(http://daz.co/media/M4TVW/Edition_30/IMG_2247_zpsddhlq2uu.jpg)

(http://daz.co/media/M4TVW/Edition_30/IMG_2248_zpsv1p6rvdv.jpg)

The new one bolted up like a dream, no issues at all.

(http://daz.co/media/M4TVW/Edition_30/IMG_2249_zpsjgq4peis.jpg)

(http://daz.co/media/M4TVW/Edition_30/IMG_2250_zps4f9scrkr.jpg)

(http://daz.co/media/M4TVW/Edition_30/IMG_2251_zps0tbmrzdg.jpg)

Lets chuck some new suspension on it. Time to crack open the fancy stuff! KW clubsports which are dampening adjustable via a little purple knob on the bottom of the strut, you can just see it in the picture.

(http://daz.co/media/M4TVW/Edition_30/IMG_2258_zpshfdl9v03.jpg)

(http://daz.co/media/M4TVW/Edition_30/IMG_2259_zpsz3613m72.jpg)

Brand new hub's for the rear.

(http://daz.co/media/M4TVW/Edition_30/IMG_2260_zpsageetkqz.jpg)

Now we are talking!

(http://daz.co/media/M4TVW/Edition_30/IMG_2261_zpsaafkzubk.jpg)

Fitting the S3 rear calipers and also fitted the fuel tank, don't have any pictures of that. It was actually quite easy so we had done it before i could take and pictures.

(http://daz.co/media/M4TVW/Edition_30/IMG_2264_zpssnpvv8qy.jpg)

(http://daz.co/media/M4TVW/Edition_30/IMG_2265_zpszpt09daz.jpg)

(http://daz.co/media/M4TVW/Edition_30/IMG_2266_zpsdkwibesu.jpg)

Before we put it on the ground we fitted the new downpipe. However it didn't quite match up with the subframe bracket so left it for another day. I suspected that the bracket was welded on at the wrong angle so would need either bending or cutting and re-welding.

(http://daz.co/media/M4TVW/Edition_30/IMG_2262_zps4hhrnanz.jpg)

(http://daz.co/media/M4TVW/Edition_30/IMG_2263_zpsyxuced1h.jpg)

Put it on the floor for the first time and its a bit low at the back. Actually it was too low to get it off the lift! We had to take it back up in the air and adjust the ride height. It's still tight now but just about manageable. Once it's running and we can drive onto the lift it will be much easier.

(http://daz.co/media/M4TVW/Edition_30/IMG_2267_zps6c9vdxl0.jpg)

(http://daz.co/media/M4TVW/Edition_30/IMG_2268_zpsujbqupkz.jpg)



Title: Re: MK5 Edition 30 #57 Track/Race Build
Post by: ChrisGT on April 14, 2017, 05:01:46 AM
Awesome, new rear subframe etc looks great  :drinking:

Chris
Title: Re: MK5 Edition 30 #57 Track/Race Build
Post by: Tfsi_Mike on April 14, 2017, 11:27:24 AM

awesome update :)  The pillar lift looks very handy!
Title: Re: MK5 Edition 30 #57 Track/Race Build
Post by: tommygti on April 25, 2017, 01:51:48 PM
Awesome updates. Its coming along nicely. What make are the 2-piece rear floating discs?
Title: Re: MK5 Edition 30 #57 Track/Race Build
Post by: M4T VW on May 02, 2017, 01:40:15 PM
I have been driving this around at the weekend, what a machine!  :laugh:

Awesome updates. Its coming along nicely. What make are the 2-piece rear floating discs?

They are made by VW Racing. That's whats on the bell anyway.
Title: Re: MK5 Edition 30 #57 Track/Race Build
Post by: M4T VW on June 05, 2017, 09:12:21 PM
Right, lets get cracking again, I'm exhausted  :grin:

This is the full BCS catback exhaust, It came up cheap even though it was new. It was the R32 style also which i was not too bothered about but i'm glad i did, it looks so much better on the car! I had to fit the new bumper but it the exhaust was so well made it fell into place with hardly any adjustment. Very impressed with the quality.

(http://daz.co/media/M4TVW/Edition_30/IMG_2273_zps2b3harth.jpg)

(http://daz.co/media/M4TVW/Edition_30/IMG_2274_zpslb5jggbs.jpg)

(http://daz.co/media/M4TVW/Edition_30/IMG_2275_zpsytcjstqj.jpg)

I had to cut and weld the bracket back on in the correct position on the ebay downpipe, It all fits perfect now.

(http://daz.co/media/M4TVW/Edition_30/IMG_2278_zpsrguksezr.jpg)

(http://daz.co/media/M4TVW/Edition_30/IMG_2279_zpsehfybfqg.jpg)

(http://daz.co/media/M4TVW/Edition_30/IMG_2280_zps2ztrdfcm.jpg)

(http://daz.co/media/M4TVW/Edition_30/IMG_2281_zpsgc5vkosv.jpg)

(http://daz.co/media/M4TVW/Edition_30/IMG_2282_zpsgnv4mtqk.jpg)

(http://daz.co/media/M4TVW/Edition_30/IMG_2283_zpsvmh6dxdn.jpg)

(http://daz.co/media/M4TVW/Edition_30/IMG_2284_zpst1tgpyb7.jpg)

(http://daz.co/media/M4TVW/Edition_30/IMG_2285_zpslh8fmwup.jpg)

(http://daz.co/media/M4TVW/Edition_30/IMG_2286_zpsvu9mkqui.jpg)
Title: Re: MK5 Edition 30 #57 Track/Race Build
Post by: Shoduchi on June 06, 2017, 12:30:29 AM
Looks great! :happy2:
Title: Re: MK5 Edition 30 #57 Track/Race Build
Post by: Pesky jones on June 06, 2017, 06:56:06 AM
Awesome work mate, giving  it 100%!

You see the last pic of reply 66, you see a small one way vent. Had a pool of water in the boot well in my old gti. Couldn't track it down. Stripped the rear down and it was just missing tnat vent, not broken, just missing. What led to that!  :signLOL:
Title: Re: MK5 Edition 30 #57 Track/Race Build
Post by: FJ1000 on June 06, 2017, 08:40:35 AM
What an epic build!

When are you hoping to get it out on track? We need video when you do!


Sent from my iPhone using Tapatalk
Title: Re: MK5 Edition 30 #57 Track/Race Build
Post by: MIJ_JAGGER on June 06, 2017, 10:34:24 AM
Now this is a build thread top work mate!
Title: Re: MK5 Edition 30 #57 Track/Race Build
Post by: M4T VW on June 07, 2017, 09:29:44 AM
Thanks guys, next update is a big one which spans over a couple of weekends due to complications so will take a day to write it up!
Title: Re: MK5 Edition 30 #57 Track/Race Build
Post by: ChrisGT on June 07, 2017, 11:40:13 AM
Thanks guys, next update is a big one which spans over a couple of weekends due to complications so will take a day to write it up!

Looking forward to it! This build thread is awesome  :drinking:

Chris
Title: Re: MK5 Edition 30 #57 Track/Race Build
Post by: M4T VW on June 07, 2017, 10:56:53 PM
Parts to fit in this instalment:

Superpro alloy lower control arms and alloy brackets.

(http://daz.co/media/M4TVW/Edition_30/ALLOY0001K_-_Logo_small_zpstbdky8v4.jpg)


Vibra-Technics Bottom Engine mount/Subframe mount

(http://daz.co/media/M4TVW/Edition_30/vag520m_1328_zpshlbal3c1.jpg)


The front FK Clubsport coilovers with adjustable top mounts

(http://daz.co/media/M4TVW/Edition_30/IMG_1717_zpsv3ahwraw.jpg)

Plus Audi S3 alloy front hubs, VW Racing front brake discs and mounting adapters for the VW racing brakes with braided lines. New outer CV’s both sides & new hubs, new droplinks to the superpro front ARB. Superpro adjustable ball joints.

Tools broken: Air impact gun, Small ½” breaker bar, Larger ½” to ¾” adapter and nearly my hand.

Right, where to start on this one. Like the rear setup I knew this was going to be hell of a job to fit all this. I planned a whole weekend and it actually took two because of a few problems along the way which you will see. It’s just nuts and bolts, should be pretty easy right?
Well firstly, let’s start by removing the driver’s side wheel and hub nut. No picture as it’s not a very interesting process! Crikey that hub nut is a bit tight, SNAP! There goes my Halfords 1/2” breaker bar. Let’s try the air impact wrench, at least 10 ugga duggs’s and BANG! There goes my trusty air impact wrench. I’m down 2 tools already and all I have taken off is a wheel! Let’s get some lunch and I will go to machine mart to see what I can find to help. A couple of hours later I have these.

A 900mm ¾” breaker bar. Sadly they didn’t have a ¾” socket in stock to fit the hub nut so I had to buy a ¾” – ½” adapter to fit the socket.

(http://daz.co/media/M4TVW/Edition_30/8D8B83C1-8049-42FE-9DCF-37473DA7D078-large_zps8wxvapwv.jpg)


This is it against the ½” Halfords bar.

(http://daz.co/media/M4TVW/Edition_30/IMG_2288_zpsxngr4s6g.jpg)


The biggest air impact gun they had on the shelf (nearly double the rating of my old one)

(http://daz.co/media/M4TVW/Edition_30/059F0203-4889-4846-9693-510DA4BEC1D1-large_zpsfsjxnwbw.jpg)


This better bloody work or I’m stuffed.
SNAP, Oh come on!! (The breaker bar in this picture is the ½” Halfords one who replaced it FOC)

(http://daz.co/media/M4TVW/Edition_30/IMG_2287_zps3lrzyde9.jpg)


The air impact gun also failed to get it off, even with heat. However the other side flew off! That was a whole day gone so gave up and went home ****ed off.
Asked around for ideas and everyone suggested to remove the whole shaft and hub. I was replacing the hub and CV anyway but at the time I didn’t know you could split the CV from the shaft with the hub bolt still in there. I could have saved half a day if I had known this. It’s still a learning curve for me.
So with a plan for Sunday we got cracking early. Removed the drive cup from the gearbox however the strut would not split from the hub so had to take the whole bloody lot out in one go. Even the 3 bolts holding the top mount on were seized and needed cutting off. All the problems we had were on this side, everything came off lovely on the passenger side.

Success!

(http://daz.co/media/M4TVW/Edition_30/IMG_2296_zpshxpk1nxv.jpg)

(http://daz.co/media/M4TVW/Edition_30/IMG_2300_zpsyhbqobs3.jpg)


Right, let’s carry on with this side and replace the lower arm and bracket first.

(http://daz.co/media/M4TVW/Edition_30/IMG_2297_zps2n1syyrs.jpg)

(http://daz.co/media/M4TVW/Edition_30/IMG_2302_zpsdm2cuijs.jpg)


The driver’s side curse strikes again, the passenger ones were fine! I was worrying at this point as it looked like a replacement subframe was required. Thankfully VW have this covered as the mounting points for the lower arms are replaceable without replacing the whole subframe. I jumped on eBay and purchased this.

(http://daz.co/media/M4TVW/Edition_30/s-l500_zps9gjqa7i3.jpg)


While we wait for that to arrive, let’s move on to the lower engine mount. I couldn’t get hold of a matching revo mount so when for the vibra-technics one which everyone said was better anyway.
It was actually quite difficult to install due to the corrosion on the subframe. Its cast alloy so not too bad, it just needed some rubbing down with emery paper so take the rough part off and make it smooth so it slid in….with a mallet.

(http://daz.co/media/M4TVW/Edition_30/IMG_2298_zpstvmh2chf.jpg)


(Old bolt used, forgot to order a new one. This has since been changed for a new one)

(http://daz.co/media/M4TVW/Edition_30/IMG_2301_zpsse3vpsbb.jpg)


Replaced the passenger side lower arm and bracket for the superpro alloy ones. They are so much lighter!

(http://daz.co/media/M4TVW/Edition_30/IMG_2299_zpsw5805xzk.jpg)


While waiting we broke out the angle grinder and cut the top off the suspension top mount. I didn’t want to take this off completely because it would lose strength and also make a lot more work to clean it up so we cut it as low as possible without marking the factory bonding stuff. After a clean-up and paint it should look good.

(http://daz.co/media/M4TVW/Edition_30/IMG_2303_zpsgvhydncd.jpg)


Also removed the other drive shaft to replace the CV so did them both at the same time.

(http://daz.co/media/M4TVW/Edition_30/IMG_2311_zps7hrnkous.jpg)

(http://daz.co/media/M4TVW/Edition_30/IMG_2312_zpsnolrkqlt.jpg)
Title: Re: MK5 Edition 30 #57 Track/Race Build
Post by: M4T VW on June 07, 2017, 10:57:57 PM
That was it for another weekend so fast forward a week. The car was stuck on the lift. Thankfully being a single post lift on wheels you can lower the car down to the ground and actually move the whole thing around! The replacement subframe arrived during the week so it meant we can crack on at the weekend and get it back on its wheels.
Fitted the subframe piece, new hub, CV, suspension and tie-rod here. However you can see a problem. The factory tie-rod is far too long for the level of drop this suspension gives, which to be honest is actually not much! The ARB is now hitting on the alloy arm.

(http://daz.co/media/M4TVW/Edition_30/IMG_2314_zpsmv8r2yhl.jpg)

(http://daz.co/media/M4TVW/Edition_30/IMG_2315_zpsg3aez2cs.jpg)

(http://daz.co/media/M4TVW/Edition_30/IMG_2316_zpsgguqpcqs.jpg)

(http://daz.co/media/M4TVW/Edition_30/IMG_2317_zpshmswvbbr.jpg)


I guess it was obvious why we cut the top off the suspension mount, right? I think it works pretty well. You can fully adjust the top-mount now quickly and easily. I gave them a lick of paint to cover the raw edge.

(http://daz.co/media/M4TVW/Edition_30/IMG_2321_zps6x7r8ewy.jpg)

 (http://daz.co/media/M4TVW/Edition_30/IMG_2322_zpsuttpruiz.jpg)


I bolted on the brake adapter and braided line but that’s as far as I could go. I was yet to get any tyres for the new wheels and the wheels I was using to move the car around wouldn’t fit with the big brake’s on so couldn’t fit the caliper’s on sadly.

 (http://daz.co/media/M4TVW/Edition_30/IMG_2319_zpsmriyrup3.jpg)

(http://daz.co/media/M4TVW/Edition_30/IMG_2320_zpshpheuqkl.jpg)


This nut gave me some issues as it’s frozen on the pipe. Managed to get the braided line on and it doesn’t leak thankfully!

(http://daz.co/media/M4TVW/Edition_30/IMG_2318_zpsmzrjxqgn.jpg)


Finally back on its wheels

(http://daz.co/media/M4TVW/Edition_30/IMG_2329_zps4ecavq5j.jpg)


 Much camber?

(http://daz.co/media/M4TVW/Edition_30/IMG_2331_zpsnowej198.jpg)
Title: Re: MK5 Edition 30 #57 Track/Race Build
Post by: Paradox1 on June 08, 2017, 10:35:49 AM
Crazy build!

im loving the attention to detail on this!!
Title: Re: MK5 Edition 30 #57 Track/Race Build
Post by: M4T VW on June 08, 2017, 01:49:26 PM
Missed off the last bit fro the above post!

I managed to get hold of some superpro adjustable tie-rods which are a lot of money for what they are.  I don’t see that they are “adjustable” more “universal” as it’s a set and forget. Please someone let me know if I’m wrong but I don’t see how adjusting the length of the tie-rod will change anything.

 (http://daz.co/media/M4TVW/Edition_30/superpro-trc10200-large-1_zpsmh54s9wx.jpg)



This pulled the ARB away from the lower arm.

 (http://daz.co/media/M4TVW/Edition_30/IMG_2330_zpstik2pobb.jpg)


I had some friends pop over with a couple of things for me to try. One of them was a spare stud from their MK1. Obviously it was the wrong size for the MK5 but I wanted to check the length against the new wheels which I have just put tyres on. I went for 4 Yokohama AD08R as my road/wet setup to start with which leaves me 6 wheels for the track tyre which I have not decided on yet. This gave me an excuse to test fit a caliper and try the new wheels on.

(http://daz.co/media/M4TVW/Edition_30/IMG_2325_zpsyax5ubd3.jpg)

(http://daz.co/media/M4TVW/Edition_30/IMG_2343_zpsufwdtpjz.jpg)
 
 (http://daz.co/media/M4TVW/Edition_30/IMG_2355_zpsghoaix1x.jpg)


However on the way down Guy (who painted the inside) noticed some brake binding on the MK1 so we took it into the workshop for a quick look. The caliper was half hanging off and needed a new adapter (G60 brakes) so they had to leave the MK1 at mine for a few days while they sourced the parts.

(http://daz.co/media/M4TVW/Edition_30/IMG_2339_zpsn7ng36tq.jpg)

That concludes this part of the build, back to the interior next and get the bloody thing running again!
Title: Re: MK5 Edition 30 #57 Track/Race Build
Post by: tommygti on June 08, 2017, 01:54:31 PM
Love the progress.

I feel your pain with those bolts. Ive snapped various bolts, rounded nuts off, stripped threads, etc... I'm no mechanic but its all a learning curve at the end of the day. I'f prefer to say I had a go at it at least before paying through the teeth for a professional to do it. Plus genuine VAG tools are stupid money.

Who needs the genuine tool anyway. Yeeehaaa  (http://daz.co/media/nn193/fiestacossie/IMG_8964_zpslzs7av1d.jpg)
Title: Re: MK5 Edition 30 #57 Track/Race Build
Post by: Shoduchi on June 08, 2017, 09:42:55 PM
Those are lovely updates! Can't wait to see more now! :drool:
Title: Re: MK5 Edition 30 #57 Track/Race Build
Post by: Orc on September 30, 2017, 07:58:17 PM
Matt, adjustable drop links ARE required for corner weighting of which you will def need going this balls deep into a track build!
Title: Re: MK5 Edition 30 #57 Track/Race Build
Post by: vag on October 01, 2017, 06:07:13 PM
What an awesome build, need to crack on my with my track Slag!
Title: Re: MK5 Edition 30 #57 Track/Race Build
Post by: davidif on January 26, 2019, 11:26:53 PM
Great read. Did this car get finished?