Smudger's 20vt Project A.K.A Patsy. (Update 07/06/2015 Got the love back)

Welcome back Andy #2! Glad you're back on it  

Cheers guys.  

watch that f23 turbo is a bit of a animal

I had a similar thing, although on a smaller scale, when I was refitting my looms. I melted an earth wire at the back of the fuse board, and as you said its a case of turning off the ignition and disconnecting the battery as soon as you here that frying sound and smell the acrid white smoke. 

I damn nearly s&*^ my pants Macca       

Welcome back Smudger, congrats on the promotion and best of luck with progress getting back on the project :-)

Loving the motor mate looks very nice 

Good to see you back on here Andy. Congrats on the promotion. Look forward to some more updates on your mk1.

Just read all 57 pages from start to finish mate, awesome build and monster machine you have there. I'm near the beginning of my 20vt AGU KO3s build!   Could you please post some photos of your hydraulic clutch conversion? I've planned everything else out but this is giving me on sore head!   Looking forward to your updates
Jambo  

Hi guys,

Not been working on the car for a while for a few reasons not least my mum is seriously unwell.

James Punter I will get some pics for you as soon as I can mate. Anything in particular you are stuck with?

Smudger

Hey Andy,
Good to see you back on it mate.
Sorry to reaf your Mum is unwell though.
Epic build thread though fella. Look forward to seeing this beast in the flesh at some point.

Cheers

Chortle

Good to see you back at it Andy.
I hope your mum makes a speefy recovery.

this mk1 is ace!!

hope ur mum gets well mate!!

Just read the entire thread, thanks for sharing.  I hope all is well.

The old girl is now in my possession, but Patsy is being nicely pampered in the garage! I'll be sticking my progress up in here if that's OK with Andy.

Brought her back, first mission was to get her nice and clean, as you can see there was a fair amount of dust (don't get me started on the cat hair, it's everywhere!)



After a clay bar session (The amount of cack that was left after 2 thorough washes was unreal), and some machine polishing she came out looking great



Also made a start mocking bits up on the engine, it's currently apart awaiting ZRP forged rods to go in but i'm debating whether or not I should do the big end, mains and thrust washers at the same time.

Anyhow, wasn't too happy with some of the piping and routing for stuff such as the brake servo vac pipe and breather set up so got busy with that today. Engine harness back in the car and most things plugged back into the fusebox. Hopefully starting to get all the intercooler pipework routed nicely and sort out some harness protection.


As you can see space is now somewhat an issue 



 

Oh wow! Nice to see this resurrected! I take it you've bought it off Andy?

Yes mate, didn't want her getting broken for bits, even if it does mean having no space or money left for anything else  

Anyway, tidied the bay up a bit more and got everything mocked up



Bores re-honed


Pistons in, the old rings were quite badly coked up and worn.



Head off, cleaned up a bit of gunk



Compressor housing and TIP adaptor are now getting machined to match as the adaptor seems to be for a standard k04 and is a touch too small. Got my R8 coil packs too so when the turbo comes back I can assemble it all and drop the head on and connect everything up.

Don't worry Ahmet money is over-rated! lol

So when do you think this will live again?

I'm not sure mate. I've got most of the engine look back in and connected but there is a couple of connectors that I don't know what they are for.


Once the turbo pieces are back the head can go back on, wiring can go back onto the engine and I'll try and turn it over. I just want to be extra cautious with the loom and last time me and Andy attempted to start it the loom caught fire. 


Once the engine is running it'll be basic tidying, fit the diagnostic port on, mount the ECU, fit the passenger seat and put the interior back together. There's really not much left, it's just the issue is time and I'm really trying to get the GTi back together as space in the garage is tight especially as I've now shoved a sandblasting cabinet in there!

Spent the last few days at work reading through this thread (shhhh dont tell the boss). I have to say it is a work of passion. Glad it didnt get broken up and hopefully will get finished. Its given me a lot on inspiration for my 20vt and cant wait to see this car in the flesh when its out at shows.