G60 Conversion

Can you not just move it further over? There looks to be room.

I reckon I could file the mounting holes on the intercooler to give me 5mm and then grind down the rear edge of the battery to give me another 5mm which should be enough.

Got a custom 1 litre swirl pot made up that's designed to be run under the car

Got busy today got the headlight loom protected in convoluted tubing and run under the battery tray and through the front beam. Tidies it away nicely and allows me to mount the battery closer to the wing to clear the intercooler pipe work. I had to modify the bonnet release catch as it was fouling the top of the radtec intercooler.

I wanted to line up the pipe work so got the charger bolted in but all I can say is Whaaaaaaaat…..

The radtec pipe work was not quite right. The Plenum to the lower intercooler pipe seems OK if not wonky but the supercharger to the top intercooler pipe is a joke. In the pictures I experimented with a 45 degree bend (spare from bartek kit) as the 90 degree just wasn't working. I seem to be missing an alloy straight pipe from the charger as well. The output from the intercooler is 60mm and the pipe I have from radtec is 70mm so its a bit loose lol.

The radiator hose at the top is also confusing as you can see from the pictures I have 2 90 degree bends and 2 alloy joiners lol

If anyone has the radtec kit I really would appreciate some help as the instructions seem to be wrong, perhaps they were for the earlier version of the kit 

Good news Radtec replaced the missing pipe work and have it connected up now I will probably tweak it over time but it's a good stating point.


Got the rocker cover and idle valve cleaned and acid etch primed:

Before:

After:

Rocker Cover:

Distributor:

This is an awesome car,that rad set up
Is a work of art!

More progress:


Fitted my oil cooler kit, tucked the radiator down at the bottom but not lower than the front lip angled slightly towards the ground.


Got the aux belt on and tensioning parts.


Attached the blanking plate to the charger. I was planning to add a boost return kit from bartek but unfortunately there is no way to fit it between the radiator and charger. After speaking to Matt at only charged dubs he reassured me that it will be ok to do. He said not to add anything except oil in the charger every 1k.



Finished with the top coat on the rocker cover, needs a wet sand and lacquer to finish her off.


Finished painting the gearbox components


billet alloy Oil catcher arrived

Wow!  

Got my gearshift cables attached but think I'm missing some lock washers to hold the cable in place.

Update:

Got the lock washers ordered up from VW, should pick them up next week and get the master cylinder fitted.

Put final coat on isv


Lacquered the Rocker cover:


Ran a brass brush over the throttle body to remove the aluminium oxide, fitted the gasket and torqued up the new stainless bolts

That's all come up nicely  

Lovely project. Loads of hard work and effort gone into this so far. Keep up the good work mate.

Smudger

Cheers guys, hopefully should get this done in one last push! Have a fortnight off from next week.

Got the final bits ordered up, boy this project has cost some   I'm too scared to look at the receipts!

Update 24/8/14:

More progress. I've put on my new wheels with sensible size tyres 195 x 50 x 15's. I need to swap over the lips on the RM's to match the fronts then put new tyres on.


Fitted my jetex exhaust and very happy with the fit. Got some stainless steel wire and welded both lambda bosses on. One for stock narrow band sensor and the other is for the wideband lambda for the AEM AFR meter I have Bought a SPA dual oil pressure and oil temperature gauge to go with my VDO boost gauge. I hope they don't look too out of place together but I plan to replace the vdo gauge in the future with a SPA boost / water temperature gauge.

Hydraulic clutch is working and located the reservoir in the scuttle panel.

Installed the 9 inch servo and 22mm master cylinder and plumbed in the brake lines but will need to remake them as the front lines are a little stretched for my liking and I need to add an inline brake light sensor.


Fuel Rail is installed with injectors and loom.


Connected the speedo cable and rev counter cable.


Things left to do: Fuel lines, electrics and boost pipes

Nice work Rich, she's looking great and coming along nicely!

Yeah it's looking great man keep it up 

golf1980 said

Yeah it's looking great man keep it up 

Melteddrummer said

Nice work Rich, she's looking great and coming along nicely!

Cheers guys,

Will be back on it Wednesday to finish the fuel system, just waiting for some wire so I can sort out my 044 pump

looking top mate! really looking forward to getting mine built up again.

Great build man. Everything looking really nice and shiny. Top notch.  

Beeno said

Great build man. Everything looking really nice and shiny. Top notch.  

Cheers chap