Originally Posted 4-21-2010
I meant to do a lot (all) of this last year, but on the way home from visiting Wisconsin for my birthday last May the differential in my GTI decided it didn't want to work anymore all over the interstate in Indiana. The Z got converted to DD duty while I taught myself how to pull a transmission. To make a very long story short it took me three months and I got a Corrado transmission, TDI 5th gears, clutch, LW flywheel, etc, and a heck of a lot of experience.
Now, a year later, the GTI is running 'great' (Or as good as it can for you VW haters. I'm looking at you 91ser...) and I have some money and time. Scratch that, I have a little money and less time. I want this car drivable a week before Memorial Day so I can drive it back to Wisconsin in time for my 2nd marathon and the ultimate frisbee College Nationals in Madison. That gives me a hair over 4 weeks to learn as much as I can about this car and do a lot of work in the process.
-New Top Speed downpipes and testpipes
-Z1 13" front big brake kit + master cylinder brace
-Specialty Z stainless steel brake lines
-Stillen Quad tip exhaust [SIZE="1"](thats the plan at least)[/SIZE]
-Driven Authority top feed fuel rail w/755cc injectors THEY FINALLY SHIPPED!!!
-6AN Stainless Steel fuel lines
-NGK BKR5E (or whatever the code is) spark plugs. [SIZE="1"]Although now that I think about it I think I need to bump it up a few steps to a 7ish...so theres 60 bucks down the drain.[/SIZE]
-Z1 motorsports ECU chip [SIZE="1"]Unless anyone has a better suggestion. I haven't purchased this yet.[/SIZE]
-Front bumper maybe
-Non-torn non-power leather seatsmaybe
-Innovative LC1 wideband
...I might be forgetting a few parts...
-Clean garage CHECK
-Remove pre-cats (tried this once before. failed miserably)
-Pull plenum (scary)
-Test fit new rotors (get 12mm spacers if necessary)
-Do all the necessary deletes when plenum is removed
-Replace all vacuum lines with silicone and clean all connectors
...I'm sure I'll come up with more soon...
I think this build will be pushing the limits of my budget, time, and abilities, but I'm excited as hell to get it started. The only part I'm really worried about are the pre-cats. I tried removing them last fall with the transmission on. I got the easy nuts started, but wasn't able to fully remove anything and gave up after a few days of frustration.
I'm mostly doing this post for myself and the few gearhead friends I've got that wanna see. But you all seem to get a kick out of these kinda write ups so I figured I'd share and document my process.
If anyone has any pointers for anything I'm doing along the way, please feel free to chime in. More preventative maintenance? What do I need? Don't like the way I hold the wrench? Tell me. I'm drinking the wrong beer? Provide me with your favorite.
[SIZE="7"]Day 1[/SIZE]I was supposed to do this during the winter, but my laziness got the better of me and I didn't feel like doing any work in the cold. This coming from the guy who runs in shorts all winter. Eh.
I hadn't cleaned the garage since I replaced the transmission in the golf, replaced the wheel bearings, replaced the suspension, bushings, and brakes. Since I converted to an MSD coilpack ignition, did my timing chains, got rid of my second transmission, replaced the cooling system, etc. Throughout all of this I never really threw anything away. I accumulated lots of tools, but had no place to store them. All of this CRAP just kinda found its way to the side of my garage and I moved it aside every time it was in my way.
Started like this:
After 2 hours of moving and vacuuming it looked like this:
It may not look like much but trust me. There was 3" of leaves, tools, metal shards, screws, nuts, washers, ball joints, tires, beer bottles, tie rods and etc coating the floor of the garage.
And then it was time for dinner, so the only REAL work I got done with the Z today was driving it up on some 2x10's to make raising it up on jack stands a little easier. And I didn't take pictures of the boards, so you'll just have to imagine what wood looks like.
Buuut since this is the Z lounge I'll include the before pictures of my car.
Notice the tape hanging from the exhaust just about everywhere. 3 weeks ago I passed emissions :-) Muffler tape is my hero.
This is the mess I'll be staring at for the next 4 weeks.
Tune in tomorrow for hot Z jacking Spotted Cow drinking action! :burnout: