Mellow Yellow 3.2ltr 24v Conversion

Ordered another V belt, the 1105mm one was too long and the tensioner was set to max to get enough grip.

Fitted the steering column finally but couldn't find the bolts for the steering wheel 

Next tried to fit the headers and Eurowise downpipe. I think I was shipped a Mk4 Golf R32 downpipe as this blatantly didn't fit  

Next got some quality of life bits in the garage.

A large screen and folding workbench to rest a laptop on.


A garage stereo, bit overkill but had an old receiver that wasn't doing anything.



A Dehumidifier which has worked wonders drying out the garage from the build and over the winter.

This week I will start to paint some parts and on Saturday mock up the radiator and oil cooler. Need to fit the secondary coolant pump and start think about the vacuum system for the variable intake . I think I have enough pictures to remember how it fitted 

Looking good mate! I'm doing same conversion Regarding the Eurowise Exhaust, they only sell Mk4 downpipes, I also have a mk5 R32 engine. I found the Mk4 manifolds instead, the solved the problem  

Hummel said

Looking good mate! I'm doing same conversion Regarding the Eurowise Exhaust, they only sell Mk4 downpipes, I also have a mk5 R32 engine. I found the Mk4 manifolds instead, the solved the problem  

Cheers chap, I have some MK4 headers coming this week . I thought that might be the case and noticed the shape of the flange were the same as the MK4.

When I ordered them up I was told they would fit Mk5 and the pic on their website has triangular flanges like the Mk5. I've contacted them to find out what went wrong.

How far along are you with your build? Have you got a build post. Would be good to share ideas

Yeah I also contacted them, they told me they could get the Mk4 manifolds for me if I wanted, offcourse for a cost. But as I'm located in Europe, I could get those myself. The triangle flanges are the same, is the angle that is the difference.

Sorry I don't have a build thread, I sucks at taking pictures when i work    The car is pre-paint assembled, soit is running and everything works, my plan is to used the summer to get everything perfect and then pull it apart and paint everything this winter..  I see if I can get some pictures. It could be nice to share knowledge and ideas.  

The engine mount kit i used was S&P.
I feel your pain with the exhuast manifold issue so iv spoke to S&P and there in the middle of making a new down pipe that bolts on the mk5 manifold.
Loving the build, thought id share some of my own 😉

Few more pics

Iv done a full head rebuild with new valves, seals and timing chain etc..
Spent a bit of time pai ting it all up. Next is the gearbox to be stripped, checked and painted.

I dont have a build thread but i am on instagram
77gls_r32

77mk1_R32 said

Few more pics

Iv done a full head rebuild with new valves, seals and timing chain etc..
Spent a bit of time pai ting it all up. Next is the gearbox to be stripped, checked and painted.

I dont have a build thread but i am on instagram
77gls_r32

That looks awesome, you're using a different type of tensioner to me as well.

I think I may have to revisit the paint once I've got it running .

Great to see other R32 builds ^,

Got some MK4 Golf R32 headers yesterday and soaked them in Bilt Hamber Deox C overnight.

Cleaned them up this afternoon with a wire brush to get in to the hard to reach places.

Wax and grease remover, masked up and painted in high temperature enamel paint

Sorted out the right length of drive belt. Tried a 1105, 1088 but settled on 1070. Perfect amount of tension.

 

Looking good as always…  

Question, is that a different tensioner than the original ?

I didn't have any issue with the belt, when i removed the AC I just bought a original belt for a car without AC ?

Hummel said

Looking good as always…  

Question, is that a different tensioner than the original ?

I didn't have any issue with the belt, when i removed the AC I just bought a original belt for a car without AC ?

Morning

I followed some advice from another MK1 R32 owner off Facebook. It's also documented on the Corrado forum as they have quite an extensive fitment guide.

You replace the alloy accessory bracket from a 2.8 24v vr6 and tensioner. This lifts the alternator above the MK1 front cross member giving plenty of clearance and also pulls it in closer to the block for the radiator so you have plenty of clearance for that.

With the Audi braket the alternator was lower down and sticking out quite a bit. Didn't want to risk issues with engine movement and the radiator getting knocked with such close proximity.

Have you test fitted the engine with the stock setup?

Cheers

Rich

So I just thought I'd compare the mk4  R32 headers to the Mk5 R32.

Quite a bit of difference in the port size.

Header to downpipe ports:

Mk4


Mk5



 

Header to cylinder block
Mk4



Mk5

Not sure whether to make earlier flanges (I think I have seen some stainless ones on ebay) and weld them to the stainless Audi header or do some porting on the cast header but not sure how that will affect it's strength.
 

Thats exactly why im waiting for S&P to make my downpipe to fit the mk5.
Regards the alternator bracket, i used the original mk5 bracket and just cut the lower half of the bracket where the AC compressor would sit. Theres planty of room.

77mk1_R32 said

Thats exactly why im waiting for S&P to make my downpipe to fit the mk5.
Regards the alternator bracket, i used the original mk5 bracket and just cut the lower half of the bracket where the AC compressor would sit. Theres planty of room.

Thats good to know  

I didn't want to take any chances with my rather expensive custom made radiator  . More clearance the better    

I'm going to port the cast manifold at the flanges and go with that for the time being and then weld up a custom one. I need to make a joining section to my Milltek classic exhaust.

To be honest the exhuast is the weakest link here as its a 2.25" bore where as the later mk5 is 2.5".

When I get the car up to Vince at Stealth he will get rid of the remaining codes on the ecu and put it on the rollers so I can gauge how restrictive it is.

I like to think with a pretty straight through exhaust and no cats it should flow reasonably.

Thought you'd have finished this by now.

Come on, crack on!  

Loving the works so far.

Ian