1991 Golf GTi project
- Thread starter natogreen16v
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natogreen16v
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- #27
I cant help myself at times lolRemoving the casting marks from everything on a vr6 is so very Connor MccannExcited to see what you make of this!
Is the CAE shifter going back in again?
The CAE is going back to Matt. Although he is selling it. I don't like driving with it and its too rich for my blood lol
natogreen16v
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- #29
Unfortunately not lol. If it's the chains done on the engine I'd have it in by now lol
Rebuild kit arrived for the calipers so I'm gona start stripping those tonight
and actually double check that I have the timing chain kit there incase I get a shock when going to do it lolnatogreen16v
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So I got some time Thursday and Friday evening to start stripping the paint off the calipers and carriers. I attacked them with the wire wheel on the grinder and got in where I could with the attachments on the drill.
I had to resist my usual urge to go ape**** on these and remove be casting marks on the calipers etc or the car would end up a long term build like the rest of my stuff.
The paint was a nightmare to remove. I think I've 3hrs in the 4 parts just stripping the paint:
Once stripped it was time to fit the new seals, dust boots and pistons.
I decided on doing these things as I bought them maybe 4 years ago and they were crusty as hell so I was worried they might be seized or sticking.
I started with this:
Dropped in various thicknesses of wood and blew the pistons out. Being twin pots I'd to be careful not to let one out and break the seal meaning the other wouldn't blow out.
In the end they came out without bother with no corrosion inside and the pistons in far better condition than I imagined. I probably could have ran these fine as the were but at least I know what I have now.
The main thing I was worried about was removing the bleed nipples. They're only M7 was convinced they'd snap off as they were stupidly tight:
A decent squirt of this stuff and the turned out free and easy which was a pleasant surprise:
I've ordered new bleed nipples too now.
Once stripped and cleaned further it was time to fit the new seals, boots and pistons.
What. A. ****. Of a job.
Something I've done a few times before without issue. @Fatman and I fought like crazy with the first 2 and took ages to do it. Thankfully the next 2 went perfectly smoothly although the ****ing around cost me the time I had to get them prepped and primed so I'll do that tomorrow night.
But for now, I'll take the win as I've only £55 into this refurb with only paint to go.
Connor
I had to resist my usual urge to go ape**** on these and remove be casting marks on the calipers etc or the car would end up a long term build like the rest of my stuff.
The paint was a nightmare to remove. I think I've 3hrs in the 4 parts just stripping the paint:
Once stripped it was time to fit the new seals, dust boots and pistons.
I decided on doing these things as I bought them maybe 4 years ago and they were crusty as hell so I was worried they might be seized or sticking.
I started with this:
Dropped in various thicknesses of wood and blew the pistons out. Being twin pots I'd to be careful not to let one out and break the seal meaning the other wouldn't blow out.
In the end they came out without bother with no corrosion inside and the pistons in far better condition than I imagined. I probably could have ran these fine as the were but at least I know what I have now.
The main thing I was worried about was removing the bleed nipples. They're only M7 was convinced they'd snap off as they were stupidly tight:
A decent squirt of this stuff and the turned out free and easy which was a pleasant surprise:
I've ordered new bleed nipples too now.
Once stripped and cleaned further it was time to fit the new seals, boots and pistons.
What. A. ****. Of a job.
Something I've done a few times before without issue. @Fatman and I fought like crazy with the first 2 and took ages to do it. Thankfully the next 2 went perfectly smoothly although the ****ing around cost me the time I had to get them prepped and primed so I'll do that tomorrow night.
But for now, I'll take the win as I've only £55 into this refurb with only paint to go.
Connor
natogreen16v
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- #32
I was very impressed you didn't sell me 2 paperweightsTights tight, just be thankful I didn't cross thread the bleed nipples
natogreen16v
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- #34
Tuesday night I got the calipers primed and painted in VW Tornado Red (LY3D). I wanted something to match the red stripe on the grille.
I read online that this is a match. Who knows but they're now all red so it's good.
Last night I couldn't resist throwing a carrier and caliper onto the car with the new R32 disc to see how it looked.
This is a 17 with the standard 256mm disc behind it:
This is with the 334mm disc:
I'm pretty happy with that. Although I'll need to match the rear now
Connor
I read online that this is a match. Who knows but they're now all red so it's good.
Last night I couldn't resist throwing a carrier and caliper onto the car with the new R32 disc to see how it looked.
This is a 17 with the standard 256mm disc behind it:
This is with the 334mm disc:
I'm pretty happy with that. Although I'll need to match the rear now
Connor
Father Stack
RMS Regular
Solid disc:wheel ratio there.
Should be class once it's done Connor!
Should be class once it's done Connor!
natogreen16v
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- #36
Cheers Gary. Aye I'm well happy.
I'd a 300mm S4 rear disc on the back of the mk3 with an R32 caliper so I might have to go that route too so the back doesn't look lost.
I'm a pervert for big brakes and this is a handy OEM solution. Obviously I already had the discs and calipers but to get them on the car with new pistons, seals and paint has only cost £60 so I'll take that
Gambit
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That 256 to 334 is just ludicrous looking 
Nazor
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Dogs diddy!! Love it dude!
Gaz86
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Tuesday night I got the calipers primed and painted in VW Tornado Red (LY3D). I wanted something to match the red stripe on the grille.
I read online that this is a match. Who knows but they're now all red so it's good.
View attachment 417233
View attachment 417234
Last night I couldn't resist throwing a carrier and caliper onto the car with the new R32 disc to see how it looked.
This is a 17 with the standard 256mm disc behind it:
View attachment 417240
This is with the 334mm disc:
View attachment 417242
I'm pretty happy with that. Although I'll need to match the rear now
Connor
Perfect
natogreen16v
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- #42
From the last update i pulled the downpipes off without snapping any exhaust studs which I was very happy about:
Next up was to replace the rear engine mount bracket with one for getting the engine onto the stand:
Once it was on I used the engine crane to get it onto the stand in the most dodgy way possible:
I then decided I'd rather do the work in the garage so we loaded it into @Fatman van and @browne174 made sure it didn't fall out:
Once down into the garage it was onto the stand and the gearbox removed to make the set up a bit lighter:
I then got the intake etc stripped, engine set to TDC on cylinder 1, timing marks checked and the cams locked out. There is a plate for this but I'd some aluminium plates which fit so I slipped those in:
Once all locked I pulled the clutch off and of course I wrung the last or 2nd last flywheel bolt
After a few attempts and not wanting to damage the flywheel cutting or drilling the bolt I welded a socket to it and backed it out. Can't slip if it's welded!
Great success!
It was around now the start of December I had MOT for the bora, a trip to Scotland then i was sick on the run up to Christmas so i didn't get much done until the Christmas break.
I'll update with it shortly
Connor
Next up was to replace the rear engine mount bracket with one for getting the engine onto the stand:
Once it was on I used the engine crane to get it onto the stand in the most dodgy way possible:
I then decided I'd rather do the work in the garage so we loaded it into @Fatman van and @browne174 made sure it didn't fall out:
Once down into the garage it was onto the stand and the gearbox removed to make the set up a bit lighter:
I then got the intake etc stripped, engine set to TDC on cylinder 1, timing marks checked and the cams locked out. There is a plate for this but I'd some aluminium plates which fit so I slipped those in:
Once all locked I pulled the clutch off and of course I wrung the last or 2nd last flywheel bolt
After a few attempts and not wanting to damage the flywheel cutting or drilling the bolt I welded a socket to it and backed it out. Can't slip if it's welded!
Great success!
It was around now the start of December I had MOT for the bora, a trip to Scotland then i was sick on the run up to Christmas so i didn't get much done until the Christmas break.
I'll update with it shortly
Connor
Ian A
RMS Regular
Fantastic work Connor, always happy to see some well informed ropiness in action.
What's the paint used on that engine? Seems to hold up to the heat very well.
What's the paint used on that engine? Seems to hold up to the heat very well.
natogreen16v
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- #44
Oh you know there's always ropiness around these parts Ian lol
It's just gloss black 2k that I sprayed on. Tbh I'd prob just brush it on to the block now where it's rough but still spray the gearbox etc. The engine mount brackets are powder coat
natogreen16v
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- #45
I bought this engine from a fire damaged car in 2015 (I think) and put it into my mk3. No idea on the mileage as the clocks were melted and no idea on history.
I didn't want to take a chance again so this time I decided to do the timing chains.
Over Christmas then when I got back into it I pulled the timing covers off and discovered the chains and guides were in really good condition and had been done before. I had a full kit sitting with a MLS head gasket and head bolts so I decided to redo it all for peace of mind:
Timing covers off:
Chains off:
Head off:
I ran a slice up one of the old head bolts and used it to chase the threads in the block. The amount of **** that came out even after a few times was shocking so well worth doing.
New MLS head gasket on:
Head back on:
I dropped a timing guide bolt into the sump. So being on the stand and seeing that the oil was drained I just flipped the engine over for convenience. It wasn't fully drained:
New crank seal fitted and a good dollop of sealer around it cos I'm not planning to come back in here:
Chains all on with the upper cover:
And all the covers back on:
Connor
I didn't want to take a chance again so this time I decided to do the timing chains.
Over Christmas then when I got back into it I pulled the timing covers off and discovered the chains and guides were in really good condition and had been done before. I had a full kit sitting with a MLS head gasket and head bolts so I decided to redo it all for peace of mind:
Timing covers off:
Chains off:
Head off:
I ran a slice up one of the old head bolts and used it to chase the threads in the block. The amount of **** that came out even after a few times was shocking so well worth doing.
New MLS head gasket on:
Head back on:
I dropped a timing guide bolt into the sump. So being on the stand and seeing that the oil was drained I just flipped the engine over for convenience. It wasn't fully drained:
New crank seal fitted and a good dollop of sealer around it cos I'm not planning to come back in here:
Chains all on with the upper cover:
And all the covers back on:
Connor
natogreen16v
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- #46
So with a last minute tattoo booking for Friday past I'd a push on to get as much done as possible.
The next up was to get the new clutch and flywheel on. Including using the traditional 14mm socket to centre the clutch plate:
Then it was time for the box. I don't think I've ever seen one go onto the spines quicker in my life. Result! :
For those curious, if you're wanting to run your VR6 without power steering or AC this is the belt to use:
At this point Stefan took his Merc off the ramp and we pushed the mk2 onto it in prep for me fitting the engine the next day.
It's 23:35 at this point and he says **** it will we fit the engine? Aye why not.
The ramp arm took the engine off the stand much more safely than the engine crane:
Stefan prepped the bay by getting **** out of the way while I prepped the engine to go in:
Engine going in:
And touch down within 10mins. A nice simple job
:
This called for a good clean up of tools and a wee 1am pint of JD and coke. God bless Christmas!
Connor
The next up was to get the new clutch and flywheel on. Including using the traditional 14mm socket to centre the clutch plate:
Then it was time for the box. I don't think I've ever seen one go onto the spines quicker in my life. Result! :
For those curious, if you're wanting to run your VR6 without power steering or AC this is the belt to use:
At this point Stefan took his Merc off the ramp and we pushed the mk2 onto it in prep for me fitting the engine the next day.
It's 23:35 at this point and he says **** it will we fit the engine? Aye why not.
The ramp arm took the engine off the stand much more safely than the engine crane:
Stefan prepped the bay by getting **** out of the way while I prepped the engine to go in:
Engine going in:
And touch down within 10mins. A nice simple job
:This called for a good clean up of tools and a wee 1am pint of JD and coke. God bless Christmas!
Connor
natogreen16v
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- #48
I'm usually pretty good at keeping build threads up to date but I've been awful with this one.
So next up I spent the next day installing the intake manifolds, engine covers, coil, plug leads, etc etc
The driveshafts that came with the car are rated for 800hp or so and total overkill with the car so I'm going to sell them if anyone fancies some for their wide track mk2 or mk3 Golf?
I removed them with their hubs and installed standard hubs, the front air struts, R32 discs and calipers and set it on the ground to see how it looked.
I got a new tattoo the Friday before NYE so I took the weekend off from the car so as not to **** it up then got back to it a few days later.
I swung the back axle down to remove the back coilovers, brake and fuel tank.
The mk2 tank runs an external fuel pump and I wanted to fit a mk3 tank with a single internal pump. It's a straight forward swap so I dropped the tank out of my green mk3 and it looked like this
A quick blast with the power washer
And beside the mk2 tank
Next up was to sort the tiny rear brakes.
The standard MK2/3 runs a 226mm disc with the bearing pressed into the centre. The disc is always the hub. It's certainly not gona fill the wheel or match the fronts.
And stripped
Connor
So next up I spent the next day installing the intake manifolds, engine covers, coil, plug leads, etc etc
The driveshafts that came with the car are rated for 800hp or so and total overkill with the car so I'm going to sell them if anyone fancies some for their wide track mk2 or mk3 Golf?
I removed them with their hubs and installed standard hubs, the front air struts, R32 discs and calipers and set it on the ground to see how it looked.
I got a new tattoo the Friday before NYE so I took the weekend off from the car so as not to **** it up then got back to it a few days later.
I swung the back axle down to remove the back coilovers, brake and fuel tank.
The mk2 tank runs an external fuel pump and I wanted to fit a mk3 tank with a single internal pump. It's a straight forward swap so I dropped the tank out of my green mk3 and it looked like this
A quick blast with the power washer
And beside the mk2 tank
Next up was to sort the tiny rear brakes.
The standard MK2/3 runs a 226mm disc with the bearing pressed into the centre. The disc is always the hub. It's certainly not gona fill the wheel or match the fronts.
And stripped
Connor
natogreen16v
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- #49
A few years back I built a rear big brake kit for the back of my mk3 using a mix of OEM parts. 2002 Polo stub axles, 2007 Polo bearings and hubs, MK4 R32 calipers and carriers, redrilled 300mm Audi S4 rear discs and a custom adapter.
I retrieved the set up from my green mk3 and on it went. Everything will get cleaned and painted up red to match the front brakes
Stefan is very unimpressed with how the Golf is sitting on the ramp pad
How it looks behind a 17
Then we fitted the rear air struts and set the car down.
It's currently held up by the tyre hitting the arch and has a few inches left to drop. Im more than happy with that cos I'll never just have the car fully dropped anyway as it's not my look.
Connor
I retrieved the set up from my green mk3 and on it went. Everything will get cleaned and painted up red to match the front brakes
Stefan is very unimpressed with how the Golf is sitting on the ramp pad
How it looks behind a 17
Then we fitted the rear air struts and set the car down.
It's currently held up by the tyre hitting the arch and has a few inches left to drop. Im more than happy with that cos I'll never just have the car fully dropped anyway as it's not my look.
Connor
big_pete
RMS Regular
That is very cool.
What’s the craic with the mk3? Just had your fun with it or further evolution?
What’s the craic with the mk3? Just had your fun with it or further evolution?