Ok guys. Finally made some noticeable progress on the car. As some of you may know I purchased a 2002 Quattro earlier this year. My old car was a 400+ HP GTI that went really nice in a straight line but did not turn and did not drive under 60mph due to the lack of traction. I am ready to change that now.
Going fast is in a straight line is fun, maybe it was a phase or something lol, but I realized going around corners seems to be more fun. So before even worrying about power this time around I want to make sure chassis and suspension is well taken care off. At the same time also want to make sure all the maintenance has been updated and the car has been restored as close to new as possible. Part of that means replacing every bolt and bushing on the car and replacing oem parts with better stuff ;P
Here is the parts list so far (EDIT updated parts list):
Go around corner stuff
Upgraded springs front/linear spring conversion rear
BFI lower front tie bar
Defcon Control Arm Inserts (with OEM bushings)
all new oem bushings and bolts for every suspension component
new bearings and hubs
powder coated frames, arms, etc
front sub frame brace welded in
CPT Rear Adjustable Control Arms (upper and lower)
Neuspeed Rear Race 25mm Sway Bar
HR front sway
Orange Haldex Controller
Ground Control Camber Plates
Stasis Alcon Front 13”
Status Racing Ring Leather (Driver & Passenger)
VF Engineering Mounts (all 3)
rota torque 18x9.5 /with Yokohama ADVAN A048 285s (all around)
Go fast stuff
Besides the above mods the goal is to drop some weight on the car as well. Plan is to get it just a tad below 3000 while keeping comfort and safety – that means keeping AC of course, stereo and speakers, airbags and interior panels. At this point all tools and spare are removed, seats, rear ballast, insulation under the carpet, and some other random stuff here and there. Another thing is going to be some stiffening of the front sub frame by welding on support braces on the front side and triangular braces in the rear.
Here is what I have been able to get done so far.
Removed the carpet to get rid of the insulation below. Quite a bit of stuff has to come off, rear seats, center console, some trim pieces to finally get the carpet out. Now on a GTI the insulation pieces below the carpet come to quite a bit of weight (15-20lbs), something I had thought is the same on the TT, I was wrong. But with all the stuff off and the carpet out of the car I figured let me get rid of it anyways. Quite painful to remove all the stuff that is glued to the carpet - My girl friend was actually helping me and doing the passenger side (yeap she is a keeper), took both of us probably 1.5-2 hours for one side by using a flat head screw driver and jamming it into the foam and prying it out. So in summary, don’t bother, honestly, I am not sure why I did not just put it back. Guess its one of those moments after spending many hours removing crap I did not want it to go to waste - so yay for <5lbs weight savings. Now that that was done I put the car on the lift, its new home for the next few months.
Started working on the rear end. Removed rear bumper and exhaust to get some more access. The bolt in the exhaust clamp in the center must have seen some rough times. It actually broke in half when taking it off. Also started removing brakes and tried to get the axle out. Being an older car no matter how hard I slammed the hammer the axle would not move – after many bad words decided to order the axle removal tool. I figured if the rear is this hard the front is going to be similar.
Probably most progress this weekend. Removed the remaining parts from each side such as trailing arms, brackets, control arms. Started taking off the sub frame bolts as well ... little tip, always do that together with a buddy. The rear diff and sub frame is a lot heavier then it looks - learned that the hard way <IMG NAME="icon" SRC="http://www.vwvortex.com/vwbb/tongue.gif" BORDER="0"> .
I loosened the sub frame bolts and then lowered the car so the rear diff would sit right on top of my little round chair (with a piece of wood for extra support). All went well, removed all sub frame bolts and pushed it backwards to remove from driveshaft. I figured I’d just try to lower the seat while holding it with my other hand – yeah did not work, sub frame decided to leave a nice mark in the floor
And another one of those “special tools needed” scenarios. Darn rear diff bracket needs a 14mm triple square bit – no one local had anything so I had to order it online. Oh well, going be out of town next week anyways so it should be home once I get back.
While everything was off inspected all threads on chassis and other areas on the under body to make sure nothing is rusted and that all under coating is still there – everything looks perfect – that made me happy since I did not want to have to deal with some re-coating below.
As you can see lots of stuff dirty and rusted, and more dirt and rust. That’s the next part, cleaning stuff, inspecting for leaks, checking all seals, and putting it back together. Already have a new rear sub frame as the one currently had too much rust buildup.
It’ll be a nice difference seeing it all cleaned up and fresh
Hopefully will have time next weekend so I can start doing the same to the front as well. Stay tuned for updates.
Modified by chaugner at 2:53 PM 1-4-2010