I always planned on giving the whole top of the engine a bit of a paint to freshen and clean it up a bit so today was that day:

I'll try and let the pics do the talking for once Sorry for the quality of the pics, only had my mobile to take them on.

Standard looking engine:




First job whip off the inlet and rocker as well as the plastic VR6 cover. Coat with a few coats of primer and let dry:



While thats drying, tape up the area's on the inlet mani that you don't want to get painted:



And then Primer:



Paint plastic cover in a nice shade of VW Tornado Red:



Once primer on Inlet manifold has dried, Paint red:



Allow to dry and then peal of tape:




Once all Paint has dried, refit all to car:







I'm fairly pleased with the way it looks

So then , another weekend arrived and another hard days work was one the cards.

During the week I had had the O/S bearings, Head gasket, head bolts and a different oil pump sourced for me and it was now up to me to fit them all. Up early and down the Pharm once again after a our usual Pre McDonalds breakfast. Breakfat of Champions and ammature Mechanics world wide.


However, as some of those that were in Germany will remember, I made a small pledge that Big Red would return, and I would make sure it came back, Bigger, Better and Redder, and this rebuild would be the start of that.

And whats this I found in the boot while getting out my camping equipment?



Only a 3mm spacer plate for lowering the compression. FI me up.


But, before I get carried away, I had big ends that needed attention. As I mentioned, previously, I regard myself to have been very lucky to get away with no marks on the crank, so it was with some glee that I scurried under the engine.



Tbh and I know its the second time I have had to do it, changing the big ends isn't too bad of a job. Its certianly a lot easier when you don't have to do it while laying on your back but beggers can't be choosers etc Getting the new shell on the bottom half of the rod is very easy, but a little trickier getting it on the rod while its still in the engine but if your patient you can get it lined up and fitting properly without much problem.

So with the bearings in it was time to torque the ARP rod bolts up. 52nm or 38lb ft if your that way inclined. Checked them all at least twice not due to OCD but cos we don't want them coming loose!

I decided to switch pumps as the one I had had taken a whack and bent the bottom of it. It was also full of bearing material that would have been an absolute mare to clean out 100% so on the new pump went, and after my baffled sump had taken some lovin' from Mr Hammer and Mr Block of Wood we had remodeled the sump back to somewhere near it should have been, they were both refitted.

Bottom end fixed. Hopefully.

Onto the head.

Usual head gasket drills to be completed. Block and head scrapped to remove anything left over from old head gasket, make sure Headbolt threads are clean and clear of water and oil etc etc.

Now, to fit the spacer plate you have to take what VW provide (standard gasket) take it apart, remove the middle bit of the gasket and replace it with the spacer plate. To do that, take one bench grinder, and carefully grind the rivits out the 4 corners and teh gasket seperates nicely.

Make sure you don't loose/forget which is the bottom and the top layer and to make life easier, make sure the locating pins are in the block.

Fit the bottom layer:



Then on goes the spacer plate. Spot the deliberate Mistake....



Now, I'm no expert, but I don't think it will quite work, so....



Thats better Nick. Round Peg, Round hole and all that.....

And she's on:




The Spacer is 3mm think. Good enough to lower the compression to 8:1 which will allow for a generous sprinkling of boost, but that will come at a later date.



For now it will run NA. It might take a small bit of a hit on performace, but on expirence it isn't too bad and it will be custom mapped in this set up to get the most out of it. We'll see on the test drive how it goes.

Then the third top layer goes on and its ready to receive the head. You have to be a little carefull when putting the head on because as the layers aren't rivetted together they can easily move. But once the head drops on Head bolt time, Torques = 40nm 60nm and then 2x 90 degree turns.

Me in action doing the second 90 degree turns. Can get quite tight this...



At this piont, my photographer needed to go home. Unfortunatly he was also my lift home so I was pretty much commited to it the car being fixed and working

Now, to relive Post 27 of this thread, we go from head just going on to pretty much finished and rebuilt engine:




So, the engine was back together. There was nothing else for it. Filled it with Fuchs oil and some water, primed the oil pump to get oil round the system and there was only one thing left. Start the bugger. It sounded fine with full (lowered) compression on all 6 so it should be fine

I was a bit nervous, always am after building an engine and trying to fire it up for the first time, but I turned it over and after a few seconds she fires into life. Straight onto 6 cylinders, no funny misfiring or struggling to start, a nice crisp start up like it had been together for years. Ok there was a bit of knocking, but there always will be on an engine that has been drained of oil and the pressure needed to force oil to the places it needed to be.

A few seconds later though it was running clean with only an intimitent tappit noise, nothing to be worried about. Topped the water up let it get to tempreture, and make sure no fluids were leaking and we were looking good. Once the fans kicked in I was happy to give it a bit of a drive round the Pharm to make sure nothing obvious was wrong and a proper test drive.

One thing was wrong though, the brakes were crap. Somewhere along the line there seems to have gotten air in the system, and quick bleed and the pedal was bake to where I should have been. Need to have a look a them in the near furture though, it shouldn't have gotten air in there so I'll need to investigate. Also need to fit some braided hoses on the front. Have them everywhere else as they came on the car, but somehow the fronts passed me by.


So, I was happy to test drive it on the road. Just a fairly quick run round the block for 5 or 10 miles and it was great. There seems to be little to no performance drop with the lower compression, so I'm happy. There may be a little gone from the top end, but the mid range grunt is still there. With no Knocks bangs or anything, a few minutes later I was driving home. Very happy with the car and its perfomance. Engine sounds sweet and the car drives very well.


Today, I ran it upto 100 miles and it was time to fit the proper oil. A bit of sacralidge throwing away brand new oil I had put in it the day before, but there was bound to be some crap in the engine I couldn't clean out and the small amount of miles would have bene enough to give it a good clean.

Out came the "old" oil and in went Silkolene Pro S 5w - 40 fully synthetic Race grade engine oil. Some proper stuff that Rigs and I had previously used in the old Vr track day car with plenty of success. Bit pricey @ £55 for 6 litres but I'm not running the risk of killing my engine again.

Running temps with this oil seemed to have dropped a couple of degree's with this stuff, and I know from expirence it is stable upto 120+ish degree's so it should do the job if I decide to do a track day or 2 in it.


So now that is left is for me to enjoy the car again. I'm hopefull of getting it upto the Donny Track day at the end of November, although I won't be ontrack in it. So if people want a nose around et me know.

I'll have hopefully given it a good clean and taken the Tent out the back by then.......


Big Red is Back. I have hopefully made it better, it will soon be bigger (or at least power out put will be) and now I just need to do something to make it redder.....

Well, its been a while, but as some of you know the Car and I made it to Germany together, however, we didn't make it home together.

On the journey over to the Nurbergring as part of the CGTI/SCN 08 Rng trip, we made it as fair as Kelberg, annoyingly only 5 miles from the Ring, before the big ends decided they wanted to spin.

To cut a long story short, and after a big end bearing change in the dirt 100 Yards away from the Ring car park that didn't solve my issues, in fact made it worse, the car ended up in Storage in Germany while it waited for Alex from Lizard Logisitics to go pick it up.

At the beginning of September the car was back in the UK and today, I finally had a chance to get down to the Pharm and get my hands on the car and see what I had broken.

After changing the Big ends at the Ring, I was pretty confident the majority of the engine would need to come to bits, and I was looking at a change of Crank, Rods, Big ends etc etc. However, the work could not begin untill the Sun rose into the optimal position:



And so the work began. Off with its Head, was the first order of the day. If the crank and rods are changing the head has to come off anyway and its just as easy to do it in position.



Exhaust downpipe was being undone here, and nothing else. I like VR6's alot, but not that much.



A few moments later the head was off:



Looking at the pistons it looks to have been running fairly well, so thats a bit of a bonus, but there was movement on Pistons 1 and 6. Put weight on them and they moved ever so slightly. So then, the new big ends have spun again. No surprise there really, I was half expecting that.

Dropped the oil out of the sump and proceeded to remove the 892849728 bolts that hold the VR Sump on.

Eventually I managed to get them off, and I have to remark, its a much nicer experience to take of a sump off in Germany within ear shot of Ferrari's, Porsches and go knows what else beign ragged than it is to the sound of Tractors somewhere in the south of England.

Now, I had noticed in Germany that the sump was looking fairly used, scratched up etc. Par for the course on an Lowered old VW with the ammount of Speed bumps the councils like putting in. However, when I took the sump off I was greeted with this:




One Battered Oil Pump. Hmmm, so our original theory of crap oil degrading and killing the engine was beginning to be changed. One things for sure that oil pump has taken a hit and is deformed badly, off it needs to come, and into the bin!




And if any doubt was needed as to whether this happen with the pump was in the car with the sump on:



Notice the marks in the sump where the oil pump has come in contact with it? The sump has definatly taken a whack and hit the oil pump.


So now the theory is this:

Somewhere along the line the sump has hit the floor, which has pushed it up and into the Oil pump. Now, I have no recollection of ever bottoming the car out either on teh way to the Ring or even back in England in the weeks on the run up to the Ring.

The only time I can think of when this happened was when I had my accident. My current working theory, and one that I would be be happy to be disproved, is that when I hit the car back in June, It pushed the front of the car down and the sump made contact with the motorway. I have evidence on the front number plate of where I hit the car in fronts Exhuast pipes (2 circular grooves in my pressed plates

Well, after 5 hours and over 3 days due to the sodding rain, I have finished washing the outside of it. If anyone dares mention the "detailing" word near me, they're gonna get it...... but it has had a good thorough wash, T cut and then a good hard polish.

Come up looking quite good really. Pics are only taken on a phone camera so not the best quality but does look nice and shiney on the outside











Now the outside is done, I now have to do the engine bay interior and sort that drooping bumper out.........


This is beginning to look a little too bling for something I built for the 'Ring.......

A litle bored this evening I decided to giv the car its first proper wash.

Drove gently down to Halfrauds and picked up an Auto Gilm cleaning kit and some T cut.

First was a good wash all over and then dried it. Then onto the T cut. A pannel at a time, I started on the bonnet and down the passenger side.

Was beginning to get dark and so I polished the area's I cut back. Then after reading a handy forum tip, I botle of linseed oil was sourced used on all the black trim. Seems to give it a nice black finish, but it was well dark by now, so I'll have to wait till morning to see the full extent of the results.

Pics will be posted Tomorrow or Wednesday!

BIG RED is now at home

Drove it home semi gently Saturday evening allowing the engine to run in a bit. Allowing it to see the revs without loading the engine up.

Tracking is a bit out and needs sorting, but where I could open it up a bit, it certainly seems to go well.

Now to see how long £50 worth of fuel lasts

Well, a very busy and very productive weekend from down on The Pharm.

We forgot to take a camera down with us on Saturday but basically I started off from where we finished last week. Engine had been finished and not much else, so I went from

This:


To:





Engine was all 100% together and turned over, and she fired up first time and idled ok and got upto temp quite well. However, it turned out to only on 5 cylinders. Hmmm poo. No exhaust was on it and the noise from it was hiding the fact that it wasn't on 6.

Soon figured out that cylinder 3 wasn't firing. Took the plug out and it looked brand new and wasn't wet from fuel etc. Looks like the injector had gone down. A quick check of the diagnostic and fault code on Cylinder 3 was injector short or open to ground. Checked the big plug on side of the head and it seemed ok. Well, we thought, either I have a wiring issue or the injector was FUBAR'd. So, off comes the inlet manifold and............oh bugger. Looks like I fogot to plug Cylinder 3 in. That'll be why its not firing then.

Put it all back together and she fires up and singing on 6. Lovely job!

While the ramp was being used we couldn't do the exhaust and brakes etc, so Saturday evening we rolled it outside for better light and started work on the seats



After a quick chat with a mate, I soon sourced some rather nice looking Mk4 GTI seats that would go in with only a bit of work.



First the seat runners needed to be modded and moved in a bit. The width of the runners are wider on a Mk4 than on a mk2 so off they cam to be rewelded on further along. They will fit in the seat runners on the floorplan so now the front mounting piont was required.

Mr Grinder needed to come out and cut the front bracket off the cross member on the floor:




Then bracket was made that mounted up to the seat



Drill a couple of holes in it:



and then after feeding the happy welding pixie on a mixture of coke, Chocolate, dohnuts and rice cripsy cakes, the braket was welded on:



A bit of primer and red paint was added and:



Then cut the carpets to fit round bracket.



And that was the end of Saturday.

Sunday morning, Repeat on the other side, fit the seats and you have something that looks like this:





Add to my Mk4 Seats and my faux wood mk4 shifter, I have a Mk4 steering wheel on. Need the centre bit though.



Interior is near as damn it done, and the ramp free and easy the car went onto the ramp.

We then bread the blakes and Crutch. Or something along those lines. Brakes now working, but a little spongey will need a rebleed next week and clutch feels very nice.

A new set of wheels were put on. Something it will run with for a bit and fit over the 280mm brakes and it was onto the exhaust.

The Exhaust was the old unit I had on Rigs' old mk2. I know its not that loud for track days and the Vr6 sounds very nice through it. I needed to again awaken the happy welding pixie to make me the Cat bypass pipe and it was all mounted up.

Started the car and up and had it running. And it sounds loverly

I think the best way to describe it is via a Youtube vid. For a new engine it does get rev'd a bit but then it will see a race car hard run in to make sure its ready for the abuse I give it from the off

http://www.youtube.com/watch?v=YveFzmYqbOw

And there we just about have it.

A few bits to do. Front bumper needs to go on properly, Accelerater cable needs to go on, Headlight wiring needs sorting, a couple of ARB links to go on, Harnesses to go in and the Throttle body needs to be changed as its sticking a 4.8% throttle every now and then.

Once thats done I'll be driving her home, and onto the ring in August. Some pics of how we left it today:








Very close to being road worthy, and I am very happy with the results so far!

Well, Sunday is over and time to check the jobs list written on Friday:

1 - Front Calipers fit and Bleed brake system - Job to be done by Bluebadger
2 - Engine Bay, Tidy wiring, wrap with new loom tape as required, give it a good clean before engine goes in. - Job to be done By Rigs
3 - Fit Engine and maybe even get it running - Job to be done by Me.

First thing to do was Job number 2. Clean up the engine bay:

Job Completed by.......Me.

Push it outside with doner wheels on to allow it to Move:



A bit of Karcher pressure washer degreeser and a pressure washer and it came up quite nicely:




Also, the first of the Project advertising has crept into the picture. See if you can spot it. Its quite apt, and a bit subtle




And then it was onto Job Number 1.

Completed by.......Me.

First things first needed to fit brake caliper carriers. Gave them a bit of a Clean and a bit of paint and bolted them on:



Then it was onto fitting the calipers. Again a good clean down and then a spot of paint



Fitting of Calipers:




And Finally Job Number 3

Completed by.........Me

Found this small thing knocking about.



Might not look much on the outside, but its nearly all brand new on the inside. Bored to 2.9, Pistons, Rings, Bearings, Chains guides etc etc. Block has been cleaned and painted but the rest is in need of some cleaning, polishing and painting. That will come later.....

Strapped up, lifted up and ready to go in...



Went in nice and easy really no real issues. Had to do the old Chassis Mod from the crank wheel. Gave it a bit of primer and paint and it was time to throw the engine at the car. And here she is:




Once the engien was in and bolted to the car, the final two 90 degree turns of torquing of the head was required. Much easier to do that in the car than chase it round the floor!!

Exhaust Downpipe was fitted and bolted together, as were the drive shafts. While it was up in the air, teh back box was fitted to the car but need Exhuats rubbers for a perment finish.

It was then a case of starting to put the wiring that wraps itself around the engine in place and have a look at tiding teh wiring and holding in it place correctly. I have a feeling that at some piont I will end up opening up the whole loom and retaping in in the correct shape to get it perfect, but it'll do for now.


All in all a sucessful bit of work for the day.

Although somehow my hired help found other things to do One had some Rallye to mess about with, while the other took his gay Jetta front end off and refitted Golf headlights. Mind you, he did finally come and help and get the apprentices job......doing up the drive shafts. and did buy breakfast. The other helped get the caliper carries off the other car, and drive me to and from The Pharm.


So now a weeks rest at my usual work and Next weekend should see a grand leap in the amount of work done/completed. I'm hopeing to have it finished by the end of the month, and tbh, theres not a great deal more required of it so fingers crossed.

Should be a bit of fun at the 'Ring trip in August

Well, finally it is here.

I have bought my own car that I can use for day to day but mre importantly for Track days. It'll be a VR6R (R for racing ya see ;-) )

This is the car. A G reg, Red Mk2 Golf. But when I got hold of it it didn't have the Wheels, Brakes, interior or the engine in it. So it was just a shell of its former self




So, as I said it was just a shell. First job as to build up a Subrame for the engine. As a VR6 is going in, a VR6 Subframe was sourced. Add to that mk3 4 stud wisbones for wide track and cleaned Hubs with new Bearings, Flanges Ball joints and Golf Rallye ARB.



Then that needed to be fitted to the car. Throw into the mix some FK fully adjustable coilovers, Power steeing rack it looks like this on the car:



Thats all the pictures that were taken at the time.

But other work that was done yesteray included fitting the rear suspension, converting the rear from 5 stud back to 4 stud and fitting the front cross member. The car is pretty much ready to recieve the engine.


Oh, talking of which..... The engine.

Currently being built up by my engine builder is a brand new 2.9 ODB2 VR6, with Schrick 268 cams with a lightened and balanaced Flywheel. Putting the power to the wheels is a VR6 gearbox with a 3.9 final drive for added acceleration but lowered top speed. A Diff has been ordered but thy are on back order from the states, but will hopefully getting one soon!