Golf Rallye 2.5 tfsi 4motion

[2fast4you2]

@2fast4you: Did you cut 2 syncro rear axles apart to get this done? it looks to me like that...
and I'm still waiting for a look underneath your dashboard. (the cuts in the front for the heater box) Should be out now because I can see the mount in the background of the pics:-)
best regards and

Yes I finished my rear axle by using two syncro axles one is the Rallye's original and the other one is from a passat syncro. About the pictures of the dash well it's not out yet the one you see in the background is from my Golf 5 GTI that was badly burned and now waiting for new parts. But on the Rallye,dash and interior are next

[35i 2000]

amazzzzzzzing build wow!!

[calyp_so_fine]

great work and awesome garage!

[2fast4you2]

It's cold so almost nothing is being done on the car but I gathered all the screws and nuts including the ones needed for the chamber adjustment and took them to be chromed.



and how they turned out







not perfect but OK

[mdeneso]

coming out amazing! i forgot about this thread for a while.

[2fast4you2]

OK so today came the last parts that I needed to finish the rear axle.

Powerflex





And these are the rings and the bonded aluminum bush that I need to finish the mounting points on the axle. There are going to be 4 mounting points something similar to the factory rear axle from golf Mk5 4 motion



and the piece between the rings is an adapter that I need to combine the Golf Mk5 brake master cylinder and the 94 Passat VR6 brake and clutch pedals. And when these piece is welded it should look like this:

[dutchbuild]

There is a lot of cutting involved in the fitting of the MK5 heating, and yes you have to cut out some space from the wind shield right below the ending of the wind screen here I will give you a link to some pictures of how some guy did it to his Golf MK2 in Germany.

http://www.golf2tfsi.de/html/dezember_09.html

I did a bit more cutting then him but you will see when I'm ready to show you. everything is a mess so first to clear it up and then will take some pictures. The wiring holes, well they will be done as on the MK5 and the ABS will be done as this guy on the link I gave you. As for the servo steering I'm still thinking of how to use the electric motor and the servo from the MK5, and if that doesn't work then it will be the Polo servo steering and pump.

Maybe it's a idea, But I'll use the mk4 R32 trailing arms with Knockels what will fit in the VR6 K-frame/Subframe. I know also that the mk5 Knuckles wil fit on this mk4 R32 trailing arms and tho the vr6 subframe It's only a idea





I have also seen that you have weld in the new place for the engine mounts but I was wonder if the place for the prop shaft is in the middle now. The because I have build in now the 2.5 5-inline I I must go more to the right for this.

[2fast4you2]

.

I see you are using an 02M (DQB) Audi S3 2001 gearbox. Would this be nesesery if you used an original TTRS gearbox

I don't have an idea how would the prop shaft come out because I still haven't found an engine( I haven't even searched ) because I have a lot of other thing to be done on my car. But I'm watching you're project on you're website.

If it's not a problem how much did you pay for you're engine?

Thanks for the tip

[dutchbuild]

I see you are using an 02M (DQB) Audi S3 2001 gearbox. Would this be nesesery if you used an original TTRS gearbox

I don't have an idea how would the prop shaft come out because I still haven't found an engine( I haven't even searched ) because I have a lot of other thing to be done on my car. But I'm watching you're project on you're website.

If it's not a problem how much did you pay for you're engine?

Thanks for the tip

Hello, I don't use a TT-RS engine because it's only interest with FSI. This because everything is different for making the FSI better like the flaps into the cylinder head etc. I want +/- 850bhp with 800Nm torque and the normal US 2.5 is perfect for this. I have buy a TT-RS inletmanifold and this are 2 peaces. That part what is between the cylinder head and the inlet-box do I want make new without the flaps inside and with injectors.
This normal 2.5 will come also in europe in the middle from this year in the Golf and Jetta
This engine is new and I have paid 2000 Euro for this in the Netherlands.
There are TT-RS engines available but at 7400 Euro. For this money you can buy a normal 2.5-engine new pistons, rods, turbo etc. There are a few different's between the TT-RS engine and the VW 2.5 like:

Inlet valves are a little bit bigger from the TT-RS, but the same as from the 2.0TFSI
The crank-bolds are stronger
Other pistons
The crank do have 8 bold and the 2.5 do have 6 like the 4-cylinders. (no other different what I can see for this crank)
a few other little parts what can changed easy with new part what can buy from the VW dealer.




You can see more pictures from the TTRS here:
http://forums.vwvortex.com/showthrea...19-TTRS-motor.

I have chosen for the 02M because I want drive with a Qauife dogbox and they don't have them yet for this new gearbox. Maybe I will switch later when Quaife do have a set for this. The dimensions are the same for the engine mounts, so have have bolt on a old DQB qearbox on it.

[ShaggysGTI]

Looking great! In for the win!

[2fast4you2]

Today I finally finished the rear axle and I really like how it turned out

Here are some pictures:











I also took the rear axle holder to be chromed

[dutchbuild]

Today I finally finished the rear axle and I really like how it turned out

Looks good, I'm interest how you will make the fuel tank

[2fast4you2]

Looks good, I'm interest how you will make the fuel tank

I plan on using an aluminium tank

[Rallye 1.8T]

Some serious fabrication

I'm watching this because I need some ideas and motivation for my Rallye Golf that is waiting...

[84vdubRabbit]

This build is outstanding and you sir have a lot of talent. I see from your other cars this isn't the 1st masterpiece you've put together, do you build these cars for a living? Or is this just like a hobby for you?

Can't wait to see how this car turns out!

[2fast4you2]

This build is outstanding and you sir have a lot of talent. I see from your other cars this isn't the 1st masterpiece you've put together, do you build these cars for a living? Or is this just like a hobby for you?

Can't wait to see how this car turns out!

I'm glad that you like my project's And no I'm not doing this for a living this is just a hobby.

[2fast4you2]

Not much done on the car but I really didn't had much time and I got the fly. But now I'm OK and will continue working on my project
Today finally the Roll Cage from OMP arrived :







... so the work continues

[xxKurt85xx]

Hello, I don't use a TT-RS engine because it's only interest with FSI. This because everything is different for making the FSI better like the flaps into the cylinder head etc. I want +/- 850bhp with 800Nm torque and the normal US 2.5 is perfect for this. I have buy a TT-RS inletmanifold and this are 2 peaces. That part what is between the cylinder head and the inlet-box do I want make new without the flaps inside and with injectors.
This normal 2.5 will come also in europe in the middle from this year in the Golf and Jetta
This engine is new and I have paid 2000 Euro for this in the Netherlands.
There are TT-RS engines available but at 7400 Euro. For this money you can buy a normal 2.5-engine new pistons, rods, turbo etc. There are a few different's between the TT-RS engine and the VW 2.5 like:

Inlet valves are a little bit bigger from the TT-RS, but the same as from the 2.0TFSI
The crank-bolds are stronger
Other pistons
The crank do have 8 bold and the 2.5 do have 6 like the 4-cylinders. (no other different what I can see for this crank)
a few other little parts what can changed easy with new part what can buy from the VW dealer.




You can see more pictures from the TTRS here:
http://forums.vwvortex.com/showthrea...19-TTRS-motor.

I have chosen for the 02M because I want drive with a Qauife dogbox and they don't have them yet for this new gearbox. Maybe I will switch later when Quaife do have a set for this. The dimensions are the same for the engine mounts, so have have bolt on a old DQB qearbox on it.

so are you using the U.S. spec 2.5L or the TTRS 2.5 TFSI?

[dutchbuild]

so are you using the U.S. spec 2.5L or the TTRS 2.5 TFSI?

Hello, This is not my topic, so I will tell it simple. I will use the US 2.5 with TT-RS specs, like the Crank and more. On this way I don't have the FSI, so I will use the best from both. The TT-RS engine is perfect up to 500bhp but I want 850, and this doesn't work on FSI. When you have more questions, please ask this in my own Topic or as PM

[2fast4you2]

I finally found a Lancia delta Integrale hood
Here are some pictures







I was looking foe these hood for a ling time and finally found one

[orangea2vr6]

love the hood i've been trying to find one myself, take some pics of the modifications to it as you go.

[2fast4you2]

Today I finally finished installing the roll cage . The roll cage needed some modifications to accept the Golf 5 dash but finally it's done Here are some pictures:









so moving forward with the project

[Tor_m]

Wow liked the cage!
And that dash, and not forget the steering wheel!! Have been thinking of a MK4 R32 steering wheel in my Rallye, but dont now how MK4, and MK5 fits inn MK2!
Love this prosjekt, keep going strong

[mdeneso]

just keeps getting better and better

[2fast4you2]

Today I finished modifying the tunnel to receive the Golf MK5 selector mechanism .
Started by cutting a bigger hole for the selector mechanism and drilling holes to get it fixed:



the small holes were made to remove the MK2 selector mechanism mounts



did some modifications on the tunnel to fit the MK5 selector mechanism



and here is how it came out:

[MK1 Rabbit GTI]

auto

[2fast4you2]

auto

Not auto but DSG or S tronic

[ShaggysGTI]

Not auto but DSG or S tronic

My friend does the same thing to me... But I'm still not sold on it. Either way, you are making great progress!

[2fast4you2]

Some progress was done these past days.
I totally redone the sub frame for the Golf MK5 dash. I newer posted pictures of the sub frame and the work done for it to be fitted because I didn't like how it was done
So I started everything over again and here is how everything was done:

first of all I bought a new subframe



and the original Golf 5 holders that the sub frame is tighten to and cut them to fit





then more cutting



and then started making some pieces to weld on the chassis that would except the holders for the sub frame







after I welded the holders I cut the rest of the sub frame to fit between the pieces







took the sub frame to be welded and here are the results:





and...







after the sub frame was fitted next was the intake for the air conditioning



first I took a part of the air conditioning to be a little modified





and then everything could be welded



After all of these I had to redo the shifter because it had to move 2 sm back ( it was too close to the dash)

[Grabbit]

wow, everything is being covered in this build. Is the plan to have it done this summer?

[2fast4you2]

wow, everything is being covered in this build. Is the plan to have it done this summer?

The plan is to get it painted this summer but for the rest... I think next year

[2fast4you2]

I'm almost finished with the roll cage and now planing on making a support to the suspension housing from the roll cage

Here are some pictures from the roll cage:





And here is the support to the suspension housing from the roll cage that I planed on doing
What do you think?

[2fast4you2]

Here are some pictures of what I have finished yesterday :

[stealthmk1]

I love how you're not afraid to admit your mistakes, and just dive back in to redo things right. Hindsight is 20/20, but most people wouldn't have the resolve to do it that way. That's how you learn, and you can be confident that when it's all complete you'll be 100% happy with your work.

[2fast4you2]

Some updates

I finished the rear reinforcement







also finished the front reinforcement from the suspension housing to the roll cage









in the mean time I mange to find time to build this :









so I can move the shell in mu garage
and some shopping was done:
Rear 4 piston calipers from Shevrolet Camaro SS 2010+ for the rear axle



brake disc for the rear :



also bought H&R FRONT SWAY BAR VW GOLF 3 VR6 25MM
and the emblems: