DarkSideGTI Big Turbo Build Round 2

[WoLfBuRgJeTTa]

Nice . I see the remote filler, how do you have it routed?

Page 12 = Owned

[DarkSideGTI]

Nice . I see the remote filler, how do you have it routed?

Page 12 = Owned

It goes down behind the ABS module and below the motor mount to the rad hose tee.

I hooked the battery up and everything seems to be working except for my air compressors. gotta figure that one out.

[huichox4]

nice man, its super nice

so this means were going to see this thing fired up and running in the next couple of days or what?

[DarkSideGTI]

nice man, its super nice

so this means were going to see this thing fired up and running in the next couple of days or what?

Hopefully. I need to go through everything and make sure all nuts/bolts are torqued to spec first.

[WoLfBuRgJeTTa]

It goes down behind the ABS module and below the motor mount to the rad hose tee.

So you're not running an overflow tank at all? Did you just plug the second hole in the remote filler or was there one with only one hole underneath?

[DarkSideGTI]

Do all MKIV's have the same A/C lines? My DP burnt a hole in one of mine by the firewall. I took it to a local hose shop last week and they couldn't fix it because our cars have metric hoses and their standard fittings would not fit. Their suggestion was to weld on two -12 AN bungs and run a -12 hose. Ideally I'd like to run custom bent hardlines, but don't have time for that. So I might just buy a used line off a junker or something. For some reason I am thinking R32's are different though.

[huichox4]

Do all MKIV's have the same A/C lines? My DP burnt a hole in one of mine by the firewall. I took it to a local hose shop last week and they couldn't fix it because our cars have metric hoses and their standard fittings would not fit. Their suggestion was to weld on two -12 AN bungs and run a -12 hose. Ideally I'd like to run custom bent hardlines, but don't have time for that. So I might just buy a used line off a junker or something. For some reason I am thinking R32's are different though.

I got the lines from a GTI, they fit but they have the refrigerant fill-up points at a different location, and a little cylinder looking thing that is part of the lines by the front of the engine instead of the back.

[huichox4]

R32 Lines



Golf lines



try sourcing the R32 line, the one from the other cars will bring something to the front of your really nicely shaved bay.

Edit: I just checked ant its barely noticeable, its just the fill up ports that sticks out from the rad support and I remember I was able to bend a little to tuck most of it under the rad support

[DarkSideGTI]

so I was sent the inner boot for a triple roller axle.

So much for getting the axle back in tonight.

[dr. b]

so I was sent the inner boot for a triple roller axle.

So much for getting the axle back in tonight.

at least your wheels clear your brakes

[DarkSideGTI]

at least your wheels clear your brakes

Go back to stock brakes?

[BIG DUB]

Do all MKIV's have the same A/C lines? My DP burnt a hole in one of mine by the firewall. I took it to a local hose shop last week and they couldn't fix it because our cars have metric hoses and their standard fittings would not fit. Their suggestion was to weld on two -12 AN bungs and run a -12 hose. Ideally I'd like to run custom bent hardlines, but don't have time for that. So I might just buy a used line off a junker or something. For some reason I am thinking R32's are different though.

I had the same thing happen with my DP but I had a shop cut the old section out, fab up a smaller loop and then weld it in and pressure test it and it was good to go. cost me 40$ that way I can cram a 4" DP soon with no worries of it hitting on stuff

[Cortexiphan]

Yup I got stainless steel washers.

I took the painters tape off.



I guess I did a couple other things too.

That is fresh

[dr. b]

Go back to stock brakes?

long gone. i'm down to 12.3's now. it's the huge caliper that is causing interference. looking into a one piece forged type deal now. still gonna be gnarly....just one piece.

love your engine bay. that purple was an inspired choice.

[DarkSideGTI]

thanks, it's a really cool color. It is a flat candy color that changes in different light.

here are all his flat candy colors.
http://www.facebook.com/media/set/?s...1.311716665858

[Brake_Dust]

test fit the wheels today.

Nice wheel.. kinda like a beefy flat spoke RC with bolts exposed

[DarkSideGTI]

Nice wheel.. kinda like a beefy flat spoke RC with bolts exposed

Thanks, It's a rep of the HRE P40

[BIG DUB]

Im digging the porsche

[DarkSideGTI]

I hooked the battery up and everything seems to be working except for my air compressors. gotta figure that one out.

haha, I feel like an idiot. forgot the compressors required key on. they work fine.

[Cortexiphan]

haha, I feel like an idiot. forgot the compressors required key on. they work fine.

smooth

Cant wait to see this thing finished man

[huichox4]

now you just need to AC lines?

[DarkSideGTI]

now you just need to AC lines?

There are a few other things left. I need to get my passenger axle back in as I was sold the wrong inner cv boot. Should have the new boot Friday. I still need to fill the car with coolant, change the trans fluid, torque motor mount bolts, and a few other small things. I bled the brakes last night using my Motive power bleeder, but it did not do so well on the clutch. I ended spraying brake fluid all over the bay.

[huichox4]

There are a few other things left. I need to get my passenger axle back in as I was sold the wrong inner cv boot. Should have the new boot Friday. I still need to fill the car with coolant, change the trans fluid, torque motor mount bolts, and a few other small things. I bled the brakes last night using my Motive power bleeder, but it did not do so well on the clutch. I ended spraying brake fluid all over the bay.

yeah I hate when that happens, just when you are about to be done you need a little more fluid and/or sprays all over somewhere else. usually works good when two or more are working on it at the same time.

[DarkSideGTI]

yeah I hate when that happens, just when you are about to be done you need a little more fluid and/or sprays all over somewhere else. usually works good when two or more are working on it at the same time.

Yeah, I will get a helper and bleed again. When the trans was out I submerged the slave cylinder in some brake fluid while depressed. I slowly let it out by hand and it sucked up a bunch of fluid. The way the stock bleeder is does not allow the slave to fully fill up with fluid while bleeding. I am hoping it is better this time around.

[DarkSideGTI]

Today I made decent progress. At the end of the day I hooked up the radiator hoses and started filling it with coolant. I only put a bit in and checked for any leaks, well I found one where the crack pipe enters the water pump housing. I took off the t-stat housing and then the crack pipe and noticed the o-ring was ripped. Must have happened when I installed it. I will probably have to wait until Monday to get a new o-ring as I doubt any auto parts stores will have any 34.5x3.55 mm o-rings. I was going to try to start it tomorrow too. o well I can wait a couple more days.

Front wheels are finally on the ground.

[dr. b]

good to see i wasn't the only one capitalizing on fantastic weather to make big strides.

[huichox4]

I bought a universal o-ring kit from autozone and one of them was good. use some coolant to get the o-ring wet and also the pump inlet housing so it slides in better then clean the excess.

it ripped on me because it was slightly misaligned and there was some interferance with something else and tried twisting it in place slowly....

have to make sure you slide it in perfectly aligned.

good progress man

[DarkSideGTI]

got the bumper back from paint and test fit it. Rad support is not aligned at all.

I bought a universal o-ring kit from autozone and one of them was good. use some coolant to get the o-ring wet and also the pump inlet housing so it slides in better then clean the excess.

it ripped on me because it was slightly misaligned and there was some interferance with something else and tried twisting it in place slowly....

have to make sure you slide it in perfectly aligned.

good progress man

I found an o-ring at Lowes that was 1 3/8" which is less than a mm off. I did lube it up with coolant and it worked like a charm. But then I noticed a tiny leak at the t-stat. I did use a new o-ring there, but did not lube it with coolant so tonight I will pull that out and get it wet and re-tighten.

[huichox4]

ohh and once the whole system is filled up you may see a leak but if its not too big try to drive it like that for a bit and the G12 will actually finish sealing it off. If it comes back then other things need to be done.

[DarkSideGTI]

ohh and once the whole system is filled up you may see a leak but if its not too big try to drive it like that for a bit and the G12 will actually finish sealing it off. If it comes back then other things need to be done.

The leak at the t-stat is pretty small. I'm still gonna take the cover off and look at it though.

[DarkSideGTI]

so anyone got a good pre-startup checklist for a new motor? I have already checked most of the bolts, fluid levels, and I plan on unplugging the fuel pump fuse and cranking it over for a bit to build up oil pressure. I just want to make sure I don't mess anything up.

[huichox4]

This list might be 2 days late but just in case you could go and take the spark plugs out and check compression at the same time you are priming it.

fluids
spark plug gaps
new or stabilized fuel (depending on how long was it been standing)
ventilated area because some times the new parts will emit some fumes
let the coolant reservoir cap open until it warms up to let the extra air pockets out but keep an eye on it to close it before your coolant overflows
clear any debris, tools, rags, beer bottles, empty beer bottles etc.
copy of the break in procedure of the engine (if you are going with the mototune route or something different)
video camera recording the event
Cigar to celebrate it works without blowing up,

[DarkSideGTI]

yeah I checked all that stuff. I tried to prime it last night, but the starter won't turn over.

[huichox4]

ohh one more fresh battery or fully charged one.

was the battery relocated? ground checked and secured?

[DarkSideGTI]

yeah battery is behind my seat now. I removed an interior panel and put the ground under a bolt going to the body, it should be good. All other electrical items work, headlights, stereo, fuel pump, etc. My battery was a little low on juice so I took it out and put it on the charger. But I did take a good battery out of another car and it still would not turn over. The starter doesn't even attempt to work. It's got to be something with the ignition switch, clutch switch, or one of the relay's. I guess it possibly could be a bad ground, but I checked them out and everything looks good. I do not yet have a motor to chassis ground hooked up yet, but it should still turn over right?