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    Thread: DarkSideGTI Big Turbo Build Round 2

    1. 05-15-2011 07:08 PM #386
      Nice . I see the remote filler, how do you have it routed?

      Page 12 = Owned
      Garage Sale, lots of parts for sale

      GLX Tails for sale $50, PM me

    2. Member DarkSideGTI's Avatar
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      05-16-2011 11:16 AM #387
      Quote Originally Posted by WoLfBuRgJeTTa View Post
      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.

    3. Member huichox4's Avatar
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      05-16-2011 12:17 PM #388
      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?

    4. Member DarkSideGTI's Avatar
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      05-16-2011 01:45 PM #389
      Quote Originally Posted by huichox4 View Post
      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.
      Last edited by DarkSideGTI; 05-16-2011 at 02:07 PM.

    5. 05-16-2011 04:29 PM #390
      Quote Originally Posted by DarkSideGTI View Post
      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?
      Garage Sale, lots of parts for sale

      GLX Tails for sale $50, PM me

    6. Member DarkSideGTI's Avatar
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      05-16-2011 04:31 PM #391
      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.

    7. Member huichox4's Avatar
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      05-16-2011 06:37 PM #392
      Quote Originally Posted by DarkSideGTI View Post
      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.

    8. Member huichox4's Avatar
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      05-16-2011 06:40 PM #393
      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
      Last edited by huichox4; 05-16-2011 at 06:55 PM.

    9. Member DarkSideGTI's Avatar
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      05-16-2011 11:28 PM #394
      so I was sent the inner boot for a triple roller axle.

      So much for getting the axle back in tonight.

    10. Member dr. b's Avatar
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      05-16-2011 11:29 PM #395
      Quote Originally Posted by DarkSideGTI View Post
      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
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    11. Member DarkSideGTI's Avatar
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      05-17-2011 12:59 AM #396
      Quote Originally Posted by dr. b View Post
      at least your wheels clear your brakes
      Go back to stock brakes?

    12. Member BIG DUB's Avatar
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      05-17-2011 04:55 AM #397
      Quote Originally Posted by DarkSideGTI View Post
      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

    13. Member Cortexiphan's Avatar
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      05-17-2011 09:39 AM #398
      Quote Originally Posted by DarkSideGTI View Post
      Yup I got stainless steel washers.

      I took the painters tape off.



      I guess I did a couple other things too.


      That is fresh

    14. Member dr. b's Avatar
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      05-17-2011 02:53 PM #399
      Quote Originally Posted by DarkSideGTI View Post
      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.
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    15. Member DarkSideGTI's Avatar
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      05-17-2011 03:06 PM #400
      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

    16. Member Brake_Dust's Avatar
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      05-17-2011 10:33 PM #401
      Quote Originally Posted by DarkSideGTI View Post
      test fit the wheels today.
      Nice wheel.. kinda like a beefy flat spoke RC with bolts exposed

    17. Member DarkSideGTI's Avatar
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      05-17-2011 11:17 PM #402
      Quote Originally Posted by Brake_Dust View Post
      Nice wheel.. kinda like a beefy flat spoke RC with bolts exposed
      Thanks, It's a rep of the HRE P40


    18. Member BIG DUB's Avatar
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      05-17-2011 11:55 PM #403
      Im digging the porsche

    19. Member DarkSideGTI's Avatar
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      05-18-2011 10:51 AM #404
      Quote Originally Posted by DarkSideGTI View Post
      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.

    20. Member Cortexiphan's Avatar
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      05-18-2011 11:00 AM #405
      Quote Originally Posted by DarkSideGTI View Post
      haha, I feel like an idiot. forgot the compressors required key on. they work fine.
      smooth

      Cant wait to see this thing finished man

    21. Member huichox4's Avatar
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      05-18-2011 11:06 AM #406
      now you just need to AC lines?

    22. Member DarkSideGTI's Avatar
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      05-18-2011 01:51 PM #407
      Quote Originally Posted by huichox4 View Post
      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.

    23. Member huichox4's Avatar
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      05-18-2011 01:54 PM #408
      Quote Originally Posted by DarkSideGTI View Post
      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.

    24. Member DarkSideGTI's Avatar
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      05-18-2011 07:03 PM #409
      Quote Originally Posted by huichox4 View Post
      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.

    25. Member DarkSideGTI's Avatar
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      05-22-2011 02:40 AM #410
      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.

    26. Member dr. b's Avatar
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      05-22-2011 11:01 AM #411
      good to see i wasn't the only one capitalizing on fantastic weather to make big strides.
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    27. Member huichox4's Avatar
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      05-23-2011 11:34 AM #412
      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

    28. Member DarkSideGTI's Avatar
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      05-23-2011 12:52 PM #413
      got the bumper back from paint and test fit it. Rad support is not aligned at all.



      Quote Originally Posted by huichox4 View Post
      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.
      Last edited by DarkSideGTI; 05-23-2011 at 12:54 PM.

    29. Member huichox4's Avatar
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      05-23-2011 01:16 PM #414
      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.

    30. Member DarkSideGTI's Avatar
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      05-23-2011 03:01 PM #415
      Quote Originally Posted by huichox4 View Post
      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.

    31. Member DarkSideGTI's Avatar
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      05-23-2011 05:24 PM #416
      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.

    32. Member huichox4's Avatar
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      05-25-2011 10:56 AM #417
      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,

    33. Member DarkSideGTI's Avatar
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      05-25-2011 10:57 AM #418
      yeah I checked all that stuff. I tried to prime it last night, but the starter won't turn over.

    34. Member huichox4's Avatar
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      05-25-2011 11:03 AM #419
      ohh one more fresh battery or fully charged one.

      was the battery relocated? ground checked and secured?

    35. Member DarkSideGTI's Avatar
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      05-25-2011 11:28 AM #420
      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?

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